WARNING-Important Safety Notice ..... ...... ..... .. ... ... .. ... .... .... ....... ....... ....... .....

... .... ii
Foreword ... .......... ......... ....... .... .... .. ... .. ... .. .... .. .. ..... .... ...... ... .......... ........... ........... ... iv
Index ...... ....... .... .... ..... .... ..... ....... .. ..... ..... ....... ... ....... ..... .. .......... ..... ..... .. rea r of book

0 ~
General Information, 00 Warnings and Cautions 02 Product Familiarization
01 Vehicle Identification 03 Maintenance
Maintenance and VIN Decoder

1 ~
13 Timing Belt , Engine Pulley, Rear 17 Engine- Lubrication System
Engine Main Seal 19 Engine-Cooling System
15 Cylinder Head Cover

~
Engine Management,

2
20 Fuel Storage and Supply 26 Exhaust System
Exhaust and 21 Turbocharger and lntercooler 27 Battery , Alternator, Starter
24 Fuel Injection 28 Ignition System
Engine Electrical

3 ~
Clutch and 30 Clutch 37 Automatic Transmission
32 Torque Converter 39 Final Drive , Driveshaft
Transmission 34 Manual Transmission

~
Suspension, 40 Front Suspension 46 Brakes-Mechanical

4 Brakes and
Steering
42
44
45
Rear Suspension
Wheels , Tires , Alignment
Antilock Brakes (ABS)
47
48
Brakes- Hydraulic
Stee ring

5 ~
Body- 50 Body-Front 57 Doors and Locks
Assembly 55 Hood and Lids

~
Body-

6 Components and
Accessories
60
63
64
Sunroof
Bumpers
Door Windows
66
69
Body-Exterior Equipment
Seat Belts , Airbags

7 ~
Body- 70 Interior Trim
Interior Trim 72 Seats

8 ~
Heating and
87 Heating and Air-conditioning
Air-conditioning

~
9 Electrical System-General 94 Exterior Lights

9 Electrical System 90
91
92
Instruments
Radio and Communication
Wipers and Washers
96
97
Interior Lights , Switches , Anti-theft
Fuses , Relays ,
Component Locations

~
EWD Electrical Wiring Diagrams
OBD On Board Diagnostics
 01-1

01 Vehicle Identification and

VIN Decoder

Vehicle identification number (VIN), decoding

Some of the information in this manual applies only to cars of a particular model year or
range of years . For example , 2003 refers to the 2003 model year but does not necessarily
match the calendar year in which the car was manufactured or sold . To be sure of the
model year of a particular car, check the vehicle identification number (VIN) on the car.

The VIN is a unique sequence of 17 characters assigned by Audi to identify each

individual car. When decoded, the VIN tells the country and year of manufacture; make,
model and serial number; assembly plant and even some equipment specifications.

The Audi VIN is on a plate mounted on the top of the dashboard , on the driver's side
where the number can be seen through the windshield . The 10th character is the model
year code. Examples: W for 1998, X for 1999, Y for 2000 , 1 for 2001 , 2 for 2002 , etc . The
table below explains some of the codes in the VIN for 1998 - 2004 Audi A6 models
covered by this manual.

Sample VIN: WAUDA24BlXN001612

VIN Description Decoding information

position
1 Manufacturing T Hungary
country w Germany
2 Manufacturer A Audi germany
R Audi Hungary
u quattro GmbH
3 Vehicle Type u Passenger vehicle
4 Series
Varies with model year.
5 Engine
See BentleyPublishers .com for more information
6 Restraint system
7-8 Model 4A A6 Avant
4B A6 , allroad quattro , S6 , RS6
9 Check digit 0 - 9 or X, calculated by NHTSA
10 Model year w 1998
x 1999
y 2000
1 2001
2 2002
3 2003
4 2004
11 Assembly plant A lngolstadt
K Karman -Rheine
N Neckarsulm
12-17 Serial number Sequential production number for specific vehicle

'---r-·~
I

' I
 02-1

02 Product Familiarization

GENERAL . ... . ... . . . . . . . . . . . . . . . . . . . . . . . . . 02-1 4 SUSPENSION, BRAKES AND STEERING . .... .. 02-19
Body dimensions ........... .. ............ 02-3 Suspension ............................ 02-1 9
allroad quattro ... .. ....... ...... .... . .... 02-4 all road quattro air suspension ... . ....... ... 02-22
Audi RS6 .. ..... .. ... ................... 02-5 RS6 suspension . ... ... .. . ... ... ........ 02-24
Antilock brakes (ABS) ................. . . . 02-24
1 ENGINE ... . . . . . . . . . . . . . ..... . . . . . . . . . . . 02-5
Brakes . .. .. . ........... . ..... . ....... . 02-26
V6 engines . . . ....... . .. .. . ......... .... 02-5
Steering column ... .. ...... . ...... . ..... 02-27
VB engines ....... . ... .... ...... . ....... 02-8
5 BoDv-AssEMBLY
2 ENGINE MANAGEMENT . .... .... .. ... . .... 02-11
6 BODY-COMPONENTS AND ACCESSORIES
3 CLUTCH AND TRANSMISSION . . . . . . . . . . . . . .. 02-14 7 BoDv-INTERIOR TRIM . . . . . . . . . . . . . . . . . . . . 02-28
Self-adjusting clutch (SAC) ....... ... ..... . 02-14
Manual transmission .. .. ... . .. . ....... ... 02-14 8 HEATING AND AIR-CONDITIONING . . . . . . ... .. 02-30
Automatic transmission ...... . ... ... ...... 02-15
9 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . ... . 02-31
Multitronic® (CVT) transmission .. .... .. .... 02-16
Instrument cluster, dashboard and controls .. . 02-32
RS6 transmission .... ... ....... . ........ 02-18
Torsen® differential ................ ... .. . 02-18

GENERAL
The information included in this section , based on introductory
material for 1998 through 2004 Audi A6 vehicles sold in the USA
and Canada, is intended to serve as a product familiarization
guide.

CAUTION-

• The information in this section is subject to change. Use it as

a general reference only. Check Audi factory repair information
or the publisher's website at www.bentleypublishers.com for
information that may supersede material in this section .

.;;;;;;(The fifth generation Audi A6 , referred to as the C5 platform , was

introduced in 1998 and continued through 2004.

The Audi A6 combines the latest engineering expertise with a

future-oriented automobile design. The primary goals were to
increase body rigidity, reduce body weight , and improve crash
properties. Despite being lighter, the body is 50% more rigid
than its predecessor. This results in better driving dynamics and
increased ride comfort.

The engine hood , window frame modules and side impact bars, for
example , are manufactured using aluminum.

' ~--~-~ -, ~~ -

~.
02-2 Product Familiarization

~ T~e alumi~um engine hood i~ the first instance in which Audi used
this material for a large exterior part on a high volume production
vehicle. It is 36 percent lighter than a conventional engine hood ,
yet 20 percent more rigid .

