Audi AMB Service Manual Download Page 648

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Fig. 338: Charge Air Cooling Components, Removing And Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Air duct

2 - Rubber grommet

3 - Air hose



Between charge air cooler and air duct in lock carrier

4 - Air hose



Between intake manifold and charge air cooler

5 - O-ring

2005 Audi A4 Quattro

ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB

2:37:39 AM

Page 47

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Summary of Contents for AMB

Page 1: ...E The engine code is also stamped on the front lifting eye visible when engine cover panel is removed Engine code AMB Manufactured 08 01 Capacity l 1 781 Power kW at RPM 125 5700 Torque Nm at RPM 210...

Page 2: ...ke manifold change over function no Camshaft timing control yes Secondary air system yes Valve timing at 1 mm valve lift and 0 mm valve clearance Intake opens after TDC 18 Intake closes after BDC 28 E...

Page 3: ...gen Sensor O2S and oxygen sensor control before Three Way Catalytic Converter TWC See HEATED OXYGEN SENSOR HO2S G39 AND OXYGEN SENSOR REGULATION BEFORE CATALYTIC CONVERTER CHECKING P0031 16415 HO2S He...

Page 4: ...ture Circuit Low P0118 16502 Engine Coolant Temperature Circuit High P0121 16505 Throttle Pedal Position Sensor Switch A Circuit Range Performance Check Throttle Valve Control Module J338 See THROTTLE...

Page 5: ...t High Voltage Bank 1 Sensor 2 P0139 16523 O2 Sensor Circuit Slow Response Bank 1 Sensor 2 P0140 16524 O2 Sensor Circuit No Activity Detected Bank 1 Sensor 2 P0141 16525 O2 Sensor Heater Circuit Bank...

Page 6: ...E CATALYTIC CONVERTER CHECKING Check Oxygen Sensor O2S and oxygen sensor control behind Three Way Catalytic Converter TWC See OXYGEN SENSORS AND OXYGEN SENSOR REGULATION BEHIND CATALYTIC CONVERTER CHE...

Page 7: ...ECKING P0262 16646 Cylinder 1 Injector Circuit High P0264 16648 Cylinder 2 Injector Circuit Low P0265 16649 Cylinder 2 Injector Circuit High P0267 16651 Cylinder 3 Injector Circuit Low P0268 16652 Cyl...

Page 8: ...38 Ignition Coil D Primary Secondary Circuit P0411 16795 Secondary Air Injection System Incorrect Flow Detected Check combination valves for Secondary Air Injection AIR system for function and proper...

Page 9: ...ANISTER PURGE REGULATOR VALVE N80 EVAP canister system check for proper seal See EVAP CANISTER SYSTEM CHECKING FOR PROPER SEAL P0442 16826 Evaporative Emission System Leak Detected small leak P0444 16...

Page 10: ...theft housing P0602 16986 Control Module Programming Error Malfunction Procedure to code Engine Control Module ECM Motronic Fuel Injection and Ignition 4 cylinder Turbo See ENCODING II ENGINE CONTROL...

Page 11: ...TWC Overview of component locations Oxygen Sensor O2S Heater 1 Z29 behind catalytic converter checking P1111 17519 Oxygen sensor control Bank 1 system too lean G39 Heated Oxygen Sensor HO2S Heated Ox...

Page 12: ...18559 Throttle Pedal Position Sensor Switch E Circuit Low Input P2128 18560 Throttle Pedal Position Sensor Switch E Circuit High Input P2138 18570 Throttle Pedal Position Sensor Switch D E Voltage Co...

Page 13: ...r The engine code is also given on the vehicle data sticker Engine data NOTE The engine code is also stamped on the front lifting eye visible when engine cover panel is removed Engine code AMB Manufac...

Page 14: ...after BDC 28 Exhaust opens before BDC 28 Exhaust closes before TDC 8 CAUTION Before beginning repairs on the electrical system Obtain the anti theft radio security code Switch the ignition off Disconn...

Page 15: ...pport bar 10 222A Lifting tackle 2024A Special tool 3147 Workshop crane VAG1202A After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar switch on the emergency back up...

Page 16: ...ition N All models Obtain radio anti theft code for vehicles with encoded radio NOTE All cable ties unfastened or cut when removing engine are to be reattached in same position during installation Eng...

Page 17: ...See Caution before beginning repairs on electrical system Engine removing and installing Fig 5 Identifying Battery Ground GND Terminal Courtesy of VOLKSWAGEN UNITED STATES INC With ignition switched...

Page 18: ...y and remove wiper arms Pull off securing clips 1 and remove panel trim Fig 7 Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove engine cover arrows CAUTION Hot steam can escape whe...

Page 19: ...urtesy of VOLKSWAGEN UNITED STATES INC Remove bolts arrows Disengage EVAP canister purge regulator valve N80 1 from air duct 2 Remove both screws arrows for air duct 2 Remove front bumper 63 BUMPER 63...

Page 20: ...aust pipe of auxiliary additional heater to sound insulation Fig 11 Removing Sound Insulation Courtesy of VOLKSWAGEN UNITED STATES INC Remove sound insulation arrows Fig 12 Unbolting Sound Insulation...

Page 21: ...aining Clip For Engine Coolant Temperature ECT Sensor G2 Off Lower Coolant Hose And Drain Coolant From Radiator Courtesy of VOLKSWAGEN UNITED STATES INC Pull retaining clip 1 for Engine Coolant Temper...

Page 22: ...harge Air Cooler At Bottom Left Of Lock Carrier Courtesy of VOLKSWAGEN UNITED STATES INC Remove air hose arrow to charge air cooler at bottom left of lock carrier Fig 17 Removing Lower Air Hose Betwee...

Page 23: ...clamp off inlet and outlet pipe of cooling coil for power steering hydraulic fluid Place suitable container under hoses Disconnect hoses from cooling coil Fig 19 Removing Air Ducts On Left Right Of R...

Page 24: ...er downward and set down Fig 21 Removing Impact Absorber Bolts On Left Right Courtesy of VOLKSWAGEN UNITED STATES INC Remove impact absorber bolts on left and right arrows Remove hood lock cable from...

Page 25: ...for left and right airbag sensor Fig 23 Unbolting Lock Carrier On Left Right Courtesy of VOLKSWAGEN UNITED STATES INC Unbolt lock carrier on left and right arrows Remove lock carrier Vehicles with au...

Page 26: ...G for 5 SPD AUTOMATIC TRANSMISSION 01V 37 AUTOMATIC TRANSMISSION CONTROLS HOUSING for 5 SPD AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE INTERNAL COMPONENTS SERVICING 37 CONTROLS HOUSING for A...

Page 27: ...uel hose from connection on fuel rail pipe To do so counterhold using an open end wrench at each hex head 1 and 3 and unscrew union nut 2 All Seal off line so that no dirt will get into fuel system NO...

Page 28: ...nnectors From Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect wires unplug connectors from 1 EVAP canister purge regulator valve 2 Mass air flow sensor 3 Wastegate bypass regulator valve N75 Disco...

Page 29: ...coolant expansion tank Lift coolant expansion tank slightly at bolt side and pull it out of catch on plenum chamber side Fig 30 Unbolting Cover Of Electronics Box In Plenum Chamber Courtesy of VOLKSWA...

Page 30: ...Retainers And Disconnecting Electrical Connectors From Engine Control Module ECM J623 Courtesy of VOLKSWAGEN UNITED STATES INC Release catches arrows and disconnect control module connectors 1 and 2...

Page 31: ...x upward to remove Disengage wiring harness from electronics box housing and plenum chamber and place on engine Fig 35 Disconnecting 4 Pin Connectors Of Oxygen Sensors Courtesy of VOLKSWAGEN UNITED ST...

Page 32: ...bination valve Fig 37 Removing Wires From Starter Insulator From Positive Connection On Starter Courtesy of VOLKSWAGEN UNITED STATES INC Remove wires 1 and 2 from starter remove insulator from positiv...

Page 33: ...rter Bolts Through Opening Of Removed Starter Courtesy of VOLKSWAGEN UNITED STATES INC Remove 3 torque converter bolts through opening of removed starter using Matra V175 15 mm A F socket attachment r...

Page 34: ...t Pipe Courtesy of VOLKSWAGEN UNITED STATES INC Remove bolts arrows securing catalytic converter to front exhaust pipe Unbolt transmission bracket for exhaust system arrow NOTE To avoid damage do not...

Page 35: ...Loosen Ribbed Belt Courtesy of VOLKSWAGEN UNITED STATES INC Swivel tensioner in direction of arrow to loosen ribbed belt Remove ribbed belt from generator pulley Fig 44 Disconnecting Compressor Clutc...

Page 36: ...ng air conditioning compressor together with condenser and connected wires at right of vehicle Use hose clamp 3093 to clamp off hose between expansion tank and power steering pump Place drip tray unde...

Page 37: ...ehind Gas Filled Strut On Suspension Strut Domes Courtesy of VOLKSWAGEN UNITED STATES INC Place support bar 10 222A behind gas filled strut on suspension strut domes Spindle at front Engage transmissi...

Page 38: ...Attach lifting tackle 2024A to engine and hook onto workshop crane VAG1202A Remove last securing bolt Lift engine over studs of engine mounts Loosen support bar 10 222A slightly Vehicles with automat...

Page 39: ...toward front of vehicle out of engine compartment Vehicles with automatic transmission If necessary secure torque converter in transmission with wire to prevent it from falling out Engine securing to...

Page 40: ...at clutch plate is properly centered A needle bearing must be installed in crankshaft on vehicles with manual transmission Install needle bearing if necessary Pilot needle bearing in crankshaft extrac...

Page 41: ...ompressor Install ribbed belt Vehicles with automatic transmission Secure ATF lines 37 AUTOMATIC TRANSMISSION CONTROLS HOUSING for 5 SPD AUTOMATIC TRANSMISSION 01V 37 AUTOMATIC TRANSMISSION CONTROLS H...

Page 42: ...tion on fuel rail pipe To do so counterhold using an open end wrench at each hex head 1 and 3 and tighten union nut 2 to 22 Nm All Electrical connections and routing Electrical Wiring Diagrams Trouble...

Page 43: ...WHEEL DRIVE INTERNAL COMPONENTS SERVICING 37 CONTROLS HOUSING for AUTOMATIC TRANSMISSION 09L FOUR WHEEL DRIVE All models Adjust headlights 94 LIGHTS SWITCHES EXTERIOR Tightening torques NOTE Drained c...

Page 44: ...ne Transmission Mountings Automatic Manual Transmission Courtesy of VOLKSWAGEN UNITED STATES INC Engine transmission mountings automatic transmission Item Bolt Nm 1 3 4 M12 x 67 65 2 6 M12 x 90 65 5 1...

Page 45: ...steering pump to bracket 25 Pulley to power steering pump 25 Pulley to coolant pump 25 Viscous fan to bearing 45 Air conditioning compressor to bracket 25 Component Nm Drain plug to coolant pump 30 To...

Page 46: ...rol Module prior to disconnecting vehicle battery 91 COMMUNICATION After reconnecting vehicle battery re code and check operation of anti theft radio Also check operation of clock and power windows ac...

Page 47: ...w Courtesy of VOLKSWAGEN UNITED STATES INC 1 45 Nm 2 45 Nm 3 10 Nm 4 10 Nm 5 Hole For special tool 3369 6 Hole in lock carrier 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo Engine Mechanical En...

Page 48: ...of VOLKSWAGEN UNITED STATES INC Remove bolts arrows securing exhaust pipe of auxiliary additional heater to sound insulation All models Fig 61 Removing Sound Insulation Courtesy of VOLKSWAGEN UNITED S...

Page 49: ...edges Remove front bumper 63 BUMPER 63 BUMPERS for CABRIOLET Remove bolts on left and right arrows Fig 63 Screwing Special Tool 3369 Into Free Holes On Left Right Courtesy of VOLKSWAGEN UNITED STATES...

Page 50: ...PER 63 BUMPERS for CABRIOLET Adjust headlights 94 LIGHTS SWITCHES EXTERIOR Tightening torques Ribbed belt for generator vane pump and air conditioner compressor Component Nm Lock carrier to longitudin...

Page 51: ...VOLKSWAGEN UNITED STATES INC 1 25 Nm 2 Tensioning roller 3 Ribbed belt Mark direction of rotation before removing Removing and installing Ribbed belt removing and installing 4 25 Nm 5 Bracket 2005 Aud...

Page 52: ...removing and installing Loosen bolted connection at top and bottom Swivel generator to side slightly and disconnect electrical connectors Remove generator 8 20 Nm 9 40 Nm 10 20 Nm 11 Power steering pu...

Page 53: ...r moving to service position Removing ribbed belt Ribbed belt removing and installing When installing vibration damper only use genuine bolts Vibration damper can only be installed in one position Hol...

Page 54: ...ioner Using Mandrel T10060 Courtesy of VOLKSWAGEN UNITED STATES INC Lock tensioner using mandrel T10060 arrow Remove ribbed belt Installing NOTE Mark direction of the ribbed belt with chalk or felt ti...

Page 55: ...ing and filling Obtain and record radio anti theft code for vehicles with a coded radio NOTE Before installing the ribbed belt make sure that all mechanical units generator air conditioning compressor...

Page 56: ...STATES INC Disconnect top coolant hose from radiator arrow Fig 72 Unboltin Generator From Bracket Courtesy of VOLKSWAGEN UNITED STATES INC Unbolt generator from bracket Disconnect wiring from generato...

Page 57: ...t disconnect connections Fig 74 Unbolting Power Steering Pump From Rear Bracket Courtesy of VOLKSWAGEN UNITED STATES INC Unbolt power steering pump from rear bracket Place power steering pump to one s...

Page 58: ...ning compressor connector right arrow Fig 76 Unbolting Air Conditioning Compressor From Bracket Courtesy of VOLKSWAGEN UNITED STATES INC Unbolt air conditioning compressor from bracket Hang air condit...

Page 59: ...ering pump and A C compressor at bolts 1 through 3 Only for replacement of bracket Remove idler roller for ribbed belt from bracket for generator power steering pump and A C compressor Installing Inst...

Page 60: ...t idler wheel for ribbed belt to bracket for generator power steering pump and air conditioning compressor All models To ease installation of power steering pump knock back bushing on rear securing bo...

Page 61: ...and A C compressor to cylinder block 40 Support for intake manifold 20 A C compressor to bracket 25 Component Nm Generator to bracket 20 Power steering pump to bracket 20 Hose clamps for coolant hose...

Page 62: ...d lower To remove unbolt vibration damper 2 10 Nm Apply D 000 600 when installing 3 Toothed belt guard center To remove unbolt ribbed belt tensioner 4 Toothed belt guard top 2005 Audi A4 Quattro ENGIN...

Page 63: ...thed drive belt removing installing and tensioning Installed position Installed position of camshaft sprocket 10 Tensioning roller 11 Washer 12 Toothed belt tensioner 13 O ring Replace Coat with coola...

Page 64: ...rtesy of VOLKSWAGEN UNITED STATES INC Narrow chamfer of camshaft sprocket must face outward arrows and marking for TDC No 1 cylinder must be visible from front Removing and installing crankshaft tooth...

Page 65: ...oothed Drive Belt Removing Installing And Tensioning Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required torque wrench 5 to 50 Nm VAG1331 Locking plate T10008 t...

Page 66: ...LKSWAGEN UNITED STATES INC Remove engine cover by lifting up arrows Remove ribbed belt Ribbed belt removing and installing Fig 84 Removing Installing Ribbed Belt Tensioner Courtesy of VOLKSWAGEN UNITE...

Page 67: ...note of the installed position of the upper part of the drive belt cover particularly where it meets the center part of the drive belt cover CAUTION The engine must only be turned in the direction of...

Page 68: ...urtesy of VOLKSWAGEN UNITED STATES INC Unbolt vibration damper Fig 88 Removing Center And Lower Part Of Drive Belt Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove center and lower part of drive...

Page 69: ...t 1 on pulley and rotate eccentric bolt clockwise in direction of arrow using special tool 3387 Mark direction of rotation of drive belt with chalk or felt tip pen Remove drive belt Installing adjusti...

Page 70: ...ow Fig 92 Identifying Marking On Camshaft Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES INC cylinder Risk of damaging valves piston crown NOTE The vibration dam...

Page 71: ...se in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with locking plate T10008 All CAUTION If the drive belt tensio...

Page 72: ...ckwise to right in direction of arrow until a gauge 2 with dimension a e g drill bit can be passed between tensioning lever and tensioner housing Dimension a 8 mm Hold eccentric bolt in this position...

Page 73: ...ft must be at TDC cylinder 1 arrows Fig 97 Checking Tensioning Roller Specified Dimension Courtesy of VOLKSWAGEN UNITED STATES INC Check dimension a between tensioning lever and tensioner housing with...

Page 74: ...ocking plate T10008 Fig 99 Releasing Tension Of Tensioner Roller Courtesy of VOLKSWAGEN UNITED STATES INC Loosen nut 1 on pulley Continue under Tensioning drive belt If dimension a is obtained Install...

Page 75: ...n Toothed drive belt removing from camshaft sprocket Special tools testers and auxiliary items required Component Nm Lower drive belt cover at cylinder block 10 See note Center drive belt cover at cyl...

Page 76: ...te T10008 For Engines With Hydraulic Tensioning Device Courtesy of VOLKSWAGEN UNITED STATES INC Locking plate T10008 With engine in vehicle Removing Move lock carrier to service position Lock carrier...

