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A408_03.

fm Page 50 Friday, October 8, 2010 1:22 PM

03-50 Maintenance
Air filter, replacing (6-cylinder)

3.2L
½ Open retaining clips (4) and disconnect air intake hose.
– Unclip fuel line retaining clip (3).

A00-10094 – Release hose clamp and disconnect hose (1).

– Remove mounting screws (2) for upper air filter housing.

– Remove upper part of air filter from bracket and pivot toward engine.

½ Remove air filter element (13) from lower air filter housing (15).
1. Screw
2. Air duct
3. Screw
A24-10087
4. Air guide
5. Air guide
6. Strainer
7. O-ring
8. Air intake hose
9. Rubber grommet
10. Expanding anchor
11. Screw
12. Upper filter housing
13. Air filter element
14. Rubber grommet
15. Lower air filter housing

– Clean filer housing and install new air filter.


• Make sure air filter is correctly installed and seated into housing.

– Install in reverse order of removal.


A408_03.fm Page 51 Friday, October 8, 2010 1:22 PM

Maintenance 03-51
Brake pads, checking

UNDER CAR MAINTENANCE

03
Brake pads, checking
Periodic maintenance of the brake system includes inspection of
front and rear brake for pads thickness. To accurately check inner
and outer brake pad thickness, it is necessary to remove the wheels.
Checking the outer pad thickness can be accomplished without
removing the wheels.

Vehicles covered by this manual may use wheel locks. The key for
the locks is usually stored in the vehicle tool kit. See Tire and wheel
service in this repair group. If using a lift or hoist, remove tool kit
before raising vehicle.

– Remove wheel bolt caps and alloy wheel center cap as required.
Before removing a wheel, mark it’s position in relation to brake rotor
so wheel can be reinstalled in same position.

– Loosen wheel bolts slightly before raising vehicle.

– Raise vehicle and support safely. See Lifting Vehicle in this repair
group.

– Remove wheel bolts and wheel.

VJ0646005
½ Measure inner and outer front brake pad thickness (distance
between arrows).

½ Alternatively, looking through brake caliper opening: Measure inner


and outer rear brake pad thickness (distance between arrows).

Wear limit
VJ0646008 Rear brake pad, minimum thickness 2 mm (0.079 in)
(without backing plate)

When brake pads have reached their wear limit, replace them.
When replacing brake pads, be sure to inspect brake discs (rotors)
for wear. See 46 Brakes–Mechanical.

– Install wheel noting reference mark made on removal. Install wheel


bolts and torque to specification in proper sequence.

Tightening torque
Wheel bolts to hub 120 Nm (89 ft-lb)

– Install wheel bolt caps and alloy wheel center cap as required.

– Lower vehicle. Stow jack, tools, and locking wheel bolt key in trunk.
A408_03.fm Page 52 Friday, October 8, 2010 1:22 PM

03-52 Maintenance
Brake system, visual inspection

Brake system, visual inspection


Check power brake servo (booster) and brake master cylinder, ABS
/ ESP hydraulic unit, front and rear brake calipers and hoses, and
brake lines for leaks and damage. Also inspect brake cables and
parking brake for proper operation and damage. Note the following:
• Brake hoses must not be twisted.
• Brake hoses must not touch any part of the vehicle when steering
is at full lock and suspension is at the limits.
• Check hoses and lines for porosity, deterioration and chafing.
• Check brake connections and attachments for correct seating,
leaks and corrosion.

Correct problems noted during the visual inspection immediately.


For parking brake adjustment, see 46 Brakes–Mechanical.

Drive axles, checking boots


½ Inspect front outer constant velocity (CV) joint boots (arrow) for
leakage, cuts and damage. Ensure that boots are correctly seated.
AT0603082.tif Right front outer shown, left front outer is similar.

½ Inspect front inner constant velocity (CV) joint boots (arrow) for
leakage, cuts and damage. Ensure that boots are correctly seated.
Right side inner is shown, left side inner is similar.