The use of magnesium and aluminum components in the running

gear such as the transmission housing , suspension components ,
brake calipers and wheels is another weight-reducing measure.

229_06
The four-link front suspension represents a breakthrough in
handling and performance. Additionally, antilock brakes , electronic
differential lock and traction control are combined to give the Audi
A6 a standard of driving safety unrivalled in its class .

All A6 models feature a host of standard equipment featu res aimed

at improving active and passive safety. Included are:

•ABS (antilock braking)

• EDL (electronic differential lock)
• EBD (electronic brake pressure distribution)
• ASR (antislip regulation)
•Ellipsoidal-principle headlights
__
229_09
• Electrically adjustable and heated outside mirrors
•Outside temperatun;) display
•Driver and passenger airbags
• Side impact airbags for front
•Three-point automatic seat belts and head restraints for all seats
• Pyrotechnic seat-belt tensioners for front and rear seats
In addition , the A6 features extensive anti-theft measures :

•Anti-theft alarm system with ultrasonic interior monitoring

• Button on inside of driver's door for central locking
•Break-in protection for door and luggage compartment locks (lock
mechanism cannot be opened even if the car is broken into)
• Remote (keyless) central locking
The A6 was introduced with an all-new engine, the 2.8 liter, thirty-
valve V6. This engine has variable intake manifold runners and
variable camshaft timing. The engine delivers 200 hp and a peak
torque of 207 lb-ft at 3200 rpm. An impressive feature of the 2.8
liter engine is that more than 188 lb-ft (91 % ) of torque is available
at engine speeds between 2500 and 5000 rpm.

Additional engines were introduced throughout the production of

the A6 , including the 450 hp, 4.2 liter VB used in the limited edition
Audi RS6. See 1 Engine for engine data.
 Product Familiarization 02-3

Body dimensions
A6 4.2

A6 Avant

4.r
t - - - -.......,.......__ _ _ _ _ _ _ _ _ _ _ _...;""-+...:;..----~ !loaded)
t - - -- - - - 108.7" _ _ _ _ __,
t--- - -- -- - - - - - 192.0 " - -- - - - -- - - -..;
56 Avant

4 .8 "
t----......,T"-------------_...;""-+...:;..----~lloaded l
t--- - - -- 108.6 " _ _ _ __ ___,
,____ _ _ _ _ _ _ __ _ 193 .4 " - - - -- - - - - - ---!

allroad quattro

l
61 .9 "

7.5 "

- - - - - - 10 9 "- - - - -- - - -
- -- 189 " _ _ _ _ _ _ _ _ _ _ __...,
Level 1 Level4 Level3 A604020 17
02-4 Product Familiarization

A60402002

allroad quattro
The allroad quattro, introduced in 2000 , shares its platform with
the second generation C5 A6 Avant (station wagon) , although an
advanced air suspension , larger wheels with all-terrain tires and
flared and unpainted bumpers give it a distinct appearance and
more overall flexibility over varying terrain . Audi 's quattro (all -wheel
drive) system is standard equipment.

The allroad quattro was not created by simply changing shock

absorbers and springs to give an A6 more ground clearance .
There are more than 1,100 new parts that make the all road a true
all-terrain vehicle .

The 4-level suspension system has two operating modes :

• Automatic mode adjusts vehicle height according to vehicle

speed and needs no driver input.
• Manual mode allows driver to select vehicle height, depending on
speed and terrain.
Other functional and visual modifications to the allroad quattro
include :

• Larger exterior mirrors

• Front and rear underbody protection
•Matte paint finish on the bumpers , roof and door sills
• Redesigned headlights
 Product Familiarization 02-5

AudiRS6
~ The Audi RS6 , a limit.ed production po~er~ouse , is t~e perfect
synthesis of extraordinary power, pract1cal1ty and poise. The
company's most powerful model to date, the RS6 features an
engine producing an amazing 450 horsepower at 6 ,500 revolutions
per minute, making it a world-class luxury sedan with the heart of a
sports car.

Tuned by quattro GmbH , the high-performance arm of Audi AG

and well known for the remarkable RS4 model sold exclusively in
Europe, the RS6 is the first vehicle quattro GmbH has produced for
the North American market.

1 ENGINE
Both V6 and V8 engines were available for the A6 . V6 power plants
included a 2.7 liter biturbo engine and 2.8 liter and 3.0 liter normally-
aspirated engines.

The three variants of the V8 engine all displace 4.2 liters , with power
output ranging from 299 hp to 450 hp.

V6 engines

2.7 liter VG biturbo, engine codes APB , BEL

~The 2.7 liter V6 biturbo engine, introduced in model year 2000 , uses
two small turbochargers , one fitted at each bank of cylinders. Due to
their lower inertia , the dual turbochargers respond more quickly than
a single larger unit.

Each turbocharger has its own intercooler for more efficient cooling
of the intake air.

2.7 liter engine, general s_p_e_ci_

fic_a_
ti_o_n_s_ _ _ I
Engine codes

Engine type
APB (2000 - 2003)
BEL (2003 - 2004)
dual overhead belt and chain-driven - _
J
camshafts, 30-valve V6
lbs-ft Nm kW hp
370 500 200 268 Engine size 2.7 liters I 163 cu . in .

==- _
333 450
.,.v- t"--...
180 24 1
Horsepower

I ~~ ; 5-~-~-~ ;~:
296 400
,V '160 214
APB
BEL
259 350 I I ~ 140 188
I y
Torque (lb-ft) 258 @ 1800 : ___450~ p~

(1)
::J
er 185
._
222 300

250 I I "'~' 120 161 ::;

100 134 ::;

0.
~ 2.7 liter engine horsepower and torque graph .

~
148 200 '
v 80 107
0

111 150 I 0 80
I
74 100

37 50
v 40

20
54

27

0 0
0 1000 2000 3000 4000 5000 6000 7000
Speed (rpm) 198 02
02-6 Product Familiarization

Turbochargers
2.7 liter turbochargers

Air distributor

I
Air filter

Charge air
intercoolers

A60402001

2.8 liter VG engine, engine codes AHA, ATQ

<Oil( The initial V6 offering was the 2 .8 liter naturally-aspirated engine
with the cylinde r banks positioned 90° apart. Other features
include 5 valves per cylinder, distributorless ignition and variable
valve timing. Two variants of this engine were available.

A redesigned combustion chamber and centrally-located spark

plug are responsible for improving combustion efficiency, reducing
fuel consumption and lowering exhaust emissions .