Page 77: ...r part of drive belt cover NOTE Take special note of the installed position of the upper part of the drive belt cover particularly where it meets the center part of the drive belt cover CAUTION The en...

Page 78: ...t TDC cylinder 1 arrows Fig 106 Inserting An Allen Wrench Into Socket Head Courtesy of VOLKSWAGEN UNITED STATES INC Push pulley on counter clockwise in direction of arrow with a socket head wrench usi...

Page 79: ...f arrow using special tool 3387 Remove drive belt from camshaft Installing Fig 108 Identifying Marking On Camshaft Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES...

Page 80: ...r at cylinder block 10 See note Vibration damper pulley at crankshaft 10 90 See note Ribbed belt tensioner at bracket 23 Drive belt tensioning pulley 27 NOTE Servicing work on clutch 30 CLUTCH for 5 S...

Page 81: ...STATES INC 1 Oil seal Install with 10 203 2 Woodruff key Make sure key is seated properly 3 25 Nm 4 Front sealing flange Remove oil pan to remove and install Oil pan removing and installing 2005 Audi...

Page 82: ...ual mass flywheel drive plate Removing and installing dual mass flywheel Dual mass flywheel drive plate removing and installing Removing and installing drive plate 9 Intermediate plate Must be located...

Page 83: ...ools Crankshaft Oil Seal Pulley End Replacing Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required Oil seal extractor 2085 Puller 3083 Counterhold 3415 Removing...

Page 84: ...n Support Courtesy of VOLKSWAGEN UNITED STATES INC Unbolt stop for torque reaction support arrows Fig 112 Removing Crankshaft Toothed Belt Sprocket Courtesy of VOLKSWAGEN UNITED STATES INC Remove cran...

Page 85: ...ler 2085 Courtesy of VOLKSWAGEN UNITED STATES INC Lubricate threaded head of oil seal extractor place in position and exerting firm pressure screw as far as possible into oil seal Loosen knurled screw...

Page 86: ...r guide sleeve Fig 116 Pushing In Oil Seal As Far As It Will Go Using Thrust Sleeve And Bolt From 3083 Courtesy of VOLKSWAGEN UNITED STATES INC Push in oil seal as far as it will go using thrust sleev...

Page 87: ...90 is a quarter turn Dual mass flywheel drive plate removing and installing Dual mass flywheel Special tools testers and auxiliary items required Fig 118 Counterhold 10 201 Courtesy of VOLKSWAGEN UNI...

Page 88: ...ion to the following Replace bolts 90 is one quarter turn Replace bolts 180 is one half turn Drive plate Special tools testers and auxiliary items required Component Nm Dual mass flywheel to crankshaf...

Page 89: ...nterhold VW558 To Drive Plate Courtesy of VOLKSWAGEN UNITED STATES INC Secure counterhold VW558 to drive plate using hex bolt M8 x 45 2 Place two M10 hex nuts 1 between counterhold and drive plate Mar...

Page 90: ...bolts and tighten to 30 Nm Fig 123 Checking Distance Between Drive Plate And Cylinder Block Courtesy of VOLKSWAGEN UNITED STATES INC Perform measurement by passing sliding calliper with depth gauge th...

Page 91: ...n Tightening torque 90 is one quarter turn CRANKSHAFT REMOVING AND INSTALLING Crankshaft removing and installing Component Nm Drive plate to crankshaft 60 90 See note NOTE Before removing crankshaft p...

Page 92: ...il groove For cylinder block with oil groove Do not interchange used bearing shells mark 2 65 Nm 1 4 turn 90 further Replace When measuring radial clearance of crankshaft tighten to 65 Nm but do not t...

Page 93: ...and installing Removing and installing sensor wheel 7 10 Nm 1 4 turn 90 further Replace Always replace sensor wheel if bolts have been removed Removing and installing sensor wheel 8 Pilot needle beari...

Page 94: ...top crankshaft bearing NOTE Always replace sensor wheel 2 if bolts 1 have been removed If the securing bolts are tightened a second time seats for the countersunk bolt heads in the sensor wheel will b...

Page 95: ...wn in illustration Bearing shell identification by color codes A Identification for bearing 1 B Identification for bearing 2 C Identification for bearing 3 D Identification for bearing 4 E Identificat...

Page 96: ...ng and driving Special tools testers and auxiliary items required Grinding dimension Crankshaft bearing journal dia Connecting rod bearing journal dia Basic dimension 0 017 48 00 0 037 0 022 42 00 0 0...

Page 97: ...ukko 22 1 4 Depth gauge Removing NOTE A pilot needle bearing must be installed in the crankshaft on vehicles with a manual transmission Install a pilot needle bearing if necessary On vehicles with an...

Page 98: ...and Kukko 22 1 Installing Fig 132 Driving In Needle Bearing Using Drift VW 207 C Courtesy of VOLKSWAGEN UNITED STATES INC Drive in with drift VW207C or centering mandrel 3176 Lettering on pilot needle...

Page 99: ...fying Special Tools Oil Pump Front Sealing Flange Drive Chain And Chain Sprocket For Oil Pump Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES INC Drift sleeve 30 100 Two arm puller commer...

Page 100: ...t chain sprocket in oven for approx 15 minutes to 220 C Fig 136 Installing Chain Sprocket Onto Crankshaft Up To Limit Stop Using Press Tube 30 100 Courtesy of VOLKSWAGEN UNITED STATES INC Install chai...

Page 101: ...ting Rods Disassembling And Assembling Overview Courtesy of VOLKSWAGEN UNITED STATES INC 1 30 Nm 1 4 turn 90 further Oil threads and contact surface To measure radial clearance tighten to 30 Nm but no...

Page 102: ...block Checking cylinder bore Checking cylinder bore Piston and cylinder dimensions Piston and cylinder dimensions 7 Bearing shell With oil drilling for piston pin lubrication Note installed position...

Page 103: ...clearance 12 Piston Checking Checking piston Mark installed position and cylinder number Arrow on piston crown must point to pulley end Install using piston ring clamp 13 Connecting rod bolt Replace...

Page 104: ...ing Piston Piston ring Dimensions in mm New Wear limit Compression ring 1 0 20 0 40 0 8 Compression ring 2 0 20 0 40 0 8 Oil scraper ring 0 25 0 50 0 8 Piston ring Dimensions in mm New Wear limit Comp...

Page 105: ...ge 50 100 mm Take measurements at 3 positions in both lateral A and longitudinal B directions Deviation from nominal dimension max 0 08 mm Piston and cylinder dimensions Dimensions without graphite co...

Page 106: ...TION NOTE Replace cylinder head bolts When performing repairs replace seals gaskets self locking nuts and bolts which have a specified tightening angle Charge air hose connections and hoses must be fr...

Page 107: ...osition Part No toward cylinder head After replacing fill with fresh coolant 2 Cylinder head Removing Cylinder head removing Checking for distortion Checking cylinder head for distortion Resurfacing l...

Page 108: ...n inner nuts first Tighten outer nuts in diagonal sequence 10 Cylinder head cover gaskets Replace if damaged or leaking Before installing gaskets apply AMV 174 004 01 at sealing points Sealing transit...

Page 109: ...16 O ring Replace Part II Fig 143 Cylinder Head Removing And Installing Overview Part II Courtesy of VOLKSWAGEN UNITED STATES INC 1 Gasket 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo Engine M...

Page 110: ...n nut for fuel supply line to fuel rail pipe Loosening and tightening union nut for fuel supply line in vehicles as of 07 03 6 Coolant line top 7 10 Nm 8 10 Nm 9 O ring For top coolant line Replace 10...

Page 111: ...nder head resurfacing limit Fig 145 Cylinder Head Resurfacing Limit Courtesy of VOLKSWAGEN UNITED STATES INC Resurfacing the cylinder head skimming is only permitted down to minimum dimension a Minimu...

Page 112: ...ster cylinder head transition 4 points Fig 147 Sealing Camshaft Adjuster Cylinder Head Transition 4 Points Courtesy of VOLKSWAGEN UNITED STATES INC Apply a small quantity of sealant Part No AMV 174 00...

Page 113: ...on on fuel rail pipe To do so counterhold using an open end wrench at each hex head 1 and 3 and tighten union nut 2 to 22 Nm Cylinder head cover removing and installing Removing Fig 149 Removing Engin...

Page 114: ...mission Canister Purge Regulator Valve N80 And Air Duct Courtesy of VOLKSWAGEN UNITED STATES INC Remove bolts arrows Disengage EVAP canister purge regulator valve N80 1 from air duct 2 Remove both scr...

Page 115: ...alve on cylinder head cover and heat shield 3 Move secondary air line slightly to one side Fig 153 Ignition Coils Ground Wire And Connectors Courtesy of VOLKSWAGEN UNITED STATES INC Remove Ground wire...

Page 116: ...nder head removing Conditions Engine in vehicle Lock carrier in service position Lock carrier moving to service position NOTE Replace gaskets and sealing rings Replace cylinder head cover gaskets if d...

Page 117: ...ribbed belt and ribbed belt tensioner Ribbed belt removing and installing Remove toothed belt from camshaft sprocket Toothed drive belt removing installing and tensioning Fig 155 Air Cleaner Cover Cou...

Page 118: ...Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect connector arrow at camshaft adjuster Fig 158 Crankcase Breather Line Secondary Air Combination Valve Line And Heat Shield Courtesy of VOLKSWAGEN UNI...

Page 119: ...Supply Line For Turbocharger Courtesy of VOLKSWAGEN UNITED STATES INC Remove bolts 1 and 2 of oil supply line Remove bolts 3 for turbocharger Fig 160 Disconnecting Connector At Coolant Temperature Se...

Page 120: ...ylinder head and move it clear Pull off coolant hose to heater unit heat exchanger at rear of cylinder head To do so first release retainers on connecting flange Fig 162 Ignition Coils Ground Wire And...

Page 121: ...ng NOTE Replace cylinder head bolts When performing repairs replace seals gaskets self locking nuts and bolts which have a specified tightening angle Secure all hose connections with standard hose cla...

Page 122: ...cylinder Remove new cylinder head gasket from packaging just before installation Handle gasket extremely carefully Damaging the silicone layer or indented area will lead to leaks No oil or coolant mu...

Page 123: ...lock Centering Pins Courtesy of VOLKSWAGEN UNITED STATES INC Place cylinder head gasket in position Note position of centering pins in cylinder block arrows Check installed position of cylinder head g...

Page 124: ...all ribbed belt and ribbed belt tensioner Ribbed belt removing and installing Install intake manifold Replace coolant Cooling system draining and filling See Caution for connecting Telematics battery...

Page 125: ...d Fig 169 Identifying Spark Plug Wrench 3122 B Courtesy of VOLKSWAGEN UNITED STATES INC Spark plug wrench 3122B Component Nm Intake manifold support to intake manifold 20 to bracket 20 Turbocharger to...

Page 126: ...rements Engine oil temperature at least 30 C Battery voltage at least 12 7 V Work sequence Fig 171 Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove engine cover arrows Switch off...

Page 127: ...e Install spark plugs and ignition coils Check Diagnostic Trouble Code DTC memory Guided Fault Finding in VAS5051 01 ON BOARD DIAGNOSTIC OBD NOTE Using the compression tester New bar Wear limit bar Di...

Page 128: ...no more than first 4 turns of spark plug threads are cracked After installing camshafts engine must not be started for approx 30 minutes Hydraulic valve compensation elements have to settle otherwise...

Page 129: ...exhaust camshaft Note installed position Narrow web of camshaft sprocket must face toward front and marking for TDC No 1 cylinder must be visible from front Install camshaft sprocket under Installing...

Page 130: ...talling Valve stem seals replacing 8 Valve spring plate 9 Valve keeper 10 Hydraulic valve lifter Checking Hydraulic valve lifters checking Removing and installing Valve stem seals replacing Do not int...

Page 131: ...installed Wear limit 0 1 mm Run out max 0 035 mm Checking axial clearance Camshaft axial clearance checking Removing and installing camshafts Camshafts and camshaft adjuster removing and installing 1...

Page 132: ...ns on scrapping valves with sodium filling Valve dimensions Do not rework only lapping is permitted Valve dimensions Valve dimensions Checking valve guides Valve guides checking Refacing valve seats V...

Page 133: ...CAUTION Worn exhaust valves with sodium filling must not be scrapped in the usual way The valves must be cut into two pieces between the shaft center and the valve head using a metal saw When doing th...

Page 134: ...ement with valve lifters removed and with bearing cap at chain sprocket end and double bearing cap at camshaft sprocket end installed Attach dial indicator with universal dial indicator holder VW387 t...

Page 135: ...s testers and auxiliary items required Oil seal extractor 2085 Counterhold 3036 Puller 3241 Assembly tool T10071 Removing Cylinder head installed Lock carrier in service position Lock carrier moving t...

Page 136: ...Camshaft Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES INC Rotate crankshaft at central bolt of crankshaft toothed belt sprocket in direction of engine rotation...

Page 137: ...Bolt Into Oil Seal As Far As Possible With Forced Pressure Courtesy of VOLKSWAGEN UNITED STATES INC Lubricate threaded head of oil seal extractor 2085 place in position and exerting firm pressure scr...

Page 138: ...leeve onto shaft journal Remove guide sleeve Fig 183 Pushing In Oil Seal As Far As It Will Go Using Thrust Sleeve 3241 1 Courtesy of VOLKSWAGEN UNITED STATES INC Push in oil seal as far as it will go...

Page 139: ...t Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES INC Align marking on camshaft sprocket with marking on cylinder head cover Align marking on vibration damper wit...

Page 140: ...NITED STATES INC Oil seal extractor 2085 Fig 187 Puller 3241 Courtesy of VOLKSWAGEN UNITED STATES INC Puller 3241 Removing Cylinder head installed Lock carrier in service position Lock carrier moving...

Page 141: ...and tensioning Fig 189 Locating Connector At Camshaft Position Sensor G40 Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect connector from Camshaft Position CMP sensor G40 arrow Remove housing for...

Page 142: ...rced Pressure Into Oil Seal Courtesy of VOLKSWAGEN UNITED STATES INC Lubricate threaded head of oil seal extractor 2085 place in position and exerting firm pressure screw as far as possible into oil s...

Page 143: ...used for oil seals with ring spring PTFE oil seals must be installed according to the direction of shaft rotation see arrow markings on oil seal Incorrect direction of rotation results in oil leakage...

Page 144: ...t Sleeve 3241 1 And Bolt 3241 3 Courtesy of VOLKSWAGEN UNITED STATES INC Push in oil seal as far as it will go using thrust sleeve 3241 1 To do so use bolt 3241 3 Install CMP sensor Install top sectio...

Page 145: ...rom camshaft sprocket Toothed drive belt removing installing and tensioning Fig 196 Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove engine cover arrows Remove secondary air combi...

Page 146: ...ull off camshaft sprocket Remove entire camshaft position sensor Fig 198 Securing Camshaft Adjuster Or Chain Tensioner Using Bracket For Chain Adjustment 3366 Courtesy of VOLKSWAGEN UNITED STATES INC...

Page 147: ...rk installed position using colored markings Fig 200 Checking Distance Between Markings Consists Of 16 Rollers Of The Drive Chain Courtesy of VOLKSWAGEN UNITED STATES INC Eistance between two arrows o...

Page 148: ...camshaft adjuster Fig 202 Identifying Bearing Cap Positions Courtesy of VOLKSWAGEN UNITED STATES INC Loosen bearing caps 2 and 4 of intake and exhaust camshafts alternately in diagonal sequence and re...

Page 149: ...188 001 02 to shaded areas Install drive chain on camshaft sprockets as follows Fig 204 Installing Chain So That Colored Markings Are In Line Courtesy of VOLKSWAGEN UNITED STATES INC If old chain is r...

Page 150: ...f both camshafts Tighten mountings of camshaft adjuster watch position of dowel sleeves Fig 206 Identifying Bearing Cap Positions Courtesy of VOLKSWAGEN UNITED STATES INC Tighten bearing caps 2 and 4...

Page 151: ...lers Installed On Chain Gears Courtesy of VOLKSWAGEN UNITED STATES INC Distance between two arrows on bearing caps or between colored markings is 16 rollers on drive chain Notch on exhaust camshaft is...

Page 152: ...haft oil seal replacing on Fig 210 Identifying Camshaft Gear Thin Rib Toward Outside And TDC Marking Visible Courtesy of VOLKSWAGEN UNITED STATES INC Install camshaft sprocket Note installed position...

Page 153: ...damage to valves and piston crowns NOTE After installing camshafts engine must not be started for approx 30 minutes Hydraulic valve compensation elements have to settle otherwise valves will strike p...

Page 154: ...f lifters to be checked are pointing upward Vehicles with manual transmission Push vehicle forward with 4th gear engaged and ignition switched off Vehicles with automatic transmission Remove sound ins...

Page 155: ...eplacing Fig 213 Identifying Special Tools Valve Stem Seals Replacing NOTE After installing camshafts engine must not be started for approx 30 minutes Hydraulic valve compensation elements have to set...

Page 156: ...nward Use spark plug wrench 3122B to remove spark plugs Set piston of appropriate cylinder to bottom dead center Fig 214 Identifying Pressure Hose VW653 3 Into Spark Plug Thread Drift VAS5161 3 In Val...

