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A408_index.

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

INDEX 1

Antilock brakes (ABS) Body


WARNING 02-16, 45-1 aluminum panels 55-1
components Cabriolet AppendixA-2
Your common sense, good judgement Bosch 5.7 45-6 dimensions 02-4
and general alertness are crucial to Bosch 8.0 45-9 front fender 50-4
safe and successful service work. diagnosis 45-4 grill 55-6
Before attempting any work on your impulse wheel overview 02-18
Audi, be sure to read front 45-12 wheel housing liner 66-1
00 Warnings and Cautions and the rear (FWD) 45-13 see also Trim
copyright page at the front of the rear (quattro) 45-16
manual. Review these warnings and B-pillar trim
wheel speed sensors 45-11
cautions each time you prepare to work 70-25
on your car. Please also read any Anti-theft
Brake booster vacuum pump
warnings and cautions that accompany 96-29
15-17
the procedures in the manual.
A-pillar
Brake fluid
connector
47-1
left 97-12
bleeding 03-30
right 97-11
A level 03-29
trim 70-23
ABS Brake light switch
Arm rest
see Antilock brakes (ABS) 46-21
70-15
Brakes
Acceleration sensors Ashtray
02-16
ABS 45-6 front 70-16
antilock 45-1
Accelerator pedal assembly Automatic transmission bleeding 03-30
20-28 02-12 booster 47-3
ATF 37-3 vacuum pressure sensor 47-8
Accessory belt
codes 37-1 vacuum pump 47-7
03-36
CVT ATF 37-5 caliper
Air-conditioning (A/C) identification 03-8 front 46-3, 46-6, 46-9
air distribution 87-7 selector mechanism 37-15 rear 46-15, 46-17
blower motor 87-12 shift lock 37-16 inspection 03-51
capacities 87-4 see also Continuously variable master cylinder 47-3
components 87-9 transmission (CVT) pads and discs
compressor 87-13 checking 03-51
controls and power supply 87-5 parking brake 46-20
dust and pollen filter 03-59 B specifications
evaporator housing 87-14 front 46-1
flap motors 87-7 Back-up lights rear 46-2
refrigerant and refrigerant oil 87-4 manual transmission 34-15 troubleshooting 47-1
repairs 87-12 vacuum pump 47-7
troubleshooting 87-2 Balance shaft see also Antilock brakes (ABS)
02-8, 17-9 see also Brake fluid
Air filter
03-46 Battery Bulbs
27-3 exterior
Airbags service 03-33 see Headlight component and
02-19, 03-58, 69-10 Taillight component diagrams in
Belt
Alignment 95 Exterior Lights
accessory 03-36
44-5 timing 03-41, 13-2, 13-10, 13-17 Bumpers
front 63-1
Alternator (generator) Bi-xenon
belt 03-36 rear 63-7
94-4, 94-10, 94-17, 94-19, 94-21,
removing and installing 27-10, 27-13, 94-25, 94-28 Bus systems
27-15, 27-17 02-22, 9-2
Bleeding brakes
Aluminum 03-30
body panels 55-1
Blower motor C
Antenna 87-12
91-3 Caliper
Antifreeze front 46-3, 46-6, 46-9
03-27, 19-5 rear 46-15, 46-17

Camshaft sensor
28-7, 28-12
A408_index.fm Page 2 Wednesday, October 13, 2010 9:38 AM

2 INDEX

CAN-bus Convertible top Disc brakes


02-22, 9-2 61-3, AppendixA-12 see Brakes
component locations AppendixB-4
Catalytic converter DLC
emergency release AppendixB-3
26-3 24-2, OBD-1
electrical system 61-5, AppendixA-56
CD changer hydraulic system 61-11, Dome light
91-3 AppendixA-30 96-5