2.8 liter engine, general specifications I

- -
Engine codes AHA (1998 - 2000) 1
I
ATQ (2000 - 2001)
Engine type dual overhead belt and chain-driven
camshafts, 30-valve V6
Engine size 2.8 liters I 169 cu . in .
Horsepower
~AHA
ATQ
__ =l 200 @ 6000
193 @
'E'.11____
6000 rpm
--

-- --

----
- -
-

Torque (lb-ft)
-----i
AHA
- -3200
207
-rpm @
----

ATQ 207 @ 3200 rpm

 Product Familiarization 02-7

3.0 liter VG engine, engine code AVK

~The 3.0 liter V6 , which replaced the 2.8 liter base engine in 2002 ,
features :

• Aluminum cylinder block manufactured using patented Cosworth

rollover casting process-a technique used for race car engines .
• Plastic two-position variable intake manifold reduces engine mass
and provides torque over a broad range with maximum power
available at high rpm.
•Dual overhead camshafts with continuously variable intake
camshaft adjustment and two-position exhaust camshaft
adjustment boost power output and torque and ensure compliance
with exhaust emissions standards.
• Five-valve-per-cylinder technology ensures optimum flow of
fuel-air mixture and exhaust gases to keep fuel consumption and
exhaust emissions low.

~ • Balance shaft integrated with oil pump into single module located
underneath engine block in sump provides for exceptional running
Crankshaft smoothness.
~ • Motronic ME 7.1.1 engine management system with "drive by
wire" electronic throttle control for immediate response to driver
input: Accelerator pedal movement is transmitted to the engine
management system instantly and without loss.
• Mapped-characteristic ignition and solid-state spark distribution
are exceptionally reliable and improve fuel mixture combustion .

Balance
shaft

~ •Tubular air-gap-insulated exhaust manifolds lower weight,

improve noise pattern , quickly heat catalytic converters to light-off
temperature , and reduce heat transfer to engine compartment.

Cyl.6 •Cylinder-bank-selective oxygen sensing , with two pre-converters

close to engine and two mai n catalytic converters farther back
ensure long-term stability in exhaust emissions .
• Ultra-low emissions vehicle (ULEV) certification .

3.0 liter engine , general specifications

- - - - - --
Engine code AVK (2002 - 2004)
- - ---------------
Engine type dual overhead belt-driven camshafts ,
30-valve V6
255_035 Engine size 3.0 liters I 182 cu . in.
-j
Horsepower 220 @ 6300 rpm
- ---- ----------------- --1
Torque (lb-ft) 221 @ 3200 rpm ___J
02-8 Product Familiarization

VB engines
VB engines, engine codes ART, AWN, BBD
~ Starting in 1999, A6 models were optionally equipped with a
normally aspi rated VS engine. Features of the 4.2 liter VS 5-va lve
engine include the following :

•Aluminum engine block with no cylinder liners

•Aluminum five-valve-per-cylinder head with roller rockers
•Belt-driven dual camshafts
•Three-stage variable intake manifold
•Bosch Motronic ME 7.1 engine management system with non-
return fuel supply system
• Water-cooled 190-ampere generator
• Oil filter module with integrated oil cooler
•Meets Low-Emission Vehicle (LEV) exhaust emission standards
•Two hot film mass air flow sensors with integrated air
temperature sensors
• One ignition coil with integrated output stage per cylinder, each
mounted directly over the spark plug
• Two electronically controlled fuel pumps
•Two electric engine cooling fans
The base VS engines (2 versions , engine codes ART and AWN )
produce 299 hp. The Audi S6 , introduced in 2002 , was equipped
with a 340 hp version of the 4.2 liter VS (engine code BBD) .

VS basic engines, general specifications I

~ - - - - -
Engine code ART (1999 - 2001) I
AWN (2002 - 2004)
BBD (2002 - 2004)
Engine type dual overhead belt-driven camshafts ,
40-valve VS
--- ---- - --- - - - - -
Engine size 4 .2 liters I 255 cu . in.
Horsepower
ART, AWN 299 @ 6000 rpm I
--- - ---- - - l

I
BBD 340 @ 6000
- - ------ - -l

Torque (lb-ft)
- - - -1
ART 302 @ 3300
~ - - - ---- -
I
AWN 305 @ 3300
BBD 295 @ 3500

allroad quattro VB engine, engine code BAS

For 2003 all road quattro models , a new 4 .2 liter VS engine was
optional. Redesi gned to fit into the slim engine compartment , this
engine uses chain drive to operate the dual overhead camshafts.
The single-row chain is on the clutch end of the engine, allowing
the engine to be shortened by 52 mm (approx. 2 in) .
 Product Familiarization 02-9

--
allroad quattro VS engine
chain drives

A60402004

Four ch ains are used to operate the camshafts and engine

accessories. The main chain drives two intermediate shafts , one
per cylinder bank. From each of these a short chain drives the two
camshafts in each cylinder head . (Camshaft chains are not shown in
illustration.)

~The auxiliary chain , driven off a second crankshaft sprocket,

operates engine accessories th rough driven sprockets or
intermediate shafts :
Auxiliary •Oil pump
chain
• Coolant pump
• Power steering pump
• A/C compressor

Power steering pump - -

A two-stage variable intake manifold made tram magnesium allows
higher engine power output at higher speeds in addition to high low-
end torque . Continuous camshaft timing control also contributes to
A60402005 increased performance over a wide range of engine speeds.

-i::--
VS allroad quattro engine , general specifications
Engine code
Engine type
Engine size
BAS
dual__overhea~ ch~in-driv~camshafts~O-v~ve VS

4.2 li~ rs ~ 5~ c~.~ -- _ __ _

--
_

(i~:ft) \ ~8()@
Horsepower 299 @ 6200 rpm

! Torque 2-700 :-460-0 rp-;;;

02-1 O Product Familiarization 02-10

RS6 biturbo VB engine, engine code BCV

At the heart of the high performance RS6 model is the 4.2 liter
V8 biturbo engine. Inspired by Audi 's victorious LeMans-winning
R8 racing ca r, this power plant makes the sleek RS6 amon g the
fastest five-passenger sport sedans ever to enter the U.S. market,
with a 0 - 60 mph time of just 4 .6 seconds.

The V8 engine has twin turbochargers , one for each cylinder bank,
to provide increased low-end torque , more power at the upper end
and overall improved engine response. Electronically controlled
waste gates and twin intercoolers optimize engine performance .
An intercooler mated with each cylinder bank prevents loss
of turbo pressure while cooling the intake air. This force-fed ,
temperature-optimized "breathing" results in minimal turbo lag and
peak engine performance.

Engine architecture includes 90° cylinder banks, a lightweight

aluminum block and five valves per cylinder-two of which are
sodium-filled for maximum valve temperature control-that help
feed and ventilate the cylinders faster, producing more torque and
power with less fuel consumption and lower emissions.
-- --1
RS6 engine, general specifications
Engine code BCY
Engine type dual overhead belt and chain-driven
I

camshafts , 40-valve V8
Engine size 4.2 liters I 255 cu. in.
~Horsepower 450 @ 5700 - 6400 rpm
----
Torque (lb-ft) 413 @ 1950 - 5600 rpm
------ - -

A60402006
 Product Familiarization 02-11

2 ENGINE MANAGEMENT

Fuel tank
The fuel tank is plastic and placed near the rear axle for crash
safety.