Page 157: ...e at right angle to direction of travel Push knurled spacer ring VAS5161 17 onto cartridge VAS5161 8 Push cartridge into guide bushing Attach pressure fork VAS5161 2 to snap in device VAS5161 6 and pr...

Page 158: ...tridge into guide bushing Attach pressure fork VAS5161 2 to snap in device VAS5161 6 and press cartridge downward Simultaneously turn knurled screw of cartridge clockwise until ends engage in valve ke...

Page 159: ...Oil Seal Valve Stem Seal Driver 3365 Courtesy of VOLKSWAGEN UNITED STATES INC To prevent damage to new valve stem seals B place plastic sleeve A on valve stem Lightly oil sealing lip of valve stem se...

Page 160: ...s were taken out of cartridge they must first be placed into insertion device VAS5161 18 Fig 221 Identifying Installation Cartridge VAS 5161 8 Courtesy of VOLKSWAGEN UNITED STATES INC Press cartridge...

Page 161: ...mshaft adjuster Valve guides checking Special tools testers and auxiliary items required Fig 223 Identifying Dial Gauge Holder VW 387 Courtesy of VOLKSWAGEN UNITED STATES INC NOTE After installing cam...

Page 162: ...lay Wear limit Valve seats refacing Special tools testers and auxiliary items required Depth gauge Valve seat grinding tool Intake valve guide Exhaust valve guide 0 80 mm 0 80 mm NOTE If wear limit is...

Page 163: ...es it is not sufficient to reface valve seats and replace valves Valve guides must also be checked for wear This is particularly important on high mileage engines Valve guides checking Valve seats sho...

Page 164: ...imension 0 4 mm NOTE If the max permissible refacing dimension is 0 mm or less than 0 mm repeat the measurement with new valve If the measured result is again 0 mm or less than 0 mm replace the cylind...

Page 165: ...be applied to the camshaft adjuster mechanical adjustment device Camshaft adjustment valve checking a 45 Valve seat angle 30 Adjustment angle top gamma 60 Adjustment angle bottom NOTE The camshaft ti...

Page 166: ...equence Start output Diagnostic Test Mode and activate camshaft adjustment valve Indicated on display This valve is actuated clicks for approx 1 minute if key is not pressed beforehand to select next...

Page 167: ...ecification 10 18 ohms If reading does not match specification Replace valve If measured value matches specification Check power supply Checking power supply Requirements Fuse for camshaft adjustment...

Page 168: ...ester VAG 1527B as follows Briefly operate starter LED must light up If LED does not light up Check for open circuit in wiring from contact 1 of connector through fuse to fuel pump relay Electrical Wi...

Page 169: ...st Mode and actuate camshaft adjustment valve Indicated on display LED must flash If LED does not flash or if it is permanently lit Connect test box VAG 1598 31 to engine control module wiring harness...

Page 170: ...system components removing and installing Viscosity grades and oil specifications Connector contact Test box VAG 1598 31 socket 2 115 NOTE If large quantities of metal shavings or particles are found...

Page 171: ...ication System Components Removing And Installing Part I Courtesy of VOLKSWAGEN UNITED STATES INC 1 28 Nm 2 Stop for torque reaction support 3 Oil pan 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Tu...

Page 172: ...of rotation before removing Check for wear 8 15 Nm 9 Front sealing flange Apply silicone sealant D 176 404 A2 before installing Sealing flanges and flywheel drive plate removing and installing Replaci...

Page 173: ...e Install oil pan immediately and tighten bolts in sequence shown under Installing 19 40 Nm 20 Sealing ring Replace 21 Oil drain plug 30 Nm 22 Gasket Always replace 23 Oil return line From turbocharge...

Page 174: ...SWAGEN UNITED STATES INC 1 Oil spray jet for piston cooling 2 Bolt with pressure relief valve 27 Nm 3 Opening pressure 1 3 to 1 6 bar Part II 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo Engin...

Page 175: ...GEN UNITED STATES INC 1 Screw plug 40 Nm 2 Sealing ring Always replace 3 Spring For pressure relief valve approx 4 bar 4 Piston For pressure relief valve approx 4 bar 2005 Audi A4 Quattro ENGINE 1 8 L...

Page 176: ...g 11 Lower coolant line 12 Screw plug 15 Nm 13 Sealing ring If seal is leaking cut open and replace 14 Oil supply line To turbocharger 15 Banjo bolt 30 Nm 16 Sealing rings Always replace 17 Oil pressu...

Page 177: ...installation instructions on oil filter Tighten to 20 Nm 22 25 Nm 23 Oil cooler See note Lubrication system components removing and installing Ensure clearance to adjacent components Coolant hose con...

Page 178: ...uxiliary items required Support bar 10 222A Lifting tackle 2024A Socket attachment 3249 or T10058 Workshop crane VAG1202A Electric drill with plastic brush attachment Protective goggles Removing Engin...

Page 179: ...AGEN UNITED STATES INC Unbolt sound insulation holder arrow Disconnect lower left air hose from charge air cooler Fig 239 Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove engine c...

Page 180: ...mounts Remove nuts 1 underneath left and right engine mounts Fig 241 Placing Support Bar 10 222A On Fender Mounting Flange Courtesy of VOLKSWAGEN UNITED STATES INC Place support bar 10 222A on fender...

Page 181: ...Engine Support Bridge 10 222A Courtesy of VOLKSWAGEN UNITED STATES INC Attach lifting tackle 2024A to lifting eyes at front and rear of engine Pre tension engine with spindle of engine support bar do...

Page 182: ...connect ATF lines from transmission NOTE Observe the rules for cleanliness when working on the automatic transmission 37 AUTOMATIC TRANSMISSION CONTROLS HOUSING for 5 SPD AUTOMATIC TRANSMISSION 01V 37...

Page 183: ...ig 247 Unclipping Operating Rod For Vehicle Levelling Sensor At Lower Transverse Link Courtesy of VOLKSWAGEN UNITED STATES INC If installed unclip operating rod for vehicle levelling sensor at lower t...

Page 184: ...me Courtesy of VOLKSWAGEN UNITED STATES INC First remove front bolts 2 and 3 from left and right subframe Then remove bolts 1 Vehicles with manual transmission NOTE The subframe should be removed and...

Page 185: ...s with automatic transmission Fig 251 Identifying Bolt Removal Sequence For Left Transmission Mount Courtesy of VOLKSWAGEN UNITED STATES INC Loosen rear bolt 2 on left transmission mount a few turns r...

Page 186: ...nsmission mount Fig 253 Subframe Supported Using Workshop Crane V A G 1202 A Courtesy of VOLKSWAGEN UNITED STATES INC Lower subframe slowly using workshop crane VAG1202A Roll out workshop crane VAG120...

Page 187: ...TES INC Remove oil pan If necessary loosen by tapping lightly using a rubber hammer NOTE Use T10058 for bolts 17 and 18 NOTE Remove both rear oil pan bolts 1 and 2 using socket attachment 3249 or T100...

Page 188: ...y must be free of oil and grease Installing Install in reverse order paying attention to the following Fig 257 Cutting Tube Nozzle At Front Marking Courtesy of VOLKSWAGEN UNITED STATES INC Cut off noz...

Page 189: ...hows position of sealant bead on cylinder block Install oil pan immediately and tighten bolts in sequence shown NOTE The sealant bead must not be thicker than 3 mm otherwise excess sealant can enter o...

Page 190: ...in diagonal sequence NOTE Replace gaskets and sealing rings Fig 260 Ensuring That Oil Pan Is Positioned Flush With Intermediate Plate At Flywheel End Courtesy of VOLKSWAGEN UNITED STATES INC When inst...

Page 191: ...SMISSION 09L FOUR WHEEL DRIVE All models Install lock carrier Lock carrier moving to service position Fill engine with oil and check oil level Vehicles with automatic transmission Check ATF level 37 A...

Page 192: ...t Remove bolts 1 and 3 and remove oil pump Installing Component Nm Oil pan to cylinder block M7 15 M10 40 Oil pan to transmission 45 Torque reaction support stop to oil pan 28 Engine mount to subframe...

Page 193: ...chain sprocket Can only be installed in one position Install oil pan Tightening torques Oil pressure and oil pressure switch checking Component Nm Chain sprocket to oil pump shaft 22 Oil pump to cyli...

Page 194: ...ogate symbol Checking oil pressure switch Disconnect wire from oil pressure switch Fig 264 Connecting Oil Pressure Tester V A G 1342 With Adapter V A G 1342 14 To Bore For Oil Pressure Switch Courtesy...

Page 195: ...screw in oil pressure tester VAG1342 Screw oil pressure switch 2 into VAG1342 Start engine engine oil temperature approx 80 C Oil pressure at idling speed 1 0 bar Oil pressure at 3000 RPM 3 5 to 4 5...

Page 196: ...after switching off engine to allow oil to flow back into oil pan Pull out dipstick wipe off with a clean cloth and insert it again as far as it will go Pull out dipstick again and read oil level Mark...

Page 197: ...nk is opened Cover cap with cloth and open carefully NOTE Cooling system is under pressure when engine is warm If necessary release pressure before repair work Secure all hose connections with standar...

Page 198: ...Heat exchanger for heater After replacing fill with fresh coolant 2 Coolant line lower 3 Expansion tank With cap Checking pressure relief valve in cap 4 Oil cooler 2005 Audi A4 Quattro ENGINE 1 8 Lite...

Page 199: ...0 Coolant pump thermostat Removing and installing coolant pump Coolant pump removing and installing Check for ease of movement 11 Turbocharger 12 Cylinder head cylinder block After replacing fill with...

Page 200: ...T10007 Drip tray VAG1306 Assembly tools for spring clips VAS5024A Draining NOTE Catch drained coolant in a clean container for re use or disposal CAUTION Hot steam can escape when cap on expansion ta...

Page 201: ...aining Clip For Engine Coolant Temperature ECT Sensor G2 Off Lower Coolant Hose And Drain Coolant From Radiator Courtesy of VOLKSWAGEN UNITED STATES INC Pull retaining clip 1 for Engine Coolant Temper...

Page 202: ...n additive On account of the higher boiling point the coolant helps to enhance engine reliability under heavy loads particularly in countries with tropical climates Frost protection must be guaranteed...

Page 203: ...Coolant Hose And Drain Coolant From Radiator Courtesy of VOLKSWAGEN UNITED STATES INC Insert Engine Coolant Temperature ECT sensor G2 2 back into lower coolant hose and attach clip 1 Attach coolant ho...

Page 204: ...lower hose on radiator becomes hot Check coolant level and top off if necessary When engine is at normal operating temperature coolant level must be at max mark When engine is cold coolant level must...

Page 205: ...l tools testers and auxiliary items required Refractometer T10007 Drip tray VAG1306 Torque wrench 5 50 Nm VAG1331 Assembly tools for spring clips VAS5024A Removing Remove front bumper 63 BUMPER 63 BUM...

Page 206: ...arrows Fig 276 Disconnecting Connector From A C Pressure Switch F129 Ambient Temperature Sensor Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect connector 1 from A C pressure switch F129 Disconnec...

Page 207: ...bolts for radiator and pull out upward arrows Swivel radiator forward out of lock carrier and lift out Installing Install in reverse order paying attention to the following Fill coolant system Cooling...

Page 208: ...nstalling Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required Refractometer T10007 Drip tray VAG1306 Torque wrench 5 to 50 Nm VAG1331 Assembly tools for spring...

Page 209: ...nnecting Fan Motor Connectors Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect connectors 1 and 2 and move fan motor wires clear Fig 281 Unbolting Coolant Fan From Radiator Cowl Courtesy of VOLKSWA...

Page 210: ...ng Fig 282 Identifying Special Tools Cooling System Components Servicing Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required Refractomet...

Page 211: ...and tensioning Fig 283 Removing Bolts Securing Coolant Pump And Coolant Pump Courtesy of VOLKSWAGEN UNITED STATES INC Remove bolts arrows securing coolant pump and remove coolant pump Installing Insta...

Page 212: ...Installing toothed belt and adjusting valve timing Toothed drive belt removing installing and tensioning Install ribbed belt tensioning element Tightening torque 25 Nm Install ribbed belt Ribbed belt...

Page 213: ...liary items required Cooling system tester VAG1274 Adapter VAG1274 8 Adapter VAG1274 9 Requirement Engine warm CAUTION Hot steam can escape when cap on expansion tank is opened Cover cap with cloth an...

Page 214: ...pump to generate pressure of approx 1 0 bar If there is a drop in pressure locate leak and eliminate fault Checking pressure relief valve in cap Fig 287 Checking Pressure Relief Valve In Filler Cap C...

Page 215: ...ure all hose connections with standard hose clamps Before performing checks or repair work make sure that all lines and hoses are securely connected and that there are no leaks Always replace gaskets...

Page 216: ...Mechanical recirculation valve 2 Wastegate Bypass Regulator Valve N75 3 Pressure regulator valve for crankshaft housing ventilation 4 Secondary Air Injection AIR Pump Motor V101 5 Air filter With Mass...

Page 217: ...hown in illustration 14 Crankshaft housing ventilation 15 Vacuum reservoir Component location Under wheelhousing liner in front left wheelhouse 16 Check valve Installed position Arrow on valve points...

Page 218: ...rger directly to catalytic converter Boost pressure regulation and vacuum control system connection diagram for vehicles as of 07 03 Fig 289 Boost Pressure Regulation And Vacuum Control System Connect...

Page 219: ...Installed position Arrow on valve points in direction of flow as shown in illustration 13 To brake booster 14 Vacuum suction jet pump 15 Check valve Installed position Arrow on valve points in directi...

Page 220: ...ure regulation When combination valve is opened mechanical boost pressure regulation valve in turbocharger is opened and secondary air is thereby channeled past turbocharger directly to catalytic conv...

Page 221: ...ault Finding in VAS5051 01 ON BOARD DIAGNOSTIC OBD Vehicle Diagnostic Testing and Information System VAS5051 or Scan Tool VAG1551 must be connected Work sequence CAUTION Always attach testers and meas...

Page 222: ...switch to position I absolute pressure Connect measuring hose to connection I NOTE Hose connections must be completely airtight otherwise measurements will not be correct Ensure that measuring hose i...

Page 223: ...for at least 3 km without stopping i e along route without traffic lights etc A second mechanic is required to note readings on tester when vehicle is moving Reading measured value block 115 1 2 3 4 N...

Page 224: ...e faulty Mechanical air recirculation valve checking checking Recirculating valve for turbocharger N249 faulty Recirculating valve for turbocharger N249 checking checking Turbocharger faulty Turbochar...

Page 225: ...ler and intake manifold 3 Charge air cooler 4 Gasket of Charge air pressure sensor G31 in charge air cooler 5 Gasket between throttle valve control module and intake manifold 6 Gasket between intake m...

Page 226: ...ck off pressure regulator knob 2 of VAG1687 fully to protect gauge when shop air supply is applied to assembly Close valve 3 before gauge Close valve 4 after gauge The shop air supply line will later...

Page 227: ...bo Install optional fitting LKI9210 50 on hose of special tool KLI9210 Fig 298 Special Tool KLI9210 Evaporative System Leak Detector Connecting To 1 8L Turbo Courtesy of VOLKSWAGEN UNITED STATES INC C...

Page 228: ...ke see instructions printed on tester With system filled with smoke Remove smoke generator hose and connect VAG1687 quickly to prevent smoke from leaking out Special tool VAG1687 connecting to pressur...

Page 229: ...of VOLKSWAGEN UNITED STATES INC With outlet hose 1 of VAG1687 connected to air pressure adapter Attach shop air supply line to previously installed male fitting Charge pressure leak test with VAG1687...

Page 230: ...l the system with smoke Apply soapy water solution or equivalent to intake system connections Inspect intake system connections for leaks Repair any leaks found Remove tester Remove plug from crankcas...

Page 231: ...p V A G 1390 Courtesy of VOLKSWAGEN UNITED STATES INC NOTE The mechanical air recirculation valve is located upstream of turbocharger It is opened by vacuum via the Recirculating valve for turbocharge...

Page 232: ...e air vent valve on vacuum pump after approx 30 seconds Air recirculation valve should close arrow If the mechanical air recirculation valve does not open and close as specified or if the valve plate...

Page 233: ...items required Multimeter VAG1526A or equivalent Voltage tester VAG1527B Connector test set VAG1594A Adapter VAG1598 31 Vehicle Diagnostic Testing and Information System VAS5051 VAS5051 with VAS5051...

Page 234: ...noid Valve N112 Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect hoses from Recirculating valve for turbocharger N249 1 leave electrical connector connected Location under intake manifold NOTE The...

Page 235: ...Valve must click and must open and close can be checked by blowing into test hose If valve does not click Check internal resistance of valve If valve does not open or close properly Replace Recirculat...

Page 236: ...GEN UNITED STATES INC Connect multimeter and measure resistance at valve Specification 27 30 ohms If reading does not match specification Replace Recirculating valve for turbocharger N249 If measured...

Page 237: ...ester VAG1527B as follows Briefly operate starter LED must light up If LED does not light up Check for open circuit in wiring from contact 1 of connector through fuse to fuel pump relay Electrical Wir...

Page 238: ...ox VAG1598 31 to engine control module wiring harness Engine control module must not be connected 24 MULTIPORT FUEL INJECTION MFI Fig 312 Identifying 2 Pin Electrical Connector Terminals Courtesy of V...