Center brake light Coolant Door


94-40 see Engine cooling system check strap and hinge lubrication
03-59
Center console Coolant pump
component carrier 57-6
70-11 removing and installing 19-7, 19-11,
courtesy light 96-8
switches 96-21 19-23, 19-32
front 57-1
Central locking Cooling system handle 57-8
service notes 57-7 see Engine cooling system rear 57-2
trim 70-17
Chain, timing C-pillar trim
02-11 70-27 Door lock
57-7
Child seat anchor Crankshaft pulley
69-1 13-4, 13-6, 13-19 Door panel
70-17
Climate control Cruise control
see Air-conditioning (A/C) 27-1 Door window
stalk switch 96-16 see Window
Clutch
bleeding 30-4 Curb weight position D-pillar trim
components 40-1 70-18
5-speed 30-16 Drive axle
CV joint
6-speed 30-18
boot checking 03- 52 boot
hydraulics 30-2
front 40-17 checking 03-52
repairs 30-16 front 40-17
rear 45-15
self-adjusting (SAC) 30-21
rear 42-7
CVT
Coil
02-13 Drive belt
see Ignition coil 03-36
ATF
Coil spring capacity 37-2
Driver information display
front 40-3 level 37-5
90-1
rear 42-3
Cylinder head
DTC
Component locations (electrical) 15-4, 15-8, 15-13, 15-15
access OBD-1
97-3
Cylinder head cover P-codes OBD-2
Compression test 15-5, 15-10
Dust and pollen filter
15-2
Cylinder leak-down test 03-59
Compressor 15-3
see Air-conditioning (A/C)
E
Console, center D
70-11
E-box (electronics box)
Constant velocity (CV) joint Dashboard 97-11
see CV joint 02-24
air outlets 87-7 ECM (engine control module)
Continuity 24-5
driver storage compartment 70-9
9-5 end trim 70-7 EDL (electronic differential lock)
Continuously variable transmission Data link connector (DLC) 45-2
(CVT) 24-2, OBD-1 Electrical system
02-13
A-pillar connector stations
ATF Diagnostic trouble code (DTC)
access OBD-1 left 97-12
capacity 37-2
right 97-111
level 37-5 P-codes OBD-2
component locations 97-3
Differential fuses 97-11
oil 39-2 grounds 97-36
troubleshooting 9-3
Dimensions
wiring diagrams EWD-8
02-4
A408_index.fm Page 3 Wednesday, October 13, 2010 9:38 AM

INDEX 3

Engine cooling system F


WARNING antifreeze concentration 03-27,19-5
bleeding 19-6, 19-9, 19-19, 19-29 Fender, front
Your common sense, good judgement capacities 03-27, 19-1
and general alertness are crucial to 50-4
coolant level 03-27
safe and successful service work. coolant pump 19-7, 19-11, 19-23, Final drive
Before attempting any work on your 19-32 oil 39-2
Audi, be sure to read draining, filling 19-6, 19-9, 19-19,
00 Warnings and Cautions and the Filter
19-29
copyright page at the front of the air 03-46
hoses, inspecting 03-29
manual. Review these warnings and dust and pollen 03-59
pressure testing 19-4
cautions each time you prepare to work fuel 03-54
thermostat 19-4, 19-16, 19-28, 19-38
on your car. Please also read any oil 03-22
radiator 19-8, 19-12, 19-24, 19-34
warnings and cautions that accompany troubleshooting 19-3 Fluid leak
the procedures in the manual.
engine compartment 03-20
Engine lubrication
components Flywheel
see Lubrication system diagrams 30-16, 30-18
Electrolyte in 17 Engine–Lubrication
03-33, 27-5 System Foglight
oil service 03-20 94-30
Electronic braking control (EBC)
45-2 Engine management Footwell light
02-5 96-9
Electronic differential lock (EDL)
applications 24-2 Front suspension
45-2
components 02-14
Electronic immobilizer see Engine compartment codes 44-2
96-29 diagrams in 24 Fuel Injection coil spring 40-3
diagnostics 24-2 control arms 40-5
Electronic stabilization program electronic throttle control (EPC) 20-37 curb weight position 40-1
(ESP) engine control module (ECM) 24-5 stabilizer bar 40-16
02-16, 45-2 engine coolant temperature (ECT) strut assembly 40-11
Electronic power control (EPC) sensor wheel bearing 40-11
02-11, 20-37 see Engine compartment
diagrams in 24 Fuel Injection Fuel filter
Electronics box (E-box) evaporative control (EVAP) 20-34 03-54, 20-32
97-11 ME7.1.1 02-10
Fuel flap
ME7.5 02-6
Emergency flasher switch lock 57-11, 96-27
MED 9.1 02-7
96-21
Motronic 24-1 Fuel injection
Emergency secondary air injection 26-36 see Engine management
convertible top AppendixVB-3 Siemens 02-11
see also Ignition system Fuel injector
sunroof closing 60-3
24-4, 24-10,
Engine EPC (electronic power control)
02-11, 20-27 Fuel level sender
02-5
20-2
accessory belt 03-36
ESP (electronic stabilization program)
applications table 02-5 Fuel pressure
02-16, 45-2
balance shaft 02-11 20-21
compartment 03-16 Evaporative control (EVAP) relieving system pressure 20-5
covers 03-18 20-34 residual pressure 20-24
identification 03-6
fluid leaks 03-20 Evaporator Fuel pump
speed sensor 28-5, 28-11 see Air-conditioning (A/C) 20-2, 20-4
technical data 02-5 high pressure 20-31
Exhaust manifold
timing belt 03-41 power supply 20-7
21-10
testing 20-4
Engine control module (ECM) Exhaust system wiring 20-16
24-5, 26-3 installation details 26-8, 26-12, 26-19,
Fuel system
Engine coolant temperature (ECT) 26-29
components 20-27
sensor see also Exhaust system diagrams in
diagnostics 20-3
24-4, 24-5, 24-7, 24-8 26 Exhaust System
delivery 20-17
evaporative emissions control 20-34
see also Engine management
A408_index.fm Page 4 Wednesday, October 13, 2010 9:38 AM