The unusual shape of the quattro fuel tank , a result of the quattro
rear axle design , necessitates three separate fuel gauge senders .
The senders are connected in series . Individual resistances of the
senders are summed to a total resistance . A microprocessor in
the instrument panel processes the fuel sender data and delivers
precise fuel level information .
229_24
The fuel pump and its baffled enclosure are inside the fuel tank on
the right. Two siphon pumps, driven by the fuel return feed fuel into
the fuel pump baffle . Access to the fuel pump is through a cover
under the rear seat cushion.

Fuel tank removal requires disassembly of the rear axle . The filler
neck is a separate part from the fuel tank .

Bleeder valve
quattro fuel tank ~------- Gravity valve

Main vent lines

- - - - - Expansion tanks

Siphon pumps

Fuel pump _ _ _ _ _ _ ___.

with battle

Fuel gauge senders

229_23
02-12 Product Familiarization

Gravity valve ,
Evaporative emissions control
venting valve
The fuel tank evaporative emissions control components are two
Rear expansion tank separate expansion tanks at the filer neck and a complex of fuel
vent lines.

When the fuel tank is filled , air escapes through the two main vent
Additional lines into the front expansion tank at the filler neck.
to Evaporative vent lines
emission control
caniste r ~ When the fuel heats up due to an external cause , such as heat from
the exhaust system or return fuel flow from the engine, the resulting
fumes enter the rear expansion tank through the three auxiliary
vent lines . Fumes are then fed to the evaporative emissions control
canister (carbon canister) via the gravity valve and the venting valve.

229 _28

Fuel return system

~ Fuel returning from the engine flows through the return line to a
T-fitting mounted on the fuel pump. From there the fuel is fed to the
', --'- '\ siphon pumps. If the return volume is excessive, the fuel backs up
'--, at the siphon pumps, increasing back-pressure in the return line ,
and in turn affecting the fuel pressure regulator.

A pressure control valve in the T-fitting limits pressure in the fuel

return line to a maximum of 14.5 psi (1 bar) . When the valve opens ,
fuel flows directly into the fuel pump baffle.

229 29
Motronic engine management
Bosch Motronic engine management systems in A6 cars combine
fuel injection , ignition and on-board diagnostic capabilities. The
Motronic engine control module (ECM) coordinates a variety of
environmental sensors, drivetrain monitors and driver wishes to
determine performance parameters for the engine. It also stores,
for later access, diagnostic trouble codes (DTCs) . Motronic systems
are fully compliant with federal and state mandated second
generation on-board diagnostic (OBD 11) standards .

The first A6 models in 1998 (2 .8 liter engine, engine code AHA)

were fitted with Bosch Motronic engine management M5.9 .2. The
throttle valve in this system is operated via traditional throttle cable.

Starting with 2000 models, A6 models were fitted with Bosch

Motronic ME 7 engine management which uses a new internal
circuit design to calculate engine torque . The ECM receives relevant
signal data from the input sensors and other sources and computes
the required amount of engine torque needed based on pre-
2
established priorities.
 Product Familiarization 02-13

Actuators

~ -----
Sensors
Mass air flow sensor Bosch Motronic ME 7.1.1 Fuel pump
(J17)
(G70) 3.0 liter V6 engine (AVK)
Fuel pump
Engine speed (rpm) ~ relay (G8)
sensor (G28) ~ ---~ Engine control module
Fuel injectors

~
(ECM) (J220)
(N30 , N31 , N32 ,
Camshaft N33, N83, N84)
sensors

~
(G40 , G163,
G300, G301)

Oxygen <j H Ignition coils

sensors (N , N128, N158,
(G39 , G108,
G130, G131)
& N163, N164, N189)

q q
Throttle control module ,
'.l
throttle drive, throttle Brake system
angle sensors (J338, vacuum pump
G186, G185, G188) (V192)
Evaporative
emission canister
valve (N80)
Secondary air
Data link ________,...._... ...__ t!J!t:!fi
(~~ injection pump
connector ~~L~ and relay
Knock sensors (G61 , G66) ABS (TV14) (V101 , J299)

t
control
module Secondary air
injection valve
Brake booster pressure ~ (J104)
(N112)
sensor (G294) 'Q

~
CAN-bus Throttle control
Throttle position sensor,
accelerator position
~.1$1 ~
J;i&i
P'±Y' (;Y ___,. 1
module , throttle
drive (J338 , G 186)
sender (G79 , G185) \ r'
~Camshaft
~ adjustment
~ valves
Brake light switch , Instrument ~ (N205 , N208)
brake pedal switch cluster
(F, F47) control
module Oxygen
Clutch vacuum switch sensor heaters
(F36) (J285)
(Z19 , Z28 ,
Auxiliary signals : ~ ~ Z29 , Z30
A/C control
A/C system panel
Crash signal A/C compressor
(E87)
Cruise control 255_046

The ME 7 ECM obtains the calculated engine torque through

precise coordination of the fo llowing output components :

•Throttle valve control module (throttle angle)

• Wh ere applicable, turbo waste gate regulator solenoid valve
(boost control)
• Fuel injectors (injection time and fuel cut-off)
• Power output stages with ignition coils (ignition timing)

NOTE-

•Audi identifies electrical components by a letter and I or a

number in the electrical schematics. See EWD Electrical Wiring
Diagrams . These electrical identifiers are listed in parenthesis as
an aid to electrical troubleshooting.
02-14 Product Familiarization

Throttle valve
control
module

I- - - - - -
B M
puts

utputs
~With ME 7 , instead of a throttle cable between the accelerator
pedal and the throttle valve there is electronic throttle control with
the following components :

• Throttle valve control module

• Accelerator pedal module
The electronic throttle valve control system is used to reduce and
Acce lerator increase torque without adversely affecting exhaust emissions.
ped al
module
The ideal com bination of throttle opening and charge pressure can
be controlled for greatest efficiency. Under acceleration , throttle
movement is programmed to best increase intake charge velocity.
On deceleration , the throttle valve can be held open to reduce
A60402007 emissions.

RS6 engine management

The Motronic adaptive engine management system controls turbo
boost pressure , engine knock and exhaust-gas temperature fo r
enhanced engine performance and efficiency.

The optimized dual-branch exhaust system with middle and rear

mufflers, larger pipe sections and metal-base catalytic converters
adds to performance and sound .

~ To save weight , the upper section of the air cleaner is made from a
carbon fiber composite. A carbon -fiber cover over the front section
of the engine adds to the striking under hood appearance.