Page 239: ...gulator Valve N75 Checking Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required Multimeter VAG1526A or equivalent Voltage tester VAG1527B Connector test set VAG1...

Page 240: ...leave connector connected Fig 314 Connecting Test Hose To Valve Connection Courtesy of VOLKSWAGEN UNITED STATES INC Connect test hose to valve connection marked with arrow Start Output Diagnostic Test...

Page 241: ...ge Courtesy of VOLKSWAGEN UNITED STATES INC Connect multimeter and measure resistance at valve Specification 25 to 35 ohms If reading does not match specification Replace Wastegate bypass regulator va...

Page 242: ...LED does not light up Check for open circuit in wiring from contact 1 of connector through fuse to fuel pump relay Electrical Wiring Diagrams Troubleshooting and Component Locations If necessary elim...

Page 243: ...rmanently lit Connect test box VAG1598 31 to engine control module wiring harness Engine control module must not be connected 24 MULTIPORT FUEL INJECTION MFI Fig 318 Identifying 2 Pin Electrical Conne...

Page 244: ...ig 319 Identifying Special Tools Charge Air Pressure Sensor G31 Checking Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required Connector contact Test box VAG1598...

Page 245: ...quence Read DTC memory of engine control module If display shows a DTC relating to Charge air pressure sensor G31 Checking power supply Fig 320 Disconnecting Connector On Charge Air Pressure Sensor Co...

Page 246: ...ng does not match specification Fig 322 Connecting Test Box VAG1598 31 To Engine Control Module Wiring Harness Courtesy of VOLKSWAGEN UNITED STATES INC Connect test box VAG1598 31 to engine control mo...

Page 247: ...connector for charge air pressure sensor Connect multimeter and measure voltage at sockets 101 and 108 of test box Start engine and let it idle Specification approx 1 90 V Increase engine speed by qu...

Page 248: ...parts removed on a clean surface and cover them over Do not use fluffy cloths Carefully cover or seal opened components if repairs are not to be performed immediately Only install clean components Do...

Page 249: ...I Courtesy of VOLKSWAGEN UNITED STATES INC 1 30 Nm Only use genuine bolt 2 Gasket Replace 3 Catalytic converter 4 30 Nm Always replace 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo Engine Mech...

Page 250: ...nd contact surface of bolt head with hot bolt paste G 052 112 A3 13 10 Nm 14 Banjo bolt 30 Nm 15 Gasket Always replace Note installed position 16 Coolant return line Tighten union nut to 30 Nm 17 30 N...

Page 251: ...ket Always replace 24 Oil return line To oil pan 25 Gasket Always replace 26 10 Nm 27 10 Nm 28 Turbocharger Checking Turbocharger and charge pressure control valve checking 29 25 Nm 30 Bracket Part II...

Page 252: ...um hose To Recirculating valve for turbocharger N249 2 Mechanical air recirculation valve Checking Mechanical air recirculation valve checking 3 Hose To air recirculation valve 4 Air hose 2005 Audi A4...

Page 253: ...0 Hose To turbocharger 11 Hose To vacuum unit for charge pressure control valve 12 Wastegate bypass regulator valve N75 13 Angle piece 14 Hose To turbocharger Turbocharger removing and installing Spec...

Page 254: ...ATES INC Hose clamps 3094 Removing Fig 328 Noise Insulation Tray Retainers Courtesy of VOLKSWAGEN UNITED STATES INC Remove sound insulation arrows 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo...

Page 255: ...ure to body with wire Fig 330 Identifying Turbocharger Bracket Oil Return Line Air Hoses Banjo Bolt Courtesy of VOLKSWAGEN UNITED STATES INC Unbolt turbocharger bracket 2 Unbolt oil return line 1 from...

Page 256: ...ws Fig 332 Air Cleaner Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove air cleaner cover arrow Fig 333 Removing Bolts Air Duct Courtesy of VOLKSWAGEN UNITED STATES INC 2005 Audi A4 Quattro ENGIN...

Page 257: ...ring connectors from 1 EVAP valve additionally remove EVAP valve from air cleaner housing 2 Mass Air Flow sensor 3 Wastegate bypass regulator valve N75 Pull off hoses move wiring clear and remove air...

Page 258: ...e Fig 336 Using Hose Clamp 3094 To Clamp Off Coolant Return Hose To Turbocharger Courtesy of VOLKSWAGEN UNITED STATES INC Use hose clamp 3094 to clamp off coolant return hose to turbocharger Release h...

Page 259: ...bolts Using bracket secure coolant supply line loosely to vacuum unit for charge pressure control valve Tighten banjo bolt to 35 Nm and then tighten securing bolt on bracket to 10 Nm NOTE To avoid da...

Page 260: ...ger 10 Turbocharger to exhaust manifold 35 See note Component Nm Turbocharger bracket to cylinder block 25 Turbocharger bracket to turbocharger 30 Catalytic converter to turbocharger 30 Oil return lin...

Page 261: ...STATES INC 1 Air duct 2 Rubber grommet 3 Air hose Between charge air cooler and air duct in lock carrier 4 Air hose Between intake manifold and charge air cooler 5 O ring 2005 Audi A4 Quattro ENGINE 1...

Page 262: ...moving and installing Removing Lock carrier in service position Lock carrier moving to service position Fig 339 Removing Air Hose Disconnect connector 2 from Charge air pressure sensor G31 Courtesy of...

Page 263: ...RVICING Exhaust system components servicing Component Nm Hose clamps for air hoses 3 5 NOTE Always replace gaskets and self locking nuts After working on the exhaust system ensure that the system is n...

Page 264: ...t Wheel Drive Vehicles Courtesy of VOLKSWAGEN UNITED STATES INC 1 Turbocharger Removing and installing Turbocharger removing and installing 2 Gasket Always replace 3 Heated Oxygen Sensor HO2S G39 50 N...

Page 265: ...impact damage Removing and installing Catalytic converter removing and installing 6 Gasket Replace 7 25 Nm 8 Front exhaust pipe With decoupling element To avoid damage do not bend decoupling element b...

Page 266: ...aust system vehicles with front wheel drive aligning stress free Replacing tailpipe Replacing tailpipe 20 Rear clamps For separate replacement of center muffler and both rear mufflers Align exhaust sy...

Page 267: ...ion of front clamp Fig 342 Installed Position Of Front Clamp Courtesy of VOLKSWAGEN UNITED STATES INC Install clamp so that ends of bolts are not below bottom circumference of clamp Bolted connection...

Page 268: ...e aligning stress free Tighten bolted connections evenly to 40 Nm Replacing tailpipe Fig 344 Replacing Tailpipe Courtesy of VOLKSWAGEN UNITED STATES INC Cut through tailpipe 1 squarely at cutting poin...

Page 269: ...Wheel Drive Vehicles Courtesy of VOLKSWAGEN UNITED STATES INC 1 Turbocharger Removing and installing Turbocharger removing and installing 2 Gasket Always replace 3 Heated Oxygen Sensor HO2S G39 50 Nm...

Page 270: ...act damage Removing and installing Catalytic converter removing and installing 6 Gasket Always replace 7 25 Nm 8 Front exhaust pipe With decoupling element To avoid damage do not bend decoupling eleme...

Page 271: ...xhaust system vehicles with all wheel drive aligning stress free Replacing tailpipe Replacing tailpipe 20 40 Nm 21 Rear clamps For separate replacement of center muffler and both rear mufflers Align e...

Page 272: ...Installed Position Of Front Clamp Courtesy of VOLKSWAGEN UNITED STATES INC Install clamp so that ends of bolts are not below bottom circumference of clamp Bolted connection on left Installed position...

Page 273: ...d connections evenly to 40 Nm Replacing tailpipe Fig 348 Replacing Tailpipe Courtesy of VOLKSWAGEN UNITED STATES INC Cut through tailpipe 1 squarely at cutting point C using body saw e g VAG1523A Push...

Page 274: ...ms required Fig 349 Identifying Body Repair Saw V A G 1523 A Courtesy of VOLKSWAGEN UNITED STATES INC Body saw VAG1523A Protective goggles Vehicles with front wheel drive Cut through exhaust pipe squa...

Page 275: ...ng stress free Tighten bolted connections on clamp evenly to 40 Nm Vehicles with all wheel drive Cut through exhaust pipe squarely using body saw e g VAG1523A at position indicated by punch marks Fig...

Page 276: ...oving Fig 352 Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove engine cover arrows Fig 353 Air Cleaner Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove air cleaner cover arro...

Page 277: ...air duct 2 Remove both screws arrows for air duct 2 Fig 355 Disconnect Wires Unplug Connectors From Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect wiring connectors from 1 EVAP valve 2 Mass Air F...

Page 278: ...air cleaner housing 9 Remove air cleaner Fig 357 Noise Insulation Tray Retainers Courtesy of VOLKSWAGEN UNITED STATES INC Remove sound insulation arrows NOTE Vacuum line to secondary air combination v...

Page 279: ...Line Front Hose Off Line To Secondary Air Combination Valve Removing Heat Shield Courtesy of VOLKSWAGEN UNITED STATES INC Pull front hose off crankcase breather line 2 Pull front hose off line to seco...

Page 280: ...1 Removing All Nuts On Exhaust Manifold Courtesy of VOLKSWAGEN UNITED STATES INC Remove all nuts arrows on exhaust manifold Remove washers and exhaust manifold Installing Install in reverse order payi...

Page 281: ...en Sensors Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect 4 pin connectors of oxygen sensors and move wires clear 1 Brown to O2S Behind TWC G130 only with engine code AMB Component Nm Exhaust man...

Page 282: ...ion Canister Purge Regulator Valve N80 And Air Duct Courtesy of VOLKSWAGEN UNITED STATES INC Remove bolts arrows Disengage EVAP canister purge regulator valve N80 1 from air duct 2 Remove both screws...

Page 283: ...366 Disconnect Wires Unplug Connectors From Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect hose to secondary air injection pump motor 8 Move wiring clear Unbolt air cleaner housing 9 Remove air...

Page 284: ...e aligning stress free and Exhaust system vehicles with all wheel drive aligning stress free Tightening torques Front exhaust pipe removing and installing Removing Components Nm Oxygen sensor to catal...

Page 285: ...Axle Courtesy of VOLKSWAGEN UNITED STATES INC Remove heat shield arrows above right side drive axle Fig 369 Separating Exhaust System At Clamp Courtesy of VOLKSWAGEN UNITED STATES INC Separate exhaust...

Page 286: ...vehicles with all wheel drive aligning stress free Tightening torques Exhaust system vehicles with front wheel drive aligning stress free Vehicles without clamp between center muffler and rear muffle...

Page 287: ...ipes Courtesy of VOLKSWAGEN UNITED STATES INC Check to make sure that distances a and b between tailpipe and bumper are equal Vehicles with clamp between center muffler and rear muffler Exhaust system...

Page 288: ...ehicle Courtesy of VOLKSWAGEN UNITED STATES INC Push rear section of exhaust system toward front of vehicle arrow until preloading at rear mounting of rear muffler is a 12 mm Also make sure that cente...

Page 289: ...heel drive aligning stress free Vehicles without clamp between center muffler and rear muffler Exhaust system must be aligned when cold Fig 377 Separating Exhaust System At Clamp Courtesy of VOLKSWAGE...

Page 290: ...System Toward Front Of Vehicle Courtesy of VOLKSWAGEN UNITED STATES INC Push front section of exhaust system toward front of vehicle arrow until preloading at right side mounting of center muffler is...

Page 291: ...led position of rear clamps Installed position of rear clamps and Installed position of rear clamp Tighten bolted connections on rear clamps evenly to 40 Nm Aligning tailpipes Fig 381 Aligning Tailpip...

Page 292: ...catalytic converter thereby reducing toxic emissions The heat generated by oxidation accelerates the light off of the catalytic converter and significantly improves exhaust gas quality during warm up...

Page 293: ...njection AIR pump motor V101 2 Air cleaner 3 Secondary air combination valve Location Location of Secondary air combination valve 4 Non return valve Installed position light dark side and direction of...

Page 294: ...head Location of Secondary Air Injection AIR solenoid valve N112 Fig 383 Identifying Secondary Air Injection AIR Solenoid Valve N112 Courtesy of VOLKSWAGEN UNITED STATES INC Under intake manifold 1 Re...

Page 295: ...Injection AIR Pump Relay J299 Courtesy of VOLKSWAGEN UNITED STATES INC 3 way relay carrier in electronics box in plenum chamber position 2 1 Engine control module 2 Secondary Air Injection AIR pump re...

Page 296: ...ve Courtesy of VOLKSWAGEN UNITED STATES INC Right rear on cylinder head Secondary Air Injection AIR solenoid valve N112 checking 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo Engine Mechanical...

Page 297: ...ary items required Multimeter VAG1526A or equivalent Voltage tester VAG1527B Connector test set VAG1594A Adapter VAG1598 31 Vehicle Diagnostic Testing and Information System VAS5051 VAS5051 with VAS50...

Page 298: ...e N112 Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect hoses from secondary Air Injection AIR solenoid valve N112 2 but leave electrical connector connected Installation location under intake mani...

Page 299: ...Valve must click and must open and close can be checked by blowing into test hose If valve does not click Check internal resistance of valve If valve does not open or close properly Replace Secondary...

Page 300: ...UNITED STATES INC Connect multimeter and measure resistance at valve Specification 27 to 30 ohms If reading does not match specification Replace Secondary Air Injection AIR solenoid valve N112 If mea...

Page 301: ...ester VAG1527B as follows Briefly operate starter LED must light up If LED does not light up Check for open circuit in wiring from contact 1 of connector through fuse to fuel pump relay Electrical Wir...

Page 302: ...test box VAG1598 31 to engine control module wiring harness Engine control module must not be connected 24 MULTIPORT FUEL INJECTION MFI Fig 394 Identifying 2 Pin Electrical Connector Terminals Courtes...

Page 303: ...tion AIR Pump Relay J299 And Secondary Air Injection AIR Pump Motor V101 Checking Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required Multimeter VAG1526A or equ...

Page 304: ...um chamber cover in direction of arrow Pull plenum chamber cover 1 toward front and remove Fig 397 Unbolting Cover Of Electronics Box In Plenum Chamber Courtesy of VOLKSWAGEN UNITED STATES INC Unbolt...

Page 305: ...power supply of secondary AIR pump relay Check actuation of secondary AIR pump relay B If relay picks up but secondary AIR pump motor does not run Check power supply for secondary AIR pump motor Chec...

Page 306: ...7 Check for open circuit in wiring from battery terminal 30 to fuse S130 to Secondary AIR pump relay J299 in 3 way relay carrier of electronics box in plenum chamber position 2 Electrical Wiring Diag...

Page 307: ...heck for open circuit in wiring from Secondary AIR pump relay J299 in 3 way relay carrier of electronics box in plenum chamber to fuel pump relay via fuse S234 in fuse box position 34 Electrical Wirin...

Page 308: ...control module wiring harness Engine control module must not be connected 24 MULTIPORT FUEL INJECTION MFI Fig 404 Identifying Secondary Air Pump Relay Terminals Courtesy of VOLKSWAGEN UNITED STATES IN...

Page 309: ...ws Fig 406 Disconnecting Connector From Secondary AIR Pump Motor V101 Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect connector from Secondary AIR pump motor V101 arrow Location right front in eng...

Page 310: ...relay J299 in 3 way relay carrier in electronics box of plenum chamber position 2 Electrical Wiring Diagrams Troubleshooting and Component Locations Check for open circuit in wiring from contact 2 of...

Page 311: ...ents No leaks along vacuum hoses or at hose connections No obstructions in vacuum hoses Work sequence Fig 409 Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove engine cover arrows...

Page 312: ...hand pump VAG1390 to vacuum hose of combination valve Fig 411 Noise Insulation Tray Retainers Courtesy of VOLKSWAGEN UNITED STATES INC Remove sound insulation arrows Fig 412 Disconnecting Hose At Lin...

Page 313: ...uum hand pump Combination valve should open It should now be possible to blow through hose If combination valve does not open Replace combination valve Secondary air combination valve removing and ins...

Page 314: ...Combination Valve Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect vacuum hose arrow at combination valve Remove 4 bolts from combination valve and remove combination valve Installing Install in re...

Page 315: ...r line to cylinder head cover 10 Secondary air line to secondary air combination valve 10 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo Engine Mechanical Engine Code s AMB 1 01 38 AM Page 303 c...

Page 316: ...t of bumper See Fig 5 Remove left and right retaining bolts until bumper is fully released See Fig 6 6 If installed disconnect hose 1 to headlight cleaning system Disconnect harness connectors 2 and r...

Page 317: ...tensioner piston can be locked with Locking Plate T10008 See Fig 15 NOTE Mark direction of ribbed belt with chalk or felt tip pen prior to removal Running a used belt in the opposite direction could...

Page 318: ...Fig 1 Removing Under Car Noise Insulation Avant Sedan Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 3 cardiagn com...

Page 319: ...Fig 2 Identifying Auxiliary Heater Exhaust Pipe Bolts Avant Sedan Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 4 cardiagn com...

Page 320: ...Fig 3 Locating Wheelhousing Fasteners Avant Sedan Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 5 cardiagn com...

Page 321: ...Fig 4 Identifying Front Bumper To Fender Fasteners Avant Sedan Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 6 cardiagn com...