AT0603085.tif

½ On quattro equipped vehicles, inspect rear outer (arrow) and inner


constant velocity (CV) joint boots for leakage, cuts and damage.
Ensure that boots are correctly seated. Right rear is shown, left rear
is similar.
AT0603086.tif
– If inspection of drive axle components reveals wear, leakage or
damage as outlined above, replacement is indicated. See 40 Front
Suspension and Drive Axles for suspension component
replacement.
A408_03.fm Page 53 Friday, October 8, 2010 1:22 PM

Maintenance 03-53
Fluid and exhaust leaks, visual inspection

Fluid and exhaust leaks, visual inspection

03
The engine and transmission, along with components in the engine
compartment should be visually inspected for leakage and damage.
Fluid leaks attract dust and dirt making them somewhat easier to spot.

A visual inspection should include:


• Engine
• Transmission (manual and automatic)
• Fuel system
• Cooling and heating systems
• Brake system
• Exhaust system

Check engine and components in engine compartment from above


and below for leaks and damage. Check hoses, pipes and connections
for routing, signs of leaks, abrasions, chafing, porosity and brittleness.

A small amount of dampness may be considered normal in some


cases, especially around axle and pulley seals since the contained
fluid helps the seal work properly.

Many expensive repairs can be avoided by prompt repair of minor


fluid leaks. If fluid losses are greater than can be reasonably
expected, determine cause and repair. See appropriate section for
additional information.

Front suspension components, checking


When vehicle is safely raised and wheels are off the ground, inspect
A00-10097 rubber boots protecting suspension and steering and drive axle
components as noted.

½ Inspect lower ball joint boots (arrows) for leakage, cuts and
damage. Ensure that boot is correctly seated.

½ Inspect lower ball joint axial play:


• Move wheel up and down (lower arrow). There should be no
noticeable or visible up/down “play” in joint (upper arrow).
• Observe lower ball joint while checking.
A00-10096
• Allow for any wheel bearing or upper strut mount “play”.
A408_03.fm Page 54 Friday, October 8, 2010 1:22 PM

03-54 Maintenance
Fuel filter, replacing

½ Inspect outer tie rod end boots (arrow) for leakage, cuts and
damage. Ensure that boots are correctly seated. Tie rods are
equipped with similar boots at their inner junctions which should be
inspected in the same manner. Use a mirror for inspection if
necessary.
A02-0041
– Check that lock nut (1) is tight.

Tightening torque
Lock nut on tie rod 40 Nm (30 ft-lb)

If inspection of front suspension components reveals wear, leakage


or damage as outlined above, replacement is indicated. See
40 Front Suspension and Drive Axles and 48 Steering for
Underbody, visual inspection

The factory recommends that underside of vehicle be inspected for


damage. Damage can be caused by normal wear and tear or by
driving over road debris.

Whenever vehicle is raised on a lift or a hoist, it is advisable to


visually inspect underbody, wheel wells, and sill/rocker panels for
damage to underbody sealants and coatings. Inspection should also
be made after major repairs to vehicle systems.

Promptly repair any damage or defects found. Use wax-based or tar-


based anti-corrosion compounds as specified. Do not use oil-based
anti-corrosion sprays due to possible incompatibility with factory ap-
plied protection. Check with an authorized Audi dealer parts depart-
ment for appropriate sealing compounds.

Inspect underbody components such as plastic panels to be sure


they are securely attached and there is no fluid leakage anywhere.

Fuel filter, replacing


Fuel filters do not have a specific replacement interval but should be
replaced as conditions or situations dictate. See 20 Fuel Storage
and Supply.

Tire and wheel service


Tire maintenance
Tire maintenance should be carried out at least as often as every
maintenance service. Pressures should be checked more often and
it should be remembered that pressures will change with seasonal
temperature changes. A “walk around” visual vehicle inspection
including the tires, is advisable before vehicle operation.

Check tire pressures when the tires are cold due to the normal
pressure rise associated with heat generated by driving. Tire
pressures vary between vehicle with different engine types and
between different model years. Refer to data label on driver’s side
“B” pillar for proper inflation pressures. See Identification Plates
and Labels at the beginning of this section. Be sure to also check
spare tire pressure.

Always replace dust caps on tire valves when checking tire


pressures. If valve extensions are used (as on steel wheels and
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
http://www.bentleypublishers.com/contact-sales
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