3 CLUTCH AND TRANSMISSION

Self-adjusting clutch (SAC)

~The 2.7 liter biturbo engine is equipped with the self-adjusting
clutch (SAC) .

The SAC is designed to maintain consistent clutch action

throughout the life of the clutch disc . If the clutch disc is replaced
without pressure plate replacement , follow the correct procedure to
reset the pressure plate adjusting ring . See 30 Clutch .

Clutch
cover Manual transmission
A6 manual transmissions are all-wheel drive (quattro) . Manual
Main
diaphragm transmission applications are as follows :
spring
• 5-speed (01 A) :
198-_42 2.8 liter V6 models, engine codes AHA , ATQ
• 6-speed (01 E):
2.7 liter biturbo V6 , engine codes APB , BEL
VB models, engine codes ART, AWN , BBD
• For transmission identification and additional application
information , see 03 Maintenance.

2
 Product Familiarization 02-15

Transmission oil pump

198_76

Transmission oil cooling

The six speed manual transmission oil is cooled by circulatin g
through a radiator heat exchan ger.

Automatic transmission

Automatic transmission versions

01 V automatic transmission
A6 automatic transmission applications are as follows :

• 5-speed front-wheel drive (01 V):

2.8 liter V6 models , engine codes AHA , ATQ
• 5-speed all-wheel drive (quattro) (01V) :
2.8 liter V6 models, engine codes AHA , ATQ
• 5-speed all-wheel drive (quattro) (01 L):
2.7 liter bitu rbo V6 engine (all ro ad quattro)
V8 models
Torsen ®
differential • Multitronic® (continuously variable transmission or CVT)
front-wheel drive (01 J) :
A60402008
3.0 liter V6 , engine code AVK
02-16 Product Familiarization

~ Thermostatically controlled ATF cooler in front of the engine

Automatic transmission
radiator.
oil cooler all wr-o::~~ Thermostat
--..-;::::~~ l""'­
Radiator- - - - - - 1 /;!I
Automatic transmission controls
Supply li ne
The automatic transmission control module (J217) receives signals
from a number of sensors. These signals are used to control wh en
I the transmission shifts and how the shift feels .

The on-board diagnostics system also monitors the transmission

for faults and stores diagnostic trouble codes (DTCs) which can be
accessed via the data link connector.

A60402010

Engine control
modu le (ECM) Transmission
(J220) solenoid valves
Transmission
control module
Transm ission input (J217)
sensor(G182) Engine control
module (ECM)
(J220)
Transm ission vehicle
speed sensor (G38)

Shift-lock
Kickdown switch (F8) solenoid

~
Brake light switch
(F)
Gear position
12::======-i·.
11
.. 11 indicator
Transmission fluid
temperature
sensor (G93) ~
Cruise control
Data link switch

~
Multifunction connector
transmission
range switch
(F125)
.
I
I
Automatic
transmission
relay

~
ABS control • Back-up lights
module (J104) " ····-· (M16 , M17)

A60402011

Multitronic® (CVT) transmission

Models with 3.0 liter engine (engi ne code AVK) were available
Reverse clutch
with the continuously variable transmission (CVT) known as the
Multitronic® .

~ The key component of the Multitronic® transmission is the variator.

It allows gear ratios to be adjusted continuously between the
starting torque multiplication ratio and the final torque multiplication
ratio. As a result , a suitable gear ratio is always available . The
engine can operate within the optimum rpm range regardless of
whether it is optimized for performance or fuel economy.

Forward clutch
 Product Familiarization 02-17

The variator has two tapered disc pairs as well as a special chain
which runs in the V-shaped gap between the two tapered pulley
pairs. The chain acts as a power transmission element.

• Pulley set 1 is driven by the engine through an auxiliary reduction

gear step.
•Engine torque is transmitted via a special chain to pulley set 2
and from there to the final drive.
One of the tapered pulley halves in each pulley can be shifted
on the shaft for variable adjustment of the chain track diameter
and transmission ratio. The two sets of pulleys are adjusted
simultaneously so that the chain is always taut and the disc
contact pressure is sufficient for power transmission purposes .

Torque is transmitted by the fri ctional force between the ends

of the cradle type pressure pieces and the contact faces of the
tapered pulleys.

Variator in starting torque ratio

~
: Narrow

,•
..,.::-

)» r::.- '
,,,..,.-

from Engine

I __.,
'---._.-

--.:
I
to Differential
:...,..__ I
I. . . . . . .

I
I Wide
; Narrow
228_043

CVT chain design

Cross-section Top view Side view

~ Tapered pulley
/ I
Cradle-type
pressure piece
contact faces 228_027

~-. - T~~---

, ' , I
02-18 Product Familiarization

RSG transmi ssion

Emphasizin g sports car-like driving , engineers specifical!y tuned a
five-speed Tiptronic automatic transmissio n for the RS6 . In Sport
setting (gear selector in S position) , gears are held longer on
upshifts and downshifts are advanced to increase pe rfo rmance .
Depending on the level of lateral acceleratio n , the transmiss ion
manageme nt system can even adjust to avoid undesirable shifts
during cornering .

The RS6 drive r can also operate the transmissio n manually in

either of two ways : by briefly pressing the gear selector front or
back in the Tiptronic shift gate, or via race-inspired shift paddles
behind the steering wheel.

The specially tuned RS6 Tiptronic transmissio n also incorporates

a Dynamic Shift Program (DSP) with hill detection capability. DSP
automatica lly selects from more than 200 shift patterns to match
driver characteristics with driving conditions , while hill detection
capability prevents gear hunt on inclines.

Torsen® differen tial

All-wheel drive (quattro) systems rely on a torque sensing
(Torsen®) center differential to distribute power between the fro nt
and rear axles. This type of differential works without electrical
connection s or computer controls . There are no driver inputs. The
Torsen differential is a sealed unit in the rear of either the manual
or the automatic transmissio n housing.

Torsen® d ifferenti a I

Housing - - - - - - - - - - - - -
to Rear
final drive
Hollow shaft

Differential pinion

Rear axle side gear

to Front
final drive

Front axle side gear _ _ _ _ _ _ __,,

A60402009
 Product Familiarization 02-19

Front axle

~-- Rear upper

control arm

Coil
spring

=====----Strut
=----"""="='~----""=---- Bearing
housing

Stabilizer--------------_.;
bar
Front lower
control arm

229_33

4 SUSPENSION, BRAKES AND STEERING

Suspension

Front suspension
A light and stable subframe rigi dly holds the front axle components
together and supports the front of the engine- transmission
assembly.
Wheel bearing unit
<Oiiiiii{ In order to save weight , many suspension components , including
Wheel hub front wheel bearing housing , wheel bearing assembly and wheel
hub are made of light-weight aluminum (Al-Mg-Si) alloy.
I

2 13_091

<Oiiiiii{ Due to the softness of the alum inum alloy, tapered ball joint stud
seats are reinforced with press-fit steel bushings.
Wheel bearing housing Lower control arm
(aluminum alloy) (aluminum alloy)

213_070
02-20 Product Familiarization

~The front wheel bearing is bolted to the wheel bearing housing .