Page 322: ...Fig 5 Removing Grilles Avant Sedan Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 7 cardiagn com...

Page 323: ...Fig 6 Identifying Bumper Fasteners Avant Sedan Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 8 cardiagn com...

Page 324: ...Fig 7 Identifying Washer Hoses Harness Connectors Avant Sedan Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 9 cardiagn com...

Page 325: ...Fig 8 Identifying Lock Carrier Components Avant Sedan Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 10 cardiagn com...

Page 326: ...Fig 9 Identifying Support Tool Part No 3369 Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 11 cardiagn com...

Page 327: ...Fig 10 Installing Support Tool 3369 Into Chassis Avant Sedan Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 12 cardiagn com...

Page 328: ...Fig 11 Securing Lock Carrier In Service Position Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 13 cardiagn com...

Page 329: ...Fig 12 Removing Installing Ribbed Belt Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 14 cardiagn com...

Page 330: ...Fig 13 Locking Ribbed Belt Tensioner Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 15 cardiagn com...

Page 331: ...Fig 14 Identifying Top Dead Center TDC Position Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 16 cardiagn com...

Page 332: ...Fig 15 Compressing Timing Belt Tensioner Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 17 cardiagn com...

Page 333: ...the bumper cover 1 2 Loosen the wheel housing liners on left and right at front Pull the wheel housing liner back Remove the bolt 2 and nuts 1 See Fig 18 Unclip bumper extension from catch B 3 Remove...

Page 334: ...lley counterclockwise in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with Locking Plate T10008 See Fig 15 10 To...

Page 335: ...Fig 17 Identifying Bumper Cover Fasteners Cabriolet Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 06 AM Page 20 cardiagn com...

Page 336: ...g 18 Identifying Bumper Cover Fasteners At Wheel Opening Cabriolet Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 07 AM Page 21 cardiagn co...

Page 337: ...Fig 19 Removing Bumper Cover Cabriolet Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 07 AM Page 22 cardiagn com...

Page 338: ...AUDI OF AMERICA INC Installation Avant Sedan CAUTION To prevent pistons from hitting valves make sure crankshaft is NOT at TDC for any piston before turning camshaft 2005 Audi A4 Quattro AUDI 1 8L 4...

Page 339: ...leys On vehicles with A C install ribbed belt to A C compressor last 6 To install lock carrier reverse removal procedures outlined in REMOVAL AVANT SEDAN Torque all fasteners to specification See TORQ...

Page 340: ...Fig 21 Releasing Locking Plate From Tensioner Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 07 AM Page 25 cardiagn com...

Page 341: ...Fig 22 Adjusting Timing Belt Tensioner Courtesy of AUDI OF AMERICA INC 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 07 AM Page 26 cardiagn com...

Page 342: ...rks See Fig 14 Install timing belt in this order water pump tensioning pulley camshaft sprocket 3 Turn eccentric bolt counterclockwise in direction of arrow using special tool 3387 See Fig 21 Hold NOT...

Page 343: ...to specification See TORQUE SPECIFICATIONS 7 To install bumper cover reverse removal procedures outlined in REMOVAL CABRIOLET Slide bumper cover onto lock carrier and connect the hose of headlight was...

Page 344: ...ct Absorber To Frame Bolts 33 45 Ribbed Belt Tensioner To Bracket Bolts 17 23 Timing Belt Tensioner Pulley Bolt 20 27 Timing Belt Tensioner To Bracket Bolts Larger Bolt 18 25 Smaller Bolt 11 15 Torque...

Page 345: ...ieving torque tighten an additional quarter turn 90 2 Install with Locking Fluid D 000 600 A2 3 Replace bolts 2005 Audi A4 Quattro AUDI 1 8L 4 Cylinder Turbo AMB Engine 2002 04 A4 12 44 07 AM Page 30...

Page 346: ...ing vehicle battery 91 COMMUNICATION After reconnecting vehicle battery re code and check operation of anti theft radio Also check operation of clock and power windows according to Repair Article and...

Page 347: ...ial tools testers and auxiliary items required Support bar 10 222A Lifting tackle 2024A Special tool 3147 Workshop crane VAG1202A Drip tray VAG1306 Socket attachment 15 mm A F Matra V 175 2005 Audi A4...

Page 348: ...io Fig 4 Removing Rubber Seal From Plenum Chamber Cover Courtesy of VOLKSWAGEN UNITED STATES INC NOTE All cable ties unfastened or cut when removing engine are to be reattached in same position during...

Page 349: ...rap arrow Use screwdriver to pry off caps 3 from wiper arms Fig 6 Removing Securing Clips And Cowl Courtesy of VOLKSWAGEN UNITED STATES INC Loosen hex nuts 4 by a few turns Tilt wiper arm 2 slightly t...

Page 350: ...Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove air cleaner cover arrow Fig 9 Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct Courtesy of VOLKSWAGEN UNITED STATES INC 2005 A...

Page 351: ...ts Securing Exhaust Pipe Of Auxiliary Additional Heater To Sound Insulation Courtesy of VOLKSWAGEN UNITED STATES INC Remove bolts arrows securing exhaust pipe of auxiliary additional heater to sound i...

Page 352: ...Air Cooler Courtesy of VOLKSWAGEN UNITED STATES INC Remove air duct in front of charge air cooler arrows Place drip tray VAG1306 under engine Fig 14 Pulling Retaining Clip For Engine Coolant Temperat...

Page 353: ...ing Coolant Hose From Oil Cooler Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect coolant hose from oil cooler arrow and drain remaining coolant Fig 16 Removing Air Hose To Charge Air Cooler At Bot...

Page 354: ...ff Inlet And Outlet Pipe Of Cooling Coil For Power Steering Hydraulic Fluid Courtesy of VOLKSWAGEN UNITED STATES INC Use 3093 to clamp off inlet and outlet pipe of cooling coil for power steering hydr...

Page 355: ...om A C pressure switch F129 Disconnect connector 2 from ambient temperature sensor Move both wires clear Unbolt condenser arrows from radiator Carefully swivel condenser downward and set down CAUTION...

Page 356: ...D LIDS 55 HOOD LIDS for CABRIOLET Fig 22 Removing Top Coolant Hose From Radiator Disconnecting Connectors For Left Right Airbag Sensor Courtesy of VOLKSWAGEN UNITED STATES INC Remove top coolant hose...

Page 357: ...secure position NOTE Observe the rules for cleanliness when working on an automatic transmission 37 AUTOMATIC TRANSMISSION CONTROLS HOUSING for 5 SPD AUTOMATIC TRANSMISSION 01V 37 AUTOMATIC TRANSMISSI...

Page 358: ...D STATES INC Disconnect fuel supply line 1 and set aside Vehicles as of 07 03 CAUTION Fuel system is under pressure Before opening system place rags around the connection point Then release pressure b...

Page 359: ...l system Fig 27 Disconnecting Fuel Supply Line Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect fuel supply line Seal off line so that no dirt can enter fuel system the connection point Then releas...

Page 360: ...purge regulator valve 2 Mass air flow sensor 3 Wastegate bypass regulator valve N75 Disconnect hoses 4 7 Disconnect hose to secondary air injection pump motor 8 Move wires clear Unbolt air cleaner ho...

Page 361: ...ion tank Lift coolant expansion tank slightly at bolt side and pull it out of catch on plenum chamber side Fig 30 Unbolting Cover Of Electronics Box In Plenum Chamber Courtesy of VOLKSWAGEN UNITED STA...

Page 362: ...Engine Control Module ECM J623 Courtesy of VOLKSWAGEN UNITED STATES INC Release catches arrows and disconnect control module connectors 1 and 2 Fig 33 Disconnecting Connectors From Connector Rail Cour...

Page 363: ...onics box housing and plenum chamber and place on engine Fig 35 Disconnecting 4 Pin Connectors Of Oxygen Sensors Courtesy of VOLKSWAGEN UNITED STATES INC Remove connectors 1 4 from mount Disconnect co...

Page 364: ...bination valve Fig 37 Removing Wires From Starter Insulator From Positive Connection On Starter Courtesy of VOLKSWAGEN UNITED STATES INC Remove wires 1 and 2 from starter remove insulator from positiv...

Page 365: ...rter Bolts Through Opening Of Removed Starter Courtesy of VOLKSWAGEN UNITED STATES INC Remove 3 torque converter bolts through opening of removed starter using Matra V175 15 mm A F socket attachment r...

Page 366: ...t Pipe Courtesy of VOLKSWAGEN UNITED STATES INC Remove bolts arrows securing catalytic converter to front exhaust pipe Unbolt transmission bracket for exhaust system arrow NOTE To avoid damage do not...

Page 367: ...Loosen Ribbed Belt Courtesy of VOLKSWAGEN UNITED STATES INC Swivel tensioner in direction of arrow to loosen ribbed belt Remove ribbed belt from generator pulley Fig 44 Disconnecting Compressor Clutc...

Page 368: ...ng air conditioning compressor together with condenser and connected wires at right of vehicle Use hose clamp 3093 to clamp off hose between expansion tank and power steering pump Place drip tray unde...

Page 369: ...ehind Gas Filled Strut On Suspension Strut Domes Courtesy of VOLKSWAGEN UNITED STATES INC Place support bar 10 222A behind gas filled strut on suspension strut domes Spindle at front Engage transmissi...

Page 370: ...Attach lifting tackle 2024A to engine and hook onto workshop crane VAG1202A Remove last securing bolt Lift engine over studs of engine mounts Loosen support bar 10 222A slightly Vehicles with automat...

Page 371: ...toward front of vehicle out of engine compartment Vehicles with automatic transmission If necessary secure torque converter in transmission with wire to prevent it from falling out Engine securing to...

Page 372: ...at clutch plate is properly centered A needle bearing must be installed in crankshaft on vehicles with manual transmission Install needle bearing if necessary Pilot needle bearing in crankshaft extrac...

Page 373: ...ompressor Install ribbed belt Vehicles with automatic transmission Secure ATF lines 37 AUTOMATIC TRANSMISSION CONTROLS HOUSING for 5 SPD AUTOMATIC TRANSMISSION 01V 37 AUTOMATIC TRANSMISSION CONTROLS H...

Page 374: ...tion on fuel rail pipe To do so counterhold using an open end wrench at each hex head 1 and 3 and tighten union nut 2 to 22 Nm All Electrical connections and routing Electrical Wiring Diagrams Trouble...

Page 375: ...WHEEL DRIVE INTERNAL COMPONENTS SERVICING 37 CONTROLS HOUSING for AUTOMATIC TRANSMISSION 09L FOUR WHEEL DRIVE All models Adjust headlights 94 LIGHTS SWITCHES EXTERIOR Tightening torques NOTE Drained c...

Page 376: ...ne Transmission Mountings Automatic Manual Transmission Courtesy of VOLKSWAGEN UNITED STATES INC Engine transmission mountings automatic transmission Item Bolt Nm 1 3 4 M12 x 67 65 2 6 M12 x 90 65 5 1...

Page 377: ...kets for ATF lines 10 Power steering pump to bracket 25 Pulley to power steering pump 25 Pulley to coolant pump 25 Viscous fan to bearing 45 Air conditioning compressor to bracket 25 Component Nm Drai...

Page 378: ...the emergency back up battery for the Telematic Telephone Control Module prior to disconnecting vehicle battery 91 COMMUNICATION After reconnecting vehicle battery re code and check operation of anti...

Page 379: ...rrier In Service Position Overview Courtesy of VOLKSWAGEN UNITED STATES INC 1 45 Nm 2 45 Nm 3 10 Nm 4 10 Nm 5 Hole For special tool 3369 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo Engine Mec...

Page 380: ...on Courtesy of VOLKSWAGEN UNITED STATES INC Remove bolts arrows securing exhaust pipe of auxiliary additional heater to sound insulation All models Fig 61 Removing Sound Insulation Courtesy of VOLKSWA...

Page 381: ...edges Remove front bumper 63 BUMPER 63 BUMPERS for CABRIOLET Remove bolts on left and right arrows Fig 63 Screwing Special Tool 3369 Into Free Holes On Left Right Courtesy of VOLKSWAGEN UNITED STATES...

Page 382: ...PER 63 BUMPERS for CABRIOLET Adjust headlights 94 LIGHTS SWITCHES EXTERIOR Tightening torques Ribbed belt for generator vane pump and air conditioner compressor Component Nm Lock carrier to longitudin...

Page 383: ...VOLKSWAGEN UNITED STATES INC 1 25 Nm 2 Tensioning roller 3 Ribbed belt Mark direction of rotation before removing Removing and installing Ribbed belt removing and installing 4 25 Nm 5 Bracket 2005 Aud...

Page 384: ...removing and installing Loosen bolted connection at top and bottom Swivel generator to side slightly and disconnect electrical connectors Remove generator 8 20 Nm 9 40 Nm 10 20 Nm 11 Power steering pu...

Page 385: ...er moving to service position Removing ribbed belt Ribbed belt removing and installing When installing vibration damper only use genuine bolts Vibration damper can only be installed in one position Ho...

Page 386: ...ioner Using Mandrel T10060 Courtesy of VOLKSWAGEN UNITED STATES INC Lock tensioner using mandrel T10060 arrow Remove ribbed belt Installing NOTE Mark direction of the ribbed belt with chalk or felt ti...

Page 387: ...ing and filling Obtain and record radio anti theft code for vehicles with a coded radio NOTE Before installing the ribbed belt make sure that all mechanical units generator air conditioning compressor...

Page 388: ...STATES INC Disconnect top coolant hose from radiator arrow Fig 72 Unboltin Generator From Bracket Courtesy of VOLKSWAGEN UNITED STATES INC Unbolt generator from bracket Disconnect wiring from generato...

Page 389: ...t disconnect connections Fig 74 Unbolting Power Steering Pump From Rear Bracket Courtesy of VOLKSWAGEN UNITED STATES INC Unbolt power steering pump from rear bracket Place power steering pump to one s...

Page 390: ...ning compressor connector right arrow Fig 76 Unbolting Air Conditioning Compressor From Bracket Courtesy of VOLKSWAGEN UNITED STATES INC Unbolt air conditioning compressor from bracket Hang air condit...

Page 391: ...ering pump and A C compressor at bolts 1 through 3 Only for replacement of bracket Remove idler roller for ribbed belt from bracket for generator power steering pump and A C compressor Installing Inst...

Page 392: ...t idler wheel for ribbed belt to bracket for generator power steering pump and air conditioning compressor All models To ease installation of power steering pump knock back bushing on rear securing bo...

Page 393: ...and A C compressor to cylinder block 40 Support for intake manifold 20 A C compressor to bracket 25 Component Nm Generator to bracket 20 Power steering pump to bracket 20 Hose clamps for coolant hose...

Page 394: ...d lower To remove unbolt vibration damper 2 10 Nm Apply D 000 600 when installing 3 Toothed belt guard center To remove unbolt ribbed belt tensioner 4 Toothed belt guard top 2005 Audi A4 Quattro ENGIN...

Page 395: ...thed drive belt removing installing and tensioning Installed position Installed position of camshaft sprocket 10 Tensioning roller 11 Washer 12 Toothed belt tensioner 13 O ring Replace Coat with coola...

Page 396: ...rtesy of VOLKSWAGEN UNITED STATES INC Narrow chamfer of camshaft sprocket must face outward arrows and marking for TDC No 1 cylinder must be visible from front Removing and installing crankshaft tooth...

Page 397: ...oothed Drive Belt Removing Installing And Tensioning Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required torque wrench 5 to 50 Nm VAG1331 Locking plate T10008 t...

Page 398: ...LKSWAGEN UNITED STATES INC Remove engine cover by lifting up arrows Remove ribbed belt Ribbed belt removing and installing Fig 84 Removing Installing Ribbed Belt Tensioner Courtesy of VOLKSWAGEN UNITE...

Page 399: ...note of the installed position of the upper part of the drive belt cover particularly where it meets the center part of the drive belt cover CAUTION The engine must only be turned in the direction of...

Page 400: ...urtesy of VOLKSWAGEN UNITED STATES INC Unbolt vibration damper Fig 88 Removing Center And Lower Part Of Drive Belt Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove center and lower part of drive...

Page 401: ...t 1 on pulley and rotate eccentric bolt clockwise in direction of arrow using special tool 3387 Mark direction of rotation of drive belt with chalk or felt tip pen Remove drive belt Installing adjusti...

Page 402: ...ow Fig 92 Identifying Marking On Camshaft Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES INC cylinder Risk of damaging valves piston crown NOTE The vibration dam...

Page 403: ...se in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with locking plate T10008 All CAUTION If the drive belt tensio...

Page 404: ...ckwise to right in direction of arrow until a gauge 2 with dimension a e g drill bit can be passed between tensioning lever and tensioner housing Dimension a 8 mm Hold eccentric bolt in this position...

Page 405: ...ft must be at TDC cylinder 1 arrows Fig 97 Checking Tensioning Roller Specified Dimension Courtesy of VOLKSWAGEN UNITED STATES INC Check dimension a between tensioning lever and tensioner housing with...

Page 406: ...ocking plate T10008 Fig 99 Releasing Tension Of Tensioner Roller Courtesy of VOLKSWAGEN UNITED STATES INC Loosen nut 1 on pulley Continue under Tensioning drive belt If dimension a is obtained Install...

Page 407: ...n Toothed drive belt removing from camshaft sprocket Special tools testers and auxiliary items required Component Nm Lower drive belt cover at cylinder block 10 See note Center drive belt cover at cyl...