4 INDEX

Fuel tank Hydraulic fading compensation (HFC) Lights, exterior


20-27 02-16 foglights 94-30
capacities 20-1 switch 96-20
filler flap lock 57-11, 96-27 taillights 94-32, 94-35
filler neck 20-30 I see also Headlight
see also Turn signal
Fuses
97-11 Ignition coil Lights, interior
28-19 96-2
Ignition shift lock dome 96-5
G 37-16 Lock carrier, front
Ignition switch service position 50-2
Gear selector
electrical 96-19
automatic transmission 37-15
manual transmission 34-9 key cylinder 96-18
M
Ignition system
Generator
28-2
see Alternator (generator) Maintenance
coil 28-19 accessory belt 03-36
Glass disabling 28-2
air filter 03-46
see Window firing order 28-2
ATF 03-58, 37-3
knock sensor 28-2, 28-7, 28-11 battery 03-33, 27-3
Glove compartment
70-8 Immobilizer body and interior 03-58
light 96-7 96-29 brake fluid 03-29
brake system 03-52
Grill Instrument cluster cooling 03-26
55-6 02-24, 90-1 CV joint boot 03-52
diagnostics 90-2 diagnostic trouble codes (DTCs)
Grounds
removing and installing 90-3 access 03-64
97-36
dust and pollen filter 03-59
Intake manifold
15-5, 15-12, 24-23 engine covers 03-18
engine oil 03-20
H see also Engine management
exhaust system 03-53
diagrams in 24 Fuel Injection
fuel filter 03-54
Hand brake Intercooler headlight adjustment 03-60
see Parking brake 21-19, 21-20 parking brake 46-20
Headlight schedules 03-66
Interior lights spark plugs 03-42
94-3, 94-21 see Lights, interior
adjusting 03-60 timing belt 03-41, 13-2, 13-10, 13-7
automatic headlight beam adjustment tires and wheels 03-54
94-2 transmission fluid 03-58
J automatic 37-3
suspension level sensor 40-19, 42-9
switch 96-20 manual 34-5
washer 92-10 Jacking vehicle underbody sealant 03-58
03-13 under car maintenance 03-58
xenon 94-4, 94-9, 94-15, 94-19,
94-21, 94-25, 94-28 windshield wipers and washers 03-62
see also Lights, exterior Manual transmission
K
Heating and ventilation 02-12
dust and pollen filter 03-59 gear selector 34-9
Knock sensor
heater core 87-17 identification 03-8
28-2, 28-7, 28-11
see also Air-conditioning (A/C) oil 34-5
removing and installing 34-16
HFC (hydraulic fading compensation) specifications 34-2
02-16 L
Master cylinder
HID headlight Leak detection brakes 47-3
see Xenon headlight 20-34 clutch 30-5
High intensity headlight License plate light MCB (Multicommunication bar)
see Xenon headlight 94-42 91-2
Hood Lid, trunk Mirror
engine hood 55-2 55-7 interior 70-2
outside 66-3
Horn Lifting vehicle switch 96-23
96-28 03-13
A408_index.fm Page 5 Wednesday, October 13, 2010 9:38 AM