This makes it possible to replace the wheel bearing without having
CV joint
Wheel bearing to remove the wheel bearing housing or the drive axle .
housing
/ Drive axle
Wheel hub -

Wheel bearing
Wheel bearing ' - - - - - - - mounting bolts

213_069

Rear suspension (front-wheel drive)

The front-wheel drive rear suspension is referred to as the
compound-link axle . The support brackets with large rubber
bushings are placed on the outside of the rear axle, thus reducing
rocking of the assembly. The placement of the shock absorbe rs
and coil springs allows a maximum cargo width of 39 .4 inches (1
meter) .

Rear axle
rear-wheel drive
Shock absober Rear axle beam
uppermount - - - - - - with stabilizer bar

Shock
absorber

Wheel
Coil bearing
spring housing

229_34

2
 Product Familiarization 02-21

~The double groove ball bearing wheel bearing and hub bolt as a
unit to the fwd rear axle.
ABS wheel speed sensor
The ABS wheel speed sensor is in the center of the wheel bearing
hub.

229_35

Rear suspension (quattro)

The all-wheel drive (quattro) rear suspension is referred to as
double transverse link rear axle . Upper and lower transverse
control arms are anchored to a tubular subframe .

•The placement of the struts allows a maximum cargo width of

39.4 inches (1 meter) .
• The subframe is suspended from the body on rubber and metal
bushings, providing good acoustical isolation for the passenger
cabin .
•Wheel bearings are double grooved contact bearings .

Rear axle, quattro

(all-wheel drive)

~---------- Subframe

Coil Upper
spring control arm
Drive axle

Wheel bearing
housing

Driveshaft ------~
Stabilizer bar

Rear differential Lower

(final drive) control arm
229_36
02-22 Product Familiarization

allroad quattro allroad quattro air suspension

front suspension
Air strut Upper
CAUTION-
control
•Before jacking up or lifting al/road quattro vehicle, place the
suspension in service mode. See allroad quattro "jack
mode" in 03 Maintenance .

~ Although derived from A6 suspension , the allroad quattro

suspension differs in a number of ways:

Front suspension
• Subframe strengthened
• Drive axle cutouts deepened fo r additional suspension travel
• Suspension level sensor brackets welded to subframe
Stabilizer bar
• Suspension strut eye lowered
Rear suspension
• Suspension level sensor bracket and coupling rod moved furthe r
Air shock absorber inboard for clearance reasons
Upper
/ control • Rear lower control arm ball joint increased in size
• Rear upper control arm angle changed
• Upper suspension bracket modified to accommodate air struts
•Front subframe bushing spacers 25 mm (1 in) thick
• Front drive axle shafts redesigned due to changed suspension
characteristics

Rear suspension
Splash plate • Upper control arm modified to accommodat e air struts
A604020 13
•Upper control arm pivot point set higher to optimize wheel
clearance
•Track rod made of aluminum for increased rigidity and improved
tracking
• Splash plate under lower control arm to deflect debris away from
brakes
•Stabilizer bar shape modified to make room for suspension air
pump
•Rear drive axle shaft diameter increased
• Rear outer CV joints reinforced
• Driveshaft center bearing adapted to higher body
 Product Familiarization 02-23

Four-level air suspension

Level4 ~The allroad quattro four-level air suspension system alters ground
Ground clearance : clearance by 2.6 inches (66 mm) in four stages. Vehicle level is
8.2 inches
_ _....,....._ _ _ __..._ _ _ _ _ (208 mm)
automatically controlled as a function of road speed . Automatic
level control overrides manual settings.

~ ~ ~:::~:clearance: The four-level air suspension system is composed of:

o.'. _t=_=_=_=~===-
_l:@_. C
....l..., _'--_~_-____i.'T"'" r1~~n~~) • Dashboard display
•Warning light

~
Level2
• Air springs
Ground clearance :
• Solenoid valves
__. .:"""
. _)_____C_)____.,..
; f1i~"~~)
• Pressure sensor

~
Level1 • Suspension level sensors
Ground clearance :
•Air compressor
f
_ _....(.....,J...·______C_)_.__~_"-_-_-_~ 1~~n~~) •Temperature sensor
A60402015
• Pressure accumulator
The air suspension system is designed for fast response and low
noise.

Right rear
allroad quattro air suspension suspension
level sensor
Right rear
air strut

Air suspension
control panel

Right front
air strut

Air pump

r} ,·
,_.
J'Electrical harness and
Right front air pressure lines
suspension
level sensor
Left front Left front
suspension air strut
level sensor A60402012
02-24 Product Familiarization

RSG suspension
~ The RS6 suspension system , known as Dynamic Ride Control
(DRC) , uses diagonally connected , hydraulically dampened shock
absorbers. By continually adjusting the hydraulic pressure at each
shock absorber, DRC limits body roll and pitch during spirited
driving .

DRC connects the shock absorbers at the opposite corners of the

vehicle via a hydraulic system incorporating a central reservoir.
During sh arp cornering , as the hydraulic pressure on the shock
absorber on the inside is reduced , hydraulic fluid is transferred
through the reservoir to increase pressure to the diagonally linked
shock absorber on the outside.

The central reservoir of the DRC also works to balance hydraulic

pressure when front or rear shock absorbers are under pressure ,
such as during hard starts and stops . By effectively stiffening
the suspension under pressure, DRC helps maintain the overall
stability of the RS6 .

Antilock brakes (ABS)

A6 vehicles are equipped with antilock braking (ABS). ABS uses
electronic control of brakes and throttle to prevent wheels from
locking during hard braking , thus helping to increase vehicle
directional control and decrease stopping distance.

Basic ABS is supplemented by software and hardware to achieve

additional safety features. The electronic components have self-
diagnostic capabilities.

Bosch ABS I ASA 5.3

system overview
ABS control module
Inputs (J104) Outputs

Antislip control (ASA)

switch (E132)
ABS return flow pump
(V39)

Front ABS wheel speed

sensors (G45 , G47)

ABS hydraulic unit

with ABS control valves
(N99 - 102, N133 - 136,
Rear ABS wheel speed N166- 168)
sensors (G44 , G46)

ABS warning light (K4 7)

Brake light switch (F) Brake system warning

light (K188)

Traction control indicator

light (K86)

Auxiliary signals Auxiliary signals

DLC connector
229_39
 Product Familiarization 02-25

Bosch ABS I ASR 5.3

Bosch ABS 5.3 includes the following vehicle stability refinements :

•Electronic brake pressure distribution (EBO) . ABS control

module regulates brake pressure to eliminate rear wheel lock-up .
EBO control ends as soon as ABS control is applied .
• Electronic differential lock (EDL) . As an aid to starting on a slick
surface , EOL automatically brakes the spinning wheel and shunts
driving torque to the wheel with traction. EOL controls slip up to 25
mph (40 kph) in a front-wheel drive vehicle and up to 50 mph (80
kph) in a quattro (all-wheel drive) vehicle.
• Antislip regulation (ASR) . On front-wheel drive vehicles , if
driving wheels spin during acceleration , ASR regulates wheel spin
by reducing engine torque . This is done through retarding ignition
timing or cyclically shutting down fuel injectors. ASR is effective
across the entire range of speed.