Page 408: ...te T10008 For Engines With Hydraulic Tensioning Device Courtesy of VOLKSWAGEN UNITED STATES INC Locking plate T10008 With engine in vehicle Removing Move lock carrier to service position Lock carrier...

Page 409: ...r part of drive belt cover NOTE Take special note of the installed position of the upper part of the drive belt cover particularly where it meets the center part of the drive belt cover CAUTION The en...

Page 410: ...t TDC cylinder 1 arrows Fig 106 Inserting An Allen Wrench Into Socket Head Courtesy of VOLKSWAGEN UNITED STATES INC Push pulley on counter clockwise in direction of arrow with a socket head wrench usi...

Page 411: ...f arrow using special tool 3387 Remove drive belt from camshaft Installing Fig 108 Identifying Marking On Camshaft Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES...

Page 412: ...r at cylinder block 10 See note Vibration damper pulley at crankshaft 10 90 See note Ribbed belt tensioner at bracket 23 Drive belt tensioning pulley 27 NOTE Servicing work on clutch 30 CLUTCH for 5 S...

Page 413: ...STATES INC 1 Oil seal Install with 10 203 2 Woodruff key Make sure key is seated properly 3 25 Nm 4 Front sealing flange Remove oil pan to remove and install Oil pan removing and installing 2005 Audi...

Page 414: ...ual mass flywheel drive plate Removing and installing dual mass flywheel Dual mass flywheel drive plate removing and installing Removing and installing drive plate 9 Intermediate plate Must be located...

Page 415: ...ools Crankshaft Oil Seal Pulley End Replacing Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required Oil seal extractor 2085 Puller 3083 Counterhold 3415 Removing...

Page 416: ...n Support Courtesy of VOLKSWAGEN UNITED STATES INC Unbolt stop for torque reaction support arrows Fig 112 Removing Crankshaft Toothed Belt Sprocket Courtesy of VOLKSWAGEN UNITED STATES INC Remove cran...

Page 417: ...ler 2085 Courtesy of VOLKSWAGEN UNITED STATES INC Lubricate threaded head of oil seal extractor place in position and exerting firm pressure screw as far as possible into oil seal Loosen knurled screw...

Page 418: ...r guide sleeve Fig 116 Pushing In Oil Seal As Far As It Will Go Using Thrust Sleeve And Bolt From 3083 Courtesy of VOLKSWAGEN UNITED STATES INC Push in oil seal as far as it will go using thrust sleev...

Page 419: ...90 is a quarter turn Dual mass flywheel drive plate removing and installing Dual mass flywheel Special tools testers and auxiliary items required Fig 118 Counterhold 10 201 Courtesy of VOLKSWAGEN UNI...

Page 420: ...ion to the following Replace bolts 90 is one quarter turn Replace bolts 180 is one half turn Drive plate Special tools testers and auxiliary items required Component Nm Dual mass flywheel to crankshaf...

Page 421: ...nterhold VW558 To Drive Plate Courtesy of VOLKSWAGEN UNITED STATES INC Secure counterhold VW558 to drive plate using hex bolt M8 x 45 2 Place two M10 hex nuts 1 between counterhold and drive plate Mar...

Page 422: ...bolts and tighten to 30 Nm Fig 123 Checking Distance Between Drive Plate And Cylinder Block Courtesy of VOLKSWAGEN UNITED STATES INC Perform measurement by passing sliding calliper with depth gauge th...

Page 423: ...n Tightening torque 90 is one quarter turn CRANKSHAFT REMOVING AND INSTALLING Crankshaft removing and installing Component Nm Drive plate to crankshaft 60 90 See note NOTE Before removing crankshaft p...

Page 424: ...il groove For cylinder block with oil groove Do not interchange used bearing shells mark 2 65 Nm 1 4 turn 90 further Replace When measuring radial clearance of crankshaft tighten to 65 Nm but do not t...

Page 425: ...and installing Removing and installing sensor wheel 7 10 Nm 1 4 turn 90 further Replace Always replace sensor wheel if bolts have been removed Removing and installing sensor wheel 8 Pilot needle beari...

Page 426: ...top crankshaft bearing NOTE Always replace sensor wheel 2 if bolts 1 have been removed If the securing bolts are tightened a second time seats for the countersunk bolt heads in the sensor wheel will b...

Page 427: ...wn in illustration Bearing shell identification by color codes A Identification for bearing 1 B Identification for bearing 2 C Identification for bearing 3 D Identification for bearing 4 E Identificat...

Page 428: ...ng and driving Special tools testers and auxiliary items required Grinding dimension Crankshaft bearing journal dia Connecting rod bearing journal dia Basic dimension 0 017 48 00 0 037 0 022 42 00 0 0...

Page 429: ...ukko 22 1 4 Depth gauge Removing NOTE A pilot needle bearing must be installed in the crankshaft on vehicles with a manual transmission Install a pilot needle bearing if necessary On vehicles with an...

Page 430: ...and Kukko 22 1 Installing Fig 132 Driving In Needle Bearing Using Drift VW 207 C Courtesy of VOLKSWAGEN UNITED STATES INC Drive in with drift VW207C or centering mandrel 3176 Lettering on pilot needle...

Page 431: ...fying Special Tools Oil Pump Front Sealing Flange Drive Chain And Chain Sprocket For Oil Pump Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES INC Drift sleeve 30 100 Two arm puller commer...

Page 432: ...t chain sprocket in oven for approx 15 minutes to 220 C Fig 136 Installing Chain Sprocket Onto Crankshaft Up To Limit Stop Using Press Tube 30 100 Courtesy of VOLKSWAGEN UNITED STATES INC Install chai...

Page 433: ...ting Rods Disassembling And Assembling Overview Courtesy of VOLKSWAGEN UNITED STATES INC 1 30 Nm 1 4 turn 90 further Oil threads and contact surface To measure radial clearance tighten to 30 Nm but no...

Page 434: ...block Checking cylinder bore Checking cylinder bore Piston and cylinder dimensions Piston and cylinder dimensions 7 Bearing shell With oil drilling for piston pin lubrication Note installed position...

Page 435: ...clearance 12 Piston Checking Checking piston Mark installed position and cylinder number Arrow on piston crown must point to pulley end Install using piston ring clamp 13 Connecting rod bolt Replace...

Page 436: ...ing Piston Piston ring Dimensions in mm New Wear limit Compression ring 1 0 20 0 40 0 8 Compression ring 2 0 20 0 40 0 8 Oil scraper ring 0 25 0 50 0 8 Piston ring Dimensions in mm New Wear limit Comp...

Page 437: ...Internal dial gauge 50 100 mm Take measurements at 3 positions in both lateral A and longitudinal B directions Deviation from nominal dimension max 0 08 mm Piston and cylinder dimensions Dimensions w...

Page 438: ...ts When performing repairs replace seals gaskets self locking nuts and bolts which have a specified tightening angle Charge air hose connections and hoses must be free from oil and grease before insta...

Page 439: ...asket Replace Removing cylinder head Cylinder head removing Installation position Part No toward cylinder head After replacing fill with fresh coolant 2 Cylinder head Removing Cylinder head removing c...

Page 440: ...and installing 6 Ignition coil 7 Cap 8 Gasket Replace if damaged or leaking 9 10 Nm Tighten inner nuts first Tighten outer nuts in diagonal sequence 10 Cylinder head cover gaskets Replace if damaged o...

Page 441: ...With coolant temperature sensor 15 10 Nm 16 O ring Replace Part II Fig 143 Cylinder Head Removing And Installing Overview Part II 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo Engine Mechanical...

Page 442: ...ening and tightening union nut for fuel supply line to fuel rail pipe Loosening and tightening union nut for fuel supply line in vehicles as of 07 03 6 Coolant line top 7 10 Nm 8 10 Nm 9 O ring For to...

Page 443: ...inder head resurfacing limit Fig 145 Cylinder Head Resurfacing Limit Courtesy of VOLKSWAGEN UNITED STATES INC Resurfacing the cylinder head skimming is only permitted down to minimum dimension a Minim...

Page 444: ...uster cylinder head transition 4 points Fig 147 Sealing Camshaft Adjuster Cylinder Head Transition 4 Points Courtesy of VOLKSWAGEN UNITED STATES INC Apply a small quantity of sealant Part No AMV 174 0...

Page 445: ...ion on fuel rail pipe To do so counterhold using an open end wrench at each hex head 1 and 3 and tighten union nut 2 to 22 Nm Cylinder head cover removing and installing Removing Fig 149 Removing Engi...

Page 446: ...Emission Canister Purge Regulator Valve N80 And Air Duct Courtesy of VOLKSWAGEN UNITED STATES INC Remove bolts arrows Disengage EVAP canister purge regulator valve N80 1 from air duct 2 Remove both sc...

Page 447: ...valve on cylinder head cover and heat shield 3 Move secondary air line slightly to one side Fig 153 Ignition Coils Ground Wire And Connectors Courtesy of VOLKSWAGEN UNITED STATES INC Remove Ground wir...

Page 448: ...inder head removing Conditions Engine in vehicle Lock carrier in service position Lock carrier moving to service position NOTE Replace gaskets and sealing rings Replace cylinder head cover gaskets if...

Page 449: ...ribbed belt and ribbed belt tensioner Ribbed belt removing and installing Remove toothed belt from camshaft sprocket Toothed drive belt removing installing and tensioning Fig 155 Air Cleaner Cover Cou...

Page 450: ...Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect connector arrow at camshaft adjuster Fig 158 Crankcase Breather Line Secondary Air Combination Valve Line And Heat Shield Courtesy of VOLKSWAGEN UN...

Page 451: ...Supply Line For Turbocharger Courtesy of VOLKSWAGEN UNITED STATES INC Remove bolts 1 and 2 of oil supply line Remove bolts 3 for turbocharger Fig 160 Disconnecting Connector At Coolant Temperature Se...

Page 452: ...ylinder head and move it clear Pull off coolant hose to heater unit heat exchanger at rear of cylinder head To do so first release retainers on connecting flange Fig 162 Ignition Coils Ground Wire And...

Page 453: ...ing NOTE Replace cylinder head bolts When performing repairs replace seals gaskets self locking nuts and bolts which have a specified tightening angle Secure all hose connections with standard hose cl...

Page 454: ...cylinder Remove new cylinder head gasket from packaging just before installation Handle gasket extremely carefully Damaging the silicone layer or indented area will lead to leaks No oil or coolant mu...

Page 455: ...Block Centering Pins Courtesy of VOLKSWAGEN UNITED STATES INC Place cylinder head gasket in position Note position of centering pins in cylinder block arrows Check installed position of cylinder head...

Page 456: ...all ribbed belt and ribbed belt tensioner Ribbed belt removing and installing Install intake manifold Replace coolant Cooling system draining and filling See Caution for connecting Telematics battery...

Page 457: ...d Fig 169 Identifying Spark Plug Wrench 3122 B Courtesy of VOLKSWAGEN UNITED STATES INC Spark plug wrench 3122B Component Nm Intake manifold support to intake manifold 20 to bracket 20 Turbocharger to...

Page 458: ...rements Engine oil temperature at least 30 C Battery voltage at least 12 7 V Work sequence Fig 171 Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove engine cover arrows Switch off...

Page 459: ...e Install spark plugs and ignition coils Check Diagnostic Trouble Code DTC memory Guided Fault Finding in VAS5051 01 ON BOARD DIAGNOSTIC OBD NOTE Using the compression tester New bar Wear limit bar Di...

Page 460: ...no more than first 4 turns of spark plug threads are cracked After installing camshafts engine must not be started for approx 30 minutes Hydraulic valve compensation elements have to settle otherwise...

Page 461: ...exhaust camshaft Note installed position Narrow web of camshaft sprocket must face toward front and marking for TDC No 1 cylinder must be visible from front Install camshaft sprocket under Installing...

Page 462: ...stalling Valve stem seals replacing 8 Valve spring plate 9 Valve keeper 10 Hydraulic valve lifter Checking Hydraulic valve lifters checking Removing and installing Valve stem seals replacing Do not in...

Page 463: ...installed Wear limit 0 1 mm Run out max 0 035 mm Checking axial clearance Camshaft axial clearance checking Removing and installing camshafts Camshafts and camshaft adjuster removing and installing 1...

Page 464: ...ons on scrapping valves with sodium filling Valve dimensions Do not rework only lapping is permitted Valve dimensions Valve dimensions Checking valve guides Valve guides checking Refacing valve seats...

Page 465: ...CAUTION Worn exhaust valves with sodium filling must not be scrapped in the usual way The valves must be cut into two pieces between the shaft center and the valve head using a metal saw When doing th...

Page 466: ...ement with valve lifters removed and with bearing cap at chain sprocket end and double bearing cap at camshaft sprocket end installed Attach dial indicator with universal dial indicator holder VW387 t...

Page 467: ...s testers and auxiliary items required Oil seal extractor 2085 Counterhold 3036 Puller 3241 Assembly tool T10071 Removing Cylinder head installed Lock carrier in service position Lock carrier moving t...

Page 468: ...Camshaft Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES INC Rotate crankshaft at central bolt of crankshaft toothed belt sprocket in direction of engine rotatio...

Page 469: ...Bolt Into Oil Seal As Far As Possible With Forced Pressure Courtesy of VOLKSWAGEN UNITED STATES INC Lubricate threaded head of oil seal extractor 2085 place in position and exerting firm pressure scr...

Page 470: ...sleeve onto shaft journal Remove guide sleeve Fig 183 Pushing In Oil Seal As Far As It Will Go Using Thrust Sleeve 3241 1 Courtesy of VOLKSWAGEN UNITED STATES INC Push in oil seal as far as it will go...

Page 471: ...ft Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES INC Align marking on camshaft sprocket with marking on cylinder head cover Align marking on vibration damper wi...

Page 472: ...UNITED STATES INC Oil seal extractor 2085 Fig 187 Puller 3241 Courtesy of VOLKSWAGEN UNITED STATES INC Puller 3241 Removing Cylinder head installed Lock carrier in service position Lock carrier moving...

Page 473: ...g and tensioning Fig 189 Locating Connector At Camshaft Position Sensor G40 Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect connector from Camshaft Position CMP sensor G40 arrow Remove housing for...

Page 474: ...rced Pressure Into Oil Seal Courtesy of VOLKSWAGEN UNITED STATES INC Lubricate threaded head of oil seal extractor 2085 place in position and exerting firm pressure screw as far as possible into oil s...

Page 475: ...used for oil seals with ring spring PTFE oil seals must be installed according to the direction of shaft rotation see arrow markings on oil seal Incorrect direction of rotation results in oil leakage...

Page 476: ...t Sleeve 3241 1 And Bolt 3241 3 Courtesy of VOLKSWAGEN UNITED STATES INC Push in oil seal as far as it will go using thrust sleeve 3241 1 To do so use bolt 3241 3 Install CMP sensor Install top sectio...

Page 477: ...rom camshaft sprocket Toothed drive belt removing installing and tensioning Fig 196 Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove engine cover arrows Remove secondary air combi...

Page 478: ...Pull off camshaft sprocket Remove entire camshaft position sensor Fig 198 Securing Camshaft Adjuster Or Chain Tensioner Using Bracket For Chain Adjustment 3366 Courtesy of VOLKSWAGEN UNITED STATES INC...

Page 479: ...ark installed position using colored markings Fig 200 Checking Distance Between Markings Consists Of 16 Rollers Of The Drive Chain Courtesy of VOLKSWAGEN UNITED STATES INC Eistance between two arrows...

Page 480: ...camshaft adjuster Fig 202 Identifying Bearing Cap Positions Courtesy of VOLKSWAGEN UNITED STATES INC Loosen bearing caps 2 and 4 of intake and exhaust camshafts alternately in diagonal sequence and r...

Page 481: ...188 001 02 to shaded areas Install drive chain on camshaft sprockets as follows Fig 204 Installing Chain So That Colored Markings Are In Line Courtesy of VOLKSWAGEN UNITED STATES INC If old chain is r...

Page 482: ...of both camshafts Tighten mountings of camshaft adjuster watch position of dowel sleeves Fig 206 Identifying Bearing Cap Positions Courtesy of VOLKSWAGEN UNITED STATES INC Tighten bearing caps 2 and 4...

Page 483: ...llers Installed On Chain Gears Courtesy of VOLKSWAGEN UNITED STATES INC Distance between two arrows on bearing caps or between colored markings is 16 rollers on drive chain Notch on exhaust camshaft i...

Page 484: ...shaft oil seal replacing on Fig 210 Identifying Camshaft Gear Thin Rib Toward Outside And TDC Marking Visible Courtesy of VOLKSWAGEN UNITED STATES INC Install camshaft sprocket Note installed position...

Page 485: ...f damage to valves and piston crowns NOTE After installing camshafts engine must not be started for approx 30 minutes Hydraulic valve compensation elements have to settle otherwise valves will strike...

Page 486: ...of lifters to be checked are pointing upward Vehicles with manual transmission Push vehicle forward with 4th gear engaged and ignition switched off Vehicles with automatic transmission Remove sound in...

Page 487: ...replacing Fig 213 Identifying Special Tools Valve Stem Seals Replacing NOTE After installing camshafts engine must not be started for approx 30 minutes Hydraulic valve compensation elements have to se...