INDEX 5

Oxygen sensor S
WARNING see Exhaust system diagrams in
26 Exhaust System SAC (self-adjusting clutch)
Your common sense, good judgement see also Fuel injection system
and general alertness are crucial to 30-21
components in 24 Fuel Injection–
safe and successful service work. Gasoline Safety
Before attempting any work on your passenger 02-19
Audi, be sure to read working under car 03-16
00 Warnings and Cautions and the
P Scan tool
copyright page at the front of the
manual. Review these warnings and OBD-2
cautions each time you prepare to work Parking brake suppliers OBD-34
on your car. Please also read any 46-20
Seat belt
warnings and cautions that accompany P-code 69-5
the procedures in the manual. OBD-2
Seats
Pollen filter front 72-1
03-59 memory 72-6
Motronic rear 72-7
Power steering
see Engine management side padding 72-15
see Steering
switch 72-7
Muffler
Power window
see Exhaust system diagrams in Secondary air injection system
see Window
26 Exhaust System 26-36
Multicommunication bar (MCB) Self-adjusting clutch (SAC)
91-2 R 30-21
Multifunction steering wheel Service position
91-7 Radiator
lock carrier 50-2
19-8, 19-12, 19-24, 19-34
Multitronic® transmission (CVT) Service reminder indicator
02-13 Radiator grill
03-65
ATF 55-6
capacity 37-2 Shift lock
Radio
level 37-3 automatic transmission 37-16
91-3
identification 03-8 removing and installing 91-4 Shock absorber
see also Sound systems 42-4

N Raising vehicle Short circuit


03-13 9-5
Navigation Rear shelf Slave cylinder, clutch
91-5 70-29 30-12
Rear suspension Sound absorber panels
O 02-15 03-18
codes 44-2
coil spring 42-3 Sound system
OBD II components 91-3
curb weight position 42-1
OBD-1 see also Radio
overview 42-3
Oil shock absorber 42-4 Spark plugs
03-20 stabilizer bar 42-5 03-42
capacities 17-1
Rear window defogger Speaker
pan 17-5, 17-8, 17-13, 17-15
control 87-5 see Sound system diagrams in
pressure switch 17-3
specifications 17-1 Refrigerant 91 Radio and Communication
see also Engine lubrication see Air-conditioning (A/C) Special tools suppliers
Oil filter Ribbed belt 03-4
03-22 see Accessory belt Spiral spring
On-board diagnostics Rollover protection 48-4, 96-13
OBD-1 AppendixB-17 Stabilizer bar
rpm sensor front 40-16
28-5, 28-11 rear 42-5
A408_index.fm Page 6 Wednesday, October 13, 2010 9:38 AM

6 INDEX

Starter Tiptronic W
27-20 02-12
removing and installing 27-20, 27-21, Washers
27-23, 27-24 Tires
44-1 92-10
Steering pressure monitoring system 44-3 fluid 03-63
angle sensor 45-3, 96-14 headlight 92-14
column 48-3 Toothed belt
see Timing belt Water pump
column switches removing and installing 19-7, 19-11,
ignition 96-19 Towing 19-23, 19-32
column trim 48-4, 70-7 03-11
fluid 48-1 Wheel alignment
interlock 48-8 Transfer case 44-5
lock 48-8 oil 39-5
Wheel bearing
pump 48-20
Transmission 40-11
rack 48-9
identification 03-8
wheel 48-4 Wheel housing liner
oil 03-58
see also Automatic transmission 66-1
Strut
front 40-11 see also Manual transmission Wheel speed sensor
Trim 45-11
Sunroof
60-1 dashboard end 70-3 Wheels
door 70-17 03-54, 44-1
Suspension driver storage compartment 70-9 alignment 44-5
02-14 pillar and side trim 70-23
checking 03-53 steering column trim 70-7 Window
curb weight position 40-1, 42-1 tailgate trim 70-32 glass service 64-2
see also Front suspension trunk trim 70-30, 70-36 motor reinitializing 64-1
see also Rear suspension motor service 64-6
Trunk switch 96-24
Switches lid 55-7
dashboard 96-21 light 96-10 Wipers
exterior lights 96-20 lock 55-11, 57-11 arms and blades 92-2
ignition and steering lock 96-19 trim 70-30, 70-36 blades 03-62
mirror 96-23 repairs 92-2, 92-6, 92-9
steering column switch module 96-12 Turbocharger
window 96-24 21-3, 21-10 Wiring
hoses 21-2, 21-5, 21-11 diagrams EWD-8
symbols EWD-7
Turn signal
T front 94-15, 94-26 Working under vehicle safely
switch 96-16 03-16
Tailgate
55-11
lock 55-16, 57-12 V X
trim 70-32