Bosch ABS I ESP 5. 7

Beginning in 2001 , A6 models are equipped with ABS
supplemented with electronic stability program (ESP) . Th is traction
control system uses acceleration sensors (rotation rate or yaw
sensor and lateral acceleration sensor) , steering angle sensor and
hydraulic pump to maintain precise control of the vehicle under
difficult traction conditions. ABS I ESP incorporates ABS I ASR
features (EOL, EBO) in addition to :

• Electronic brake control (EBC) . This feature prevents driven

wheels from locking (and skidding) due to engine braking.

Bosch ABS I ESP 5.7 Steering angle

system components sensor (G85)

ABS control
module (J104) ABS wheel speed
sensors (G44, G45 ,
G46, G47)

Rotation rate
(yaw) sensor
Brake booster (G202)
and master
cylinder

Transverse
Hydraulic pressure acceleration
sensor (G201) sensor
(G200)

ESP hydraulic ABS hydraulic

pump (V156) unit (N55)
A60402016
02-26 Product Familiarization

Brakes

Front brake calipers

The A6 has a diagonally partitione d dual circuit brake system with
front and rear disc brakes. The front brake disks are ventilated .

~ Beginning with 2000 models, the high performan ce HP-2 front

brake caliper was fitted (except allroad quattro and RS6) . This
caliper, partly made of aluminum , makes it possible to reduce the
weight of the front axle by 4.9 lb (2 .2 kg) despite the fact that the
front discs are larger.

_ _ _ _ _ _ 2 13_068

~ High performan ce Brembo front brakes are fitted to RS6 models.

There are four pads per caliper. A stainless steel central leaf spring
allows brake pads to be changed with no special tools and without
the need to remove the caliper.

To prevent contact corrosion between aluminum and steel

componen ts , the caliper carrier and outer (floating) caliper are
coated with zinc-cobalt.

Rear brake calipers

~The aluminum rear brake caliper reduces weight by approximately
1.1 lb (0 .5 kg) per side. The parking brake cable attaches to the
Parking brake
mechanism rear caliper and operates the pads .

21 3_047
 Product Familiarization 02-27

Steering column
The manually adjustable steering column has a range in length
of 2 inches (50 mm) and in height of 1.6 inches (40 mm) . The
steering column adjustment lock system consists of eight plates
on either side of the steering shaft. Of these four are for length
adjustment and four are for height adjustment. The lock plates
have large surfaces, providing for good clamping and ease of use .

The magnesium slide and bearing block supporting the steering

column are designed to collapse in case of an accident.

An electrically powered adjustable steering column is an available

option with some models.

Manually adjustable
steering column

Steering column
lock plates

229_42
02-28 Product Familiarization

A6 body structure

D High-strength sheet steel

• Thick I thin metal
• Aluminum
229_ 12

5 Boov-AssEMBLY
6 Boov-COMPONENTS AND ACCESSORIES
7 Boov-INTERIOR TRIM

Body structure
The A6 body sets high standards for crash safety and meets
demands for lighter structure as well.

•Thin high-strength steel structure and sheet metal keeps down

vehicle weight without reducing rigidity.
• Continuous laser welds connect the roof and side members,
increasing the overall rigidity of the body.
•Aluminum , used in the engine hood , is as strong as steel when
utilized correctly.
• Deformation elements in the front and rear insure that the body
structure remains intact in minor accidents.

Service position
<;;;ii{ About 2.8 inches (70 mm) of clearance is gained for working in
the engine compartment by placing the front lock carrier (radiator
support panel) in service position . Use special tools VAG 3369 to
support lock carrier panel. See 50 Body-Front .
 Product Familiarization 02-29

Seats
~ The power seat is adjusted with convenient self-explanatory
button-levers on the side of the seat cushion .

~ Automatic driver and passenger seat adjustment with memory

function is an option . The system stores seat and outside rear-view
mirror settings for three drivers .

The passenger side outside mirror swivels downward when the

vehicle is in reverse , allowing a view of the right rear wheel and the
curb.

Passenger safety
A6 passenger safety features include:

• Driver and passenger airbags

• Side (thorax) airbags in seat back bolsters
•Optional side curtain airbags
• Pyrotechnic seat belt retractor reels

Side curtain - - - - - - - - - - - - - -
airbag

Passenger_~~~~~...!....-:...,,....:::;;~
airbag

A60402019
02-30 Product Familiarization

Climate control housing

Left side
temperature flaps
Fresh air -
~----- recirculation
flap

Right side
temperature flaps

Evaporator - - - --

Heater core - - - - - ~----------- Center vent

flap

229_80

8 HEATING AND AIR-COND ITIONING

The climate control housing under the dashboard contains the
Rear window evaporator, heater core (heat exchanger) and blower.
defogger
Windshield
Right seat Electric motors operate heating and air-conditionin g vent flaps :
heater
defroster
control • Fresh air-recirculatio n flap is combined with the dynamic pressure
Left seat
heater flap.
control
•One tempe rature flap for each side of the passenger cabin .
•Three-part flap for the center vent and the foot well vents .
Climate control function is fully automatic, with separate
temperature controls for left and right.
Interior air
temperature Air distribution ~The climate control panel on the dashboard features :
sensor vent control
229_79 • Rear window heater and windshield defroster control integrated
with control panel.
•Left and right side cabin temperature independently adjustable
between 64° and 86°F (18 ° to 30°C).
Sunlight sensor - - - -
• Interior air temperature vent and sensor integrated with panel.
~The sunlight sensor, located in the top of the dashboard , detects
which side of the vehicle the sunlight is coming from and signals the
climate control system to heat or cool that side to compensate .

229_92
 Product Familiarization 02-31

9 ELECTRICAL SYSTEM

CAN-bus
~ In response to the growing number of electronic modules and
controls, later A6 models were equipped with bus data transfer
systems. In these systems, digital signals are shared among
the modules. The controller area network (CAN) bus is the most
frequently used of these systems. See 9 Electrical System-
General.

CAN-bus lines

186_19

Graduated speed display

Transition from ~ Vehicle speed display in the instrument cluster is not proportional.
fine to coarse The graduations are wider in the lower speed up to 50 mph (80
graduations "" kph) , making it easier to maintain a steady rate at speeds that are
used most often .

229_64
Xenon (HID) headlights
~ Optional high intensity discharge (HID) or xenon headlights are
designed to use one xenon bulb for both high and low beam. An
High beam electric beam adjusting motor switches bulb position in relation to
the reflector. An additional halogen (H7) high beam bulb provides
long-range illumination and acts as a headlight flasher when the
lights are not switchE:id on .

I I
I I
II
Beam Low 11 High
adjusting beam --i le- beam
motor posWon posWon
213_036

~ Vehicles with xenon headlights are additionally equipped with a

, Headlight headlight cleaning system and an automatic headlight aiming
~ aiming motor

__
system. The aiming system adapts headlight aim to vehicle load .
/ (V48 , V49)
NOTE-
----:

•Headlight aim control module position depicted for models up

to 2000. In 2000 - 2004 models, module is behind the glove
compartment on a bracket.

suspension
level
_J.L Front suspension level sensor sensor

-- T ~. ~

• I
I
02-32 Product Familiarization

Instrument cluster, dashboard and cont els

1. Dashboard vent 14. Light switch

2. Engine oil temperature gauge 15. Engine hood release lever

3. Tachometer with analog clock and warning lights 16. Instrument cluster dimmer

4. Engine coolant temperature gauge 17. Ho rn button

Driver airbag
5. Fuel gauge
18. Steering column adjustment lever
6. Speedometer with warning lights
19. Concert radio
7. Voltmeter
20 . Climate control panel
8. Wiper and washer stalk switch
Trip computer function switch 21. Seat heater control

9. Storage compartment or 22 . Windshie ld defroster switch

ASR I ESP switch
23. Gear selector
10. Emergency flasher switch
24. Interior ai r temperature sampling vent
11 . Cup holder
25 . Rear window defogger switch
12. Glove compartment lock

13. Passenger airbag

 03-1

03 Maintenance

GENERAL .. . . . .... .. ... .. . ... . .... .. .... 03-2 ENGINE ACCESSORY BELT . . .... . ........ 03-34
How to use this manual . . .... .. . ... ... .. . . . 03-2 Accessory belt, checking .. . . . .... .. . ...... 03-34
Warnings , Cautions and Notes . . .... ... . .. . . 03-3 Accessory belt, replacin g
TOWING AND TRANSPORT. . .. ... ......... . 03-3 (2.7 liter or 2.S liter V6 engine) . . .. . .. .. ... 03-35
Vehi cle transport and towing eyes . ........ . . 03-3 Accessory belt , replacing
(3.0 liter V6 engine) . ... ... ... . .. .... . . . 03-36
RAISING VEHICLE .... .. . ... .... .... .. .. .. 03-4 Accessory belt and components
Raising ca r safely using car jack .. .. .. . . . .... 03-4 (VS engine , not al lroad quattro) . .. ..... . .. 03-3S
Raising car safely with lift . ... ..... . ..... . .. 03-6 Accessory belt, replacing
Raising car safely using floor jack .. .. . .. .. ... 03-7 (VS engine , not allroad quattro) ....... . .. . 03-39
allroad quattro "jack mode" . . .. ... .. . . ... .. . 03-7 Alternator belt and components
Working under vehicle safely .. ... .. . .. .. .. . 03-S (VS engine , allroad quattro) . . .. . .. . .. . ... 03-40
BASIC SERVICE INFORMATION . .. . . .. ... . .. 03-S Alternator belt , removing and install ing
(VS engine , allroad quattro) ..... . . .... . .. 03-41
Diagnostic trouble codes (DTCs) , accessing . .. 03-S
Se rvice rem inder indicator (SRI) , resetting ..... 03-S TIMING BELT (TOOTHED BELT) . .. .. ...... 03-42
Non-reusable fasteners ... . ..... . ... . ... .. 03-9 SPARK PLUGS . .. . . ...... ..... .. ...... .. 03-42
Tightening fastene rs .. . ......... . ........ 03-10 Spark plugs , replacing .. . ... . . ... . . .. .. . .. 03-42
Buyi ng pa rts . . .... ... . . . . .. ..... ... .... 03-10 AIR FILTER .. . . . . ... .. . . . . . . .. . . ... . ... . 03-44
Genuine Audi parts .. .. ..... . ... ... ... . . 03-11 Air filter element, replacing .. .... .. .. .. . . .. 03-44
Non-retu rn able parts ........ . .. . ... . .. .. 03-11
UNDER CAR MAINTENANCE .. . . ... . .... . . 03-45
Aud i service ......... . .. .. ..... ... ... . . 03-11
Trans mission and final drive oil . . . ...... . ... 03-45
Too ls .................. .. . .. .. .. . . . . . 03-11
Brake system , visual inspection . .. . . .. .... . 03-45
IDENTIFICATION PLATES AND LABELS . . . .. 03-12 Brake pads , checking ........ . . .. . . .... . . 03-45
Info rmation you need to know . .. ........ . . 03-12 Tire and wheel service . .... . .. . .. ... . .... 03-46
Veh icle identification number (VIN) ...... . . . 03-13 Suspension components , checking .... .. .... 03-49
Data labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-13 Underbody visual inspection . .... . . ... . .... 03-49
Eng ine identification ..... . ...... . . . .. . .. . 03-14
BODY AND INTERIOR MAINTENANCE . . .. . .. 03-50
Transmission identification .. . .. ....... . ... 03-1 S
Airbags , visual inspection ........ . . . . . .. . . 03-50
ENGINE COMPARTMENT . . .. .... ......... 03-20 Door check strap and hinges , lubricating ... .. 03-50
Flu id leaks , visual inspection .. . ... .. ... .. . 03-20 Door lock service .. .. .. .. ...... . .. . .... . . 03-51
2.7 liter V6 biturbo engine compartment . .. . . 03-21 Sunroof service . .. . .. . . . . . .. . ... . ... . .. . 03-51
2.S liter V6 eng ine compartment . . .... .. . . . 03-21 Dust and pollen filter element, replacing ...... 03-51
3.0 liter V6 engine compartment .. .... . ... . 03-21 Interior motion detector, checking .. . ... .. .. 03-52
4.2 liter VS engine compartment ..... . .. . . . 03-22 Windshield wiper blade , replacing .. . . . ...... 03-52
Engine covers , ,·emoving . . .. . . .. . ........ 03-22 Washer fluid, topping off .. .. . . . ..... . .. .. 03-52
ENGINE OIL .. .... .. .. .. ....... ..... . ... 03-24 Headlights , adjusting .. . .. ... . .... . ..... .. 03-53
Engine oil level , checking . ... .. . . .... . .. . . 03-24 MAINTENANCE SCHEDULES .. .... . . . ... . . 03-53
Engine oil and filter, changing .. . .. . . . .... . . 03