Page 488: ...wnward Use spark plug wrench 3122B to remove spark plugs Set piston of appropriate cylinder to bottom dead center Fig 214 Identifying Pressure Hose VW653 3 Into Spark Plug Thread Drift VAS5161 3 In Va...

Page 489: ...e at right angle to direction of travel Push knurled spacer ring VAS5161 17 onto cartridge VAS5161 8 Push cartridge into guide bushing Attach pressure fork VAS5161 2 to snap in device VAS5161 6 and pr...

Page 490: ...tridge into guide bushing Attach pressure fork VAS5161 2 to snap in device VAS5161 6 and press cartridge downward Simultaneously turn knurled screw of cartridge clockwise until ends engage in valve ke...

Page 491: ...Oil Seal Valve Stem Seal Driver 3365 Courtesy of VOLKSWAGEN UNITED STATES INC To prevent damage to new valve stem seals B place plastic sleeve A on valve stem Lightly oil sealing lip of valve stem se...

Page 492: ...rs were taken out of cartridge they must first be placed into insertion device VAS5161 18 Fig 221 Identifying Installation Cartridge VAS 5161 8 Courtesy of VOLKSWAGEN UNITED STATES INC Press cartridge...

Page 493: ...mshaft adjuster Valve guides checking Special tools testers and auxiliary items required Fig 223 Identifying Dial Gauge Holder VW 387 Courtesy of VOLKSWAGEN UNITED STATES INC NOTE After installing cam...

Page 494: ...lay Wear limit Valve seats refacing Special tools testers and auxiliary items required Depth gauge Valve seat grinding tool Intake valve guide Exhaust valve guide 0 80 mm 0 80 mm NOTE If wear limit is...

Page 495: ...ves it is not sufficient to reface valve seats and replace valves Valve guides must also be checked for wear This is particularly important on high mileage engines Valve guides checking Valve seats sh...

Page 496: ...imension 0 4 mm NOTE If the max permissible refacing dimension is 0 mm or less than 0 mm repeat the measurement with new valve If the measured result is again 0 mm or less than 0 mm replace the cylind...

Page 497: ...o be applied to the camshaft adjuster mechanical adjustment device Camshaft adjustment valve checking a 45 Valve seat angle 30 Adjustment angle top gamma 60 Adjustment angle bottom NOTE The camshaft t...

Page 498: ...sequence Start output Diagnostic Test Mode and activate camshaft adjustment valve Indicated on display This valve is actuated clicks for approx 1 minute if key is not pressed beforehand to select next...

Page 499: ...ecification 10 18 ohms If reading does not match specification Replace valve If measured value matches specification Check power supply Checking power supply Requirements Fuse for camshaft adjustment...

Page 500: ...tester VAG 1527B as follows Briefly operate starter LED must light up If LED does not light up Check for open circuit in wiring from contact 1 of connector through fuse to fuel pump relay Electrical W...

Page 501: ...st Mode and actuate camshaft adjustment valve Indicated on display LED must flash If LED does not flash or if it is permanently lit Connect test box VAG 1598 31 to engine control module wiring harness...

Page 502: ...ng wiring connection Eliminate any short circuits to Ground or open circuits If wiring is OK Replace engine control module If no malfunction is found Replace mechanical camshaft adjuster Connector con...

Page 503: ...n repairing an engine clean the oil passages carefully and replace the oil cooler in order to prevent further damage occurring later The oil level must not be above the max mark danger of damage to th...

Page 504: ...pport 3 Oil pan Apply silicone sealant D 176 404 A2 before installing Removing and installing Oil pan removing and installing 4 Oil pump With pressure relief valve 12 bar Removing and installing Oil p...

Page 505: ...ng Sealing flanges and flywheel drive plate removing and installing Replacing crankshaft oil seal pulley end Crankshaft oil seal pulley end replacing 10 Chain tensioner Tighten to 16 Nm Do not disasse...

Page 506: ...lts in sequence shown under Installing 19 40 Nm 20 Sealing ring Replace 21 Oil drain plug 30 Nm 22 Gasket Always replace 23 Oil return line From turbocharger 24 10 Nm Oil spray jet and pressure relief...

Page 507: ...pening pressure 1 3 to 1 6 bar Part II Fig 236 Lubrication System Components Removing And Installing Part II Courtesy of VOLKSWAGEN UNITED STATES INC 1 Screw plug 40 Nm 2 Sealing ring Always replace 2...

Page 508: ...s replace 8 Retaining clip 9 Line For crankcase breather 10 20 Nm Apply locking fluid D 000 600 A2 when installing 11 Lower coolant line 12 Screw plug 15 Nm 13 Sealing ring If seal is leaking cut open...

Page 509: ...vals Refer to 01 MAINTENANCE 01 MAINTENANCE for CABRIOLET Observe installation instructions on oil filter Tighten to 20 Nm 22 25 Nm 23 Oil cooler See note Lubrication system components removing and in...

Page 510: ...auxiliary items required Support bar 10 222A Lifting tackle 2024A Socket attachment 3249 or T10058 Workshop crane VAG1202A Electric drill with plastic brush attachment Protective goggles Removing Engi...

Page 511: ...WAGEN UNITED STATES INC Unbolt sound insulation holder arrow Disconnect lower left air hose from charge air cooler Fig 239 Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove engine...

Page 512: ...mounts Remove nuts 1 underneath left and right engine mounts Fig 241 Placing Support Bar 10 222A On Fender Mounting Flange Courtesy of VOLKSWAGEN UNITED STATES INC Place support bar 10 222A on fender...

Page 513: ...Engine Support Bridge 10 222A Courtesy of VOLKSWAGEN UNITED STATES INC Attach lifting tackle 2024A to lifting eyes at front and rear of engine Pre tension engine with spindle of engine support bar do...

Page 514: ...connect ATF lines from transmission NOTE Observe the rules for cleanliness when working on the automatic transmission 37 AUTOMATIC TRANSMISSION CONTROLS HOUSING for 5 SPD AUTOMATIC TRANSMISSION 01V 37...

Page 515: ...ig 247 Unclipping Operating Rod For Vehicle Levelling Sensor At Lower Transverse Link Courtesy of VOLKSWAGEN UNITED STATES INC If installed unclip operating rod for vehicle levelling sensor at lower t...

Page 516: ...me Courtesy of VOLKSWAGEN UNITED STATES INC First remove front bolts 2 and 3 from left and right subframe Then remove bolts 1 Vehicles with manual transmission NOTE The subframe should be removed and...

Page 517: ...s with automatic transmission Fig 251 Identifying Bolt Removal Sequence For Left Transmission Mount Courtesy of VOLKSWAGEN UNITED STATES INC Loosen rear bolt 2 on left transmission mount a few turns r...

Page 518: ...ansmission mount Fig 253 Subframe Supported Using Workshop Crane V A G 1202 A Courtesy of VOLKSWAGEN UNITED STATES INC Lower subframe slowly using workshop crane VAG1202A Roll out workshop crane VAG12...

Page 519: ...TES INC Remove oil pan If necessary loosen by tapping lightly using a rubber hammer NOTE Use T10058 for bolts 17 and 18 NOTE Remove both rear oil pan bolts 1 and 2 using socket attachment 3249 or T100...

Page 520: ...ey must be free of oil and grease Installing Install in reverse order paying attention to the following Fig 257 Cutting Tube Nozzle At Front Marking Courtesy of VOLKSWAGEN UNITED STATES INC Cut off no...

Page 521: ...hows position of sealant bead on cylinder block Install oil pan immediately and tighten bolts in sequence shown NOTE The sealant bead must not be thicker than 3 mm otherwise excess sealant can enter o...

Page 522: ...in diagonal sequence NOTE Replace gaskets and sealing rings Fig 260 Ensuring That Oil Pan Is Positioned Flush With Intermediate Plate At Flywheel End Courtesy of VOLKSWAGEN UNITED STATES INC When inst...

Page 523: ...SMISSION 09L FOUR WHEEL DRIVE All models Install lock carrier Lock carrier moving to service position Fill engine with oil and check oil level Vehicles with automatic transmission Check ATF level 37 A...

Page 524: ...t Remove bolts 1 and 3 and remove oil pump Installing Component Nm Oil pan to cylinder block M7 15 M10 40 Oil pan to transmission 45 Torque reaction support stop to oil pan 28 Engine mount to subframe...

Page 525: ...chain sprocket Can only be installed in one position Install oil pan Tightening torques Oil pressure and oil pressure switch checking Component Nm Chain sprocket to oil pump shaft 22 Oil pump to cyli...

Page 526: ...ogate symbol Checking oil pressure switch Disconnect wire from oil pressure switch Fig 264 Connecting Oil Pressure Tester V A G 1342 With Adapter V A G 1342 14 To Bore For Oil Pressure Switch Courtesy...

Page 527: ...d screw in oil pressure tester VAG1342 Screw oil pressure switch 2 into VAG1342 Start engine engine oil temperature approx 80 C Oil pressure at idling speed 1 0 bar Oil pressure at 3000 RPM 3 5 to 4 5...

Page 528: ...after switching off engine to allow oil to flow back into oil pan Pull out dipstick wipe off with a clean cloth and insert it again as far as it will go Pull out dipstick again and read oil level Mark...

Page 529: ...area NOTE Oil level must not be above mark a on dipstick 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo Engine Mechanical Engine Code s AMB 2 35 34 AM Page 27 cardiagn com...

Page 530: ...pressure when engine is warm If necessary release pressure before repair work Secure all hose connections with standard hose clamps Special tool VAS5024A is recommended for installing spring clips Al...

Page 531: ...Heat exchanger for heater After replacing fill with fresh coolant 2 Coolant line lower 3 Expansion tank With cap Checking pressure relief valve in cap 4 Oil cooler 2005 Audi A4 Quattro ENGINE 1 8 Lit...

Page 532: ...10 Coolant pump thermostat Removing and installing coolant pump Coolant pump removing and installing Check for ease of movement 11 Turbocharger 12 Cylinder head cylinder block After replacing fill wit...

Page 533: ...r T10007 Drip tray VAG1306 Assembly tools for spring clips VAS5024A Draining NOTE Catch drained coolant in a clean container for re use or disposal CAUTION Hot steam can escape when cap on expansion t...

Page 534: ...taining Clip For Engine Coolant Temperature ECT Sensor G2 Off Lower Coolant Hose And Drain Coolant From Radiator Courtesy of VOLKSWAGEN UNITED STATES INC Pull retaining clip 1 for Engine Coolant Tempe...

Page 535: ...on additive On account of the higher boiling point the coolant helps to enhance engine reliability under heavy loads particularly in countries with tropical climates Frost protection must be guarantee...

Page 536: ...Coolant Hose And Drain Coolant From Radiator Courtesy of VOLKSWAGEN UNITED STATES INC Insert Engine Coolant Temperature ECT sensor G2 2 back into lower coolant hose and attach clip 1 Attach coolant h...

Page 537: ...lower hose on radiator becomes hot Check coolant level and top off if necessary When engine is at normal operating temperature coolant level must be at max mark When engine is cold coolant level must...

Page 538: ...al tools testers and auxiliary items required Refractometer T10007 Drip tray VAG1306 Torque wrench 5 50 Nm VAG1331 Assembly tools for spring clips VAS5024A Removing Remove front bumper 63 BUMPER 63 BU...

Page 539: ...arrows Fig 276 Disconnecting Connector From A C Pressure Switch F129 Ambient Temperature Sensor Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect connector 1 from A C pressure switch F129 Disconnec...

Page 540: ...bolts for radiator and pull out upward arrows Swivel radiator forward out of lock carrier and lift out Installing Install in reverse order paying attention to the following Fill coolant system Coolin...

Page 541: ...Installing Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required Refractometer T10007 Drip tray VAG1306 Torque wrench 5 to 50 Nm VAG1331 Assembly tools for spring...

Page 542: ...onnecting Fan Motor Connectors Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect connectors 1 and 2 and move fan motor wires clear Fig 281 Unbolting Coolant Fan From Radiator Cowl Courtesy of VOLKSW...

Page 543: ...ng Fig 282 Identifying Special Tools Cooling System Components Servicing Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required Refractomet...

Page 544: ...and tensioning Fig 283 Removing Bolts Securing Coolant Pump And Coolant Pump Courtesy of VOLKSWAGEN UNITED STATES INC Remove bolts arrows securing coolant pump and remove coolant pump Installing Inst...

Page 545: ...m Installing toothed belt and adjusting valve timing Toothed drive belt removing installing and tensioning Install ribbed belt tensioning element Tightening torque 25 Nm Install ribbed belt Ribbed bel...

Page 546: ...iliary items required Cooling system tester VAG1274 Adapter VAG1274 8 Adapter VAG1274 9 Requirement Engine warm CAUTION Hot steam can escape when cap on expansion tank is opened Cover cap with cloth a...

Page 547: ...d pump to generate pressure of approx 1 0 bar If there is a drop in pressure locate leak and eliminate fault Checking pressure relief valve in cap Fig 287 Checking Pressure Relief Valve In Filler Cap...

Page 548: ...Pressure relief valve must open at pressure of 1 4 to 1 6 bar 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo Engine Mechanical Engine Code s AMB 2 36 19 AM Page 19 cardiagn com...

Page 549: ...has sufficient clearance from bodywork If necessary loosen clamps and align mufflers and exhaust pipes so that sufficient clearance is maintained to bodywork at all points and mountings are evenly lo...

Page 550: ...g Turbocharger removing and installing 2 Gasket Always replace 3 Heated Oxygen Sensor HO2S G39 50 Nm Black connector Grease threads only with hot bolt paste G 052 112 A3 paste must not be allowed to c...

Page 551: ...nd installing 6 Gasket Replace 7 25 Nm 8 Front exhaust pipe With decoupling element To avoid damage do not bend decoupling element by more than 10 9 Front clamp Align exhaust system so it is free of s...

Page 552: ...em vehicles with front wheel drive aligning stress free Replacing tailpipe Replacing tailpipe 20 Rear clamps For separate replacement of center muffler and both rear mufflers Align exhaust system so i...

Page 553: ...ig 342 Installed Position Of Front Clamp Courtesy of VOLKSWAGEN UNITED STATES INC Install clamp so that ends of bolts are not below bottom circumference of clamp Bolted connection on left Installed po...

Page 554: ...nly to 40 Nm Replacing tailpipe Fig 344 Replacing Tailpipe Courtesy of VOLKSWAGEN UNITED STATES INC Cut through tailpipe 1 squarely at cutting point C using body saw e g VAG1523A Push on tailpipe 3 up...

Page 555: ...Turbocharger removing and installing 2 Gasket Always replace 3 Heated Oxygen Sensor HO2S G39 50 Nm Black connector Grease threads only with hot bolt paste G 052 112 A3 paste must not be allowed to co...

Page 556: ...alling 6 Gasket Always replace 7 25 Nm 8 Front exhaust pipe With decoupling element To avoid damage do not bend decoupling element by more than 10 9 Front clamp Align exhaust system so it is free of s...

Page 557: ...vehicles with all wheel drive aligning stress free Replacing tailpipe Replacing tailpipe 20 40 Nm 21 Rear clamps For separate replacement of center muffler and both rear mufflers Align exhaust system...

Page 558: ...alled Position Of Front Clamp Courtesy of VOLKSWAGEN UNITED STATES INC Install clamp so that ends of bolts are not below bottom circumference of clamp Bolted connection on left Installed position of r...

Page 559: ...d connections evenly to 40 Nm Replacing tailpipe Fig 348 Replacing Tailpipe Courtesy of VOLKSWAGEN UNITED STATES INC Cut through tailpipe 1 squarely at cutting point C using body saw e g VAG1523A Push...

Page 560: ...ms required Fig 349 Identifying Body Repair Saw V A G 1523 A Courtesy of VOLKSWAGEN UNITED STATES INC Body saw VAG1523A Protective goggles Vehicles with front wheel drive Cut through exhaust pipe squa...

Page 561: ...ng stress free Tighten bolted connections on clamp evenly to 40 Nm Vehicles with all wheel drive Cut through exhaust pipe squarely using body saw e g VAG1523A at position indicated by punch marks Fig...

Page 562: ...oving Fig 352 Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove engine cover arrows Fig 353 Air Cleaner Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove air cleaner cover arro...

Page 563: ...air duct 2 Remove both screws arrows for air duct 2 Fig 355 Disconnect Wires Unplug Connectors From Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect wiring connectors from 1 EVAP valve 2 Mass Air F...

Page 564: ...air cleaner housing 9 Remove air cleaner Fig 357 Noise Insulation Tray Retainers Courtesy of VOLKSWAGEN UNITED STATES INC Remove sound insulation arrows NOTE Vacuum line to secondary air combination...

Page 565: ...Line Front Hose Off Line To Secondary Air Combination Valve Removing Heat Shield Courtesy of VOLKSWAGEN UNITED STATES INC Pull front hose off crankcase breather line 2 Pull front hose off line to seco...

Page 566: ...61 Removing All Nuts On Exhaust Manifold Courtesy of VOLKSWAGEN UNITED STATES INC Remove all nuts arrows on exhaust manifold Remove washers and exhaust manifold Installing Install in reverse order pay...

Page 567: ...en Sensors Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect 4 pin connectors of oxygen sensors and move wires clear 1 Brown to O2S Behind TWC G130 only with engine code AMB Component Nm Exhaust man...

Page 568: ...ion Canister Purge Regulator Valve N80 And Air Duct Courtesy of VOLKSWAGEN UNITED STATES INC Remove bolts arrows Disengage EVAP canister purge regulator valve N80 1 from air duct 2 Remove both screws...

Page 569: ...g 366 Disconnect Wires Unplug Connectors From Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect hose to secondary air injection pump motor 8 Move wiring clear Unbolt air cleaner housing 9 Remove air...

Page 570: ...e aligning stress free and Exhaust system vehicles with all wheel drive aligning stress free Tightening torques Front exhaust pipe removing and installing Removing Components Nm Oxygen sensor to catal...

Page 571: ...Axle Courtesy of VOLKSWAGEN UNITED STATES INC Remove heat shield arrows above right side drive axle Fig 369 Separating Exhaust System At Clamp Courtesy of VOLKSWAGEN UNITED STATES INC Separate exhaus...

Page 572: ...vehicles with all wheel drive aligning stress free Tightening torques Exhaust system vehicles with front wheel drive aligning stress free Vehicles without clamp between center muffler and rear muffle...

Page 573: ...ipes Courtesy of VOLKSWAGEN UNITED STATES INC Check to make sure that distances a and b between tailpipe and bumper are equal Vehicles with clamp between center muffler and rear muffler Exhaust system...

Page 574: ...ehicle Courtesy of VOLKSWAGEN UNITED STATES INC Push rear section of exhaust system toward front of vehicle arrow until preloading at rear mounting of rear muffler is a 12 mm Also make sure that cente...

Page 575: ...heel drive aligning stress free Vehicles without clamp between center muffler and rear muffler Exhaust system must be aligned when cold Fig 377 Separating Exhaust System At Clamp Courtesy of VOLKSWAGE...

Page 576: ...System Toward Front Of Vehicle Courtesy of VOLKSWAGEN UNITED STATES INC Push front section of exhaust system toward front of vehicle arrow until preloading at right side mounting of center muffler is...

Page 577: ...led position of rear clamps Installed position of rear clamps and Installed position of rear clamp Tighten bolted connections on rear clamps evenly to 40 Nm Aligning tailpipes Fig 381 Aligning Tailpip...

Page 578: ...catalytic converter thereby reducing toxic emissions The heat generated by oxidation accelerates the light off of the catalytic converter and significantly improves exhaust gas quality during warm up...

Page 579: ...Injection AIR pump motor V101 2 Air cleaner 3 Secondary air combination valve Location Location of Secondary air combination valve 4 Non return valve Installed position light dark side and direction o...

Page 580: ...head Location of Secondary Air Injection AIR solenoid valve N112 Fig 383 Identifying Secondary Air Injection AIR Solenoid Valve N112 Courtesy of VOLKSWAGEN UNITED STATES INC Under intake manifold 1 Re...

Page 581: ...Injection AIR Pump Relay J299 Courtesy of VOLKSWAGEN UNITED STATES INC 3 way relay carrier in electronics box in plenum chamber position 2 1 Engine control module 2 Secondary Air Injection AIR pump re...

Page 582: ...lve Courtesy of VOLKSWAGEN UNITED STATES INC Right rear on cylinder head Secondary Air Injection AIR solenoid valve N112 checking 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo Engine Mechanical...

Page 583: ...iary items required Multimeter VAG1526A or equivalent Voltage tester VAG1527B Connector test set VAG1594A Adapter VAG1598 31 Vehicle Diagnostic Testing and Information System VAS5051 VAS5051 with VAS5...

Page 584: ...ve N112 Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect hoses from secondary Air Injection AIR solenoid valve N112 2 but leave electrical connector connected Installation location under intake man...

Page 585: ...Valve must click and must open and close can be checked by blowing into test hose If valve does not click Check internal resistance of valve If valve does not open or close properly Replace Secondary...

Page 586: ...N UNITED STATES INC Connect multimeter and measure resistance at valve Specification 27 to 30 ohms If reading does not match specification Replace Secondary Air Injection AIR solenoid valve N112 If me...

Page 587: ...ester VAG1527B as follows Briefly operate starter LED must light up If LED does not light up Check for open circuit in wiring from contact 1 of connector through fuse to fuel pump relay Electrical Wir...

Page 588: ...test box VAG1598 31 to engine control module wiring harness Engine control module must not be connected 24 MULTIPORT FUEL INJECTION MFI Fig 394 Identifying 2 Pin Electrical Connector Terminals Courte...

Page 589: ...tion AIR Pump Relay J299 And Secondary Air Injection AIR Pump Motor V101 Checking Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required Multimeter VAG1526A or equ...

Page 590: ...um chamber cover in direction of arrow Pull plenum chamber cover 1 toward front and remove Fig 397 Unbolting Cover Of Electronics Box In Plenum Chamber Courtesy of VOLKSWAGEN UNITED STATES INC Unbolt...

Page 591: ...k power supply of secondary AIR pump relay Check actuation of secondary AIR pump relay B If relay picks up but secondary AIR pump motor does not run Check power supply for secondary AIR pump motor Che...

Page 592: ...7 Check for open circuit in wiring from battery terminal 30 to fuse S130 to Secondary AIR pump relay J299 in 3 way relay carrier of electronics box in plenum chamber position 2 Electrical Wiring Diag...

Page 593: ...heck for open circuit in wiring from Secondary AIR pump relay J299 in 3 way relay carrier of electronics box in plenum chamber to fuel pump relay via fuse S234 in fuse box position 34 Electrical Wirin...

Page 594: ...control module wiring harness Engine control module must not be connected 24 MULTIPORT FUEL INJECTION MFI Fig 404 Identifying Secondary Air Pump Relay Terminals Courtesy of VOLKSWAGEN UNITED STATES I...

Page 595: ...ws Fig 406 Disconnecting Connector From Secondary AIR Pump Motor V101 Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect connector from Secondary AIR pump motor V101 arrow Location right front in eng...

Page 596: ...p relay J299 in 3 way relay carrier in electronics box of plenum chamber position 2 Electrical Wiring Diagrams Troubleshooting and Component Locations Check for open circuit in wiring from contact 2 o...

Page 597: ...ments No leaks along vacuum hoses or at hose connections No obstructions in vacuum hoses Work sequence Fig 409 Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove engine cover arrows...

Page 598: ...hand pump VAG1390 to vacuum hose of combination valve Fig 411 Noise Insulation Tray Retainers Courtesy of VOLKSWAGEN UNITED STATES INC Remove sound insulation arrows Fig 412 Disconnecting Hose At Lin...

Page 599: ...uum hand pump Combination valve should open It should now be possible to blow through hose If combination valve does not open Replace combination valve Secondary air combination valve removing and ins...

Page 600: ...Combination Valve Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect vacuum hose arrow at combination valve Remove 4 bolts from combination valve and remove combination valve Installing Install in re...

Page 601: ...ir line to cylinder head cover 10 Secondary air line to secondary air combination valve 10 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo Engine Mechanical Engine Code s AMB 2 39 06 AM Page 53 c...

Page 602: ...r work make sure that all lines and hoses are securely connected and that there are no leaks Always replace gaskets sealing rings and self locking nuts CAUTION Always attach testers and measuring inst...

Page 603: ...Mechanical recirculation valve 2 Wastegate Bypass Regulator Valve N75 3 Pressure regulator valve for crankshaft housing ventilation 4 Secondary Air Injection AIR Pump Motor V101 5 Air filter With Mas...

Page 604: ...shown in illustration 14 Crankshaft housing ventilation 15 Vacuum reservoir Component location Under wheelhousing liner in front left wheelhouse 16 Check valve Installed position Arrow on valve points...

Page 605: ...arger directly to catalytic converter Boost pressure regulation and vacuum control system connection diagram for vehicles as of 07 03 Fig 289 Boost Pressure Regulation And Vacuum Control System Connec...

Page 606: ...Installed position Arrow on valve points in direction of flow as shown in illustration 13 To brake booster 14 Vacuum suction jet pump 15 Check valve Installed position Arrow on valve points in direct...

Page 607: ...sure regulation When combination valve is opened mechanical boost pressure regulation valve in turbocharger is opened and secondary air is thereby channeled past turbocharger directly to catalytic con...

Page 608: ...Fault Finding in VAS5051 01 ON BOARD DIAGNOSTIC OBD Vehicle Diagnostic Testing and Information System VAS5051 or Scan Tool VAG1551 must be connected Work sequence CAUTION Always attach testers and mea...

Page 609: ...r switch to position I absolute pressure Connect measuring hose to connection I NOTE Hose connections must be completely airtight otherwise measurements will not be correct Ensure that measuring hose...

Page 610: ...for at least 3 km without stopping i e along route without traffic lights etc A second mechanic is required to note readings on tester when vehicle is moving Reading measured value block 115 1 2 3 4...

Page 611: ...ve faulty Mechanical air recirculation valve checking checking Recirculating valve for turbocharger N249 faulty Recirculating valve for turbocharger N249 checking checking Turbocharger faulty Turbocha...

Page 612: ...ler and intake manifold 3 Charge air cooler 4 Gasket of Charge air pressure sensor G31 in charge air cooler 5 Gasket between throttle valve control module and intake manifold 6 Gasket between intake m...

Page 613: ...ack off pressure regulator knob 2 of VAG1687 fully to protect gauge when shop air supply is applied to assembly Close valve 3 before gauge Close valve 4 after gauge The shop air supply line will later...

Page 614: ...bo Install optional fitting LKI9210 50 on hose of special tool KLI9210 Fig 298 Special Tool KLI9210 Evaporative System Leak Detector Connecting To 1 8L Turbo Courtesy of VOLKSWAGEN UNITED STATES INC C...

Page 615: ...oke see instructions printed on tester With system filled with smoke Remove smoke generator hose and connect VAG1687 quickly to prevent smoke from leaking out Special tool VAG1687 connecting to pressu...

Page 616: ...y of VOLKSWAGEN UNITED STATES INC With outlet hose 1 of VAG1687 connected to air pressure adapter Attach shop air supply line to previously installed male fitting Charge pressure leak test with VAG168...

Page 617: ...ll the system with smoke Apply soapy water solution or equivalent to intake system connections Inspect intake system connections for leaks Repair any leaks found Remove tester Remove plug from crankca...

Page 618: ...mp V A G 1390 Courtesy of VOLKSWAGEN UNITED STATES INC NOTE The mechanical air recirculation valve is located upstream of turbocharger It is opened by vacuum via the Recirculating valve for turbocharg...

Page 619: ...te air vent valve on vacuum pump after approx 30 seconds Air recirculation valve should close arrow If the mechanical air recirculation valve does not open and close as specified or if the valve plate...

Page 620: ...y items required Multimeter VAG1526A or equivalent Voltage tester VAG1527B Connector test set VAG1594A Adapter VAG1598 31 Vehicle Diagnostic Testing and Information System VAS5051 VAS5051 with VAS5051...

Page 621: ...noid Valve N112 Courtesy of VOLKSWAGEN UNITED STATES INC Disconnect hoses from Recirculating valve for turbocharger N249 1 leave electrical connector connected Location under intake manifold NOTE The...

Page 622: ...Valve must click and must open and close can be checked by blowing into test hose If valve does not click Check internal resistance of valve If valve does not open or close properly Replace Recirculat...

Page 623: ...GEN UNITED STATES INC Connect multimeter and measure resistance at valve Specification 27 30 ohms If reading does not match specification Replace Recirculating valve for turbocharger N249 If measured...

Page 624: ...tester VAG1527B as follows Briefly operate starter LED must light up If LED does not light up Check for open circuit in wiring from contact 1 of connector through fuse to fuel pump relay Electrical Wi...

Page 625: ...box VAG1598 31 to engine control module wiring harness Engine control module must not be connected 24 MULTIPORT FUEL INJECTION MFI Fig 312 Identifying 2 Pin Electrical Connector Terminals Courtesy of...

Page 626: ...gulator Valve N75 Checking Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required Multimeter VAG1526A or equivalent Voltage tester VAG1527B Connector test set VAG1...

Page 627: ...leave connector connected Fig 314 Connecting Test Hose To Valve Connection Courtesy of VOLKSWAGEN UNITED STATES INC Connect test hose to valve connection marked with arrow Start Output Diagnostic Test...

Page 628: ...ge Courtesy of VOLKSWAGEN UNITED STATES INC Connect multimeter and measure resistance at valve Specification 25 to 35 ohms If reading does not match specification Replace Wastegate bypass regulator va...

Page 629: ...LED does not light up Check for open circuit in wiring from contact 1 of connector through fuse to fuel pump relay Electrical Wiring Diagrams Troubleshooting and Component Locations If necessary elim...

Page 630: ...ermanently lit Connect test box VAG1598 31 to engine control module wiring harness Engine control module must not be connected 24 MULTIPORT FUEL INJECTION MFI Fig 318 Identifying 2 Pin Electrical Conn...

Page 631: ...Fig 319 Identifying Special Tools Charge Air Pressure Sensor G31 Checking Courtesy of VOLKSWAGEN UNITED STATES INC Special tools testers and auxiliary items required Connector contact Test box VAG1598...

Page 632: ...equence Read DTC memory of engine control module If display shows a DTC relating to Charge air pressure sensor G31 Checking power supply Fig 320 Disconnecting Connector On Charge Air Pressure Sensor C...

Page 633: ...ng does not match specification Fig 322 Connecting Test Box VAG1598 31 To Engine Control Module Wiring Harness Courtesy of VOLKSWAGEN UNITED STATES INC Connect test box VAG1598 31 to engine control mo...

Page 634: ...connector for charge air pressure sensor Connect multimeter and measure voltage at sockets 101 and 108 of test box Start engine and let it idle Specification approx 1 90 V Increase engine speed by qu...

Page 635: ...e parts removed on a clean surface and cover them over Do not use fluffy cloths Carefully cover or seal opened components if repairs are not to be performed immediately Only install clean components D...

Page 636: ...t I Courtesy of VOLKSWAGEN UNITED STATES INC 1 30 Nm Only use genuine bolt 2 Gasket Replace 3 Catalytic converter 4 30 Nm Always replace 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo Engine Mec...

Page 637: ...and contact surface of bolt head with hot bolt paste G 052 112 A3 13 10 Nm 14 Banjo bolt 30 Nm 15 Gasket Always replace Note installed position 16 Coolant return line Tighten union nut to 30 Nm 17 30...

Page 638: ...ket Always replace 24 Oil return line To oil pan 25 Gasket Always replace 26 10 Nm 27 10 Nm 28 Turbocharger Checking Turbocharger and charge pressure control valve checking 29 25 Nm 30 Bracket Part II...

Page 639: ...um hose To Recirculating valve for turbocharger N249 2 Mechanical air recirculation valve Checking Mechanical air recirculation valve checking 3 Hose To air recirculation valve 4 Air hose 2005 Audi A4...

Page 640: ...10 Hose To turbocharger 11 Hose To vacuum unit for charge pressure control valve 12 Wastegate bypass regulator valve N75 13 Angle piece 14 Hose To turbocharger Turbocharger removing and installing Spe...

Page 641: ...TATES INC Hose clamps 3094 Removing Fig 328 Noise Insulation Tray Retainers Courtesy of VOLKSWAGEN UNITED STATES INC Remove sound insulation arrows 2005 Audi A4 Quattro ENGINE 1 8 Liter 4 Cyl 5V Turbo...

Page 642: ...cure to body with wire Fig 330 Identifying Turbocharger Bracket Oil Return Line Air Hoses Banjo Bolt Courtesy of VOLKSWAGEN UNITED STATES INC Unbolt turbocharger bracket 2 Unbolt oil return line 1 fro...

Page 643: ...ws Fig 332 Air Cleaner Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove air cleaner cover arrow Fig 333 Removing Bolts Air Duct Courtesy of VOLKSWAGEN UNITED STATES INC 2005 Audi A4 Quattro ENGIN...

Page 644: ...ring connectors from 1 EVAP valve additionally remove EVAP valve from air cleaner housing 2 Mass Air Flow sensor 3 Wastegate bypass regulator valve N75 Pull off hoses move wiring clear and remove air...

Page 645: ...se Fig 336 Using Hose Clamp 3094 To Clamp Off Coolant Return Hose To Turbocharger Courtesy of VOLKSWAGEN UNITED STATES INC Use hose clamp 3094 to clamp off coolant return hose to turbocharger Release...

Page 646: ...bolts Using bracket secure coolant supply line loosely to vacuum unit for charge pressure control valve Tighten banjo bolt to 35 Nm and then tighten securing bolt on bracket to 10 Nm NOTE To avoid da...

Page 647: ...ger 10 Turbocharger to exhaust manifold 35 See note Component Nm Turbocharger bracket to cylinder block 25 Turbocharger bracket to turbocharger 30 Catalytic converter to turbocharger 30 Oil return lin...

Page 648: ...STATES INC 1 Air duct 2 Rubber grommet 3 Air hose Between charge air cooler and air duct in lock carrier 4 Air hose Between intake manifold and charge air cooler 5 O ring 2005 Audi A4 Quattro ENGINE 1...

Page 649: ...moving and installing Removing Lock carrier in service position Lock carrier moving to service position Fig 339 Removing Air Hose Disconnect connector 2 from Charge air pressure sensor G31 Courtesy of...

Page 650: ...o charge air cooler Remove charge air cooler from underneath Installing Install in reverse order paying attention to the following Install lock carrier Lock carrier moving to service position Tighteni...

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Audi AMB, Service Manual

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