Taillight Vacuum pressure sensor Xenon headlight


94-32, 94-35 47-8 94-4, 94-9, 94-15, 94-19, 94-21,
94-25, 94-28
Telematics Vacuum pump see also Headlight
91-7 brake booster 15-17, 47-7

Telephone Vehicle identification number (VIN)


91-5 01-1, 03-5

Thermostat Vehicle level sensor


19-4, 19-16, 19-28, 19-38 40-19, 42-9

Throttle control Ventilation


20-37 dust and pollen filter 03-59
see also Air conditioning (A/C)
Tie-rod see also Heating and ventilation
48-18
Vibration damper
Timing belt 13-4, 13-6, 13-19
03-41, 13-2, 13-10, 13-17
Voltage
Timing chain (camshaft drive chain) 9-4
02-11
established 1950
Automotive Reference™

BentleyPublishers
.com

Audi A4 (B6, B7)


Service Manual: 2002-2008
1.8L turbo, 2.0L turbo, 3.0L, 3.2L
including Avant and Cabriolet
Price: $149.95
Bentley Stock Number: A408
Publication Date: 2010.dec.20
ISBN: 978-0-8376-1574-5
Hardcover, 8 3/8 in. x 11 in.
Case quantity: 1
1430 pages, 2610 photos, illustrations and diagrams
The Audi A4 Service Manual: 2002-2008 contains in-depth
maintenance, service and repair information for Audi A4 models from
2002 to 2008 built on the B6 or B7 platforms. Service to Audi owners is
of top priority to Audi and has always included the continuing
development and introduction of new and expanded services.
Whether you’re a professional or a do-it-yourself Audi owner, this
Technical model introduction
manual will help you understand, care for and repair your Audi. information in full color
02 Product Familiarization
Technical features:
• Covers Audi A4 Sedan, A4 Avant (station wagon) and A4 Cabriolet
models including quattro versions. (Does not cover S4 or RS4 sport
models.)
• Audi A4 product familiarization section in full color, highlighting
Preventative maintenance
technical features, year-to-year changes and application procedures, including brake
information. system inspection and service
03 Maintenance
• Maintenance procedures from routine oil changes to brake pad and
rotor inspection and replacement.
• Engine and cylinder head service, including timing belt and brake
booster vacuum pump replacement.
• Component testing, removal and installation for engine lubrication,
cooling, turbocharger and exhaust systems.
• Fuel supply system service, including fuel pump delivery volume
test, EVAP system component locations and electronic power
Wiring diagrams and
control (EPC). component locations
• Fuel injection and ignition system component identification and EWD Electrical Wiring
Diagrams
technical data, including intake manifold removal and installation.
• Drivetrain maintenance, troubleshooting, adjustment and repair,
including hydraulic clutch, gearshift linkage and axles. Engines covered:
• Repair information for ABS brake systems. 1.8L turbo gasoline (engine code: AMB)
2.0L turbo FSI gasoline (engine codes: BGP, BWT)
• Suspension component replacement, including struts, stabilizer bar,
3.0L gasoline (engine codes: AVK, BGN)
multi-link elements and wheel bearings.
3.2L gasoline (engine codes: BKH)
• Body adjustment and repairs, including doors, fenders, front
radiator support, dashboard, sunroof and seats.
• Heating and air-conditioning repair, including A/C component Transmissions covered:
5-speed Manual (transmission codes: 012, 01W, 01A)
replacement such as evaporator housing.
6-speed Manual (transmission codes: 01E, 01X, 02X)
• Includes factory wiring diagrams, component locations and a
5-speed Automatic (transmission code: 01V)
general explanation of electrical circuitry. 6-speed Automatic (transmission code: 09L)
• Audi OBD II diagnostic trouble code section, including SAE and CVT (transmission code: 01J)
manufacturer defined P-codes.

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USA


Tel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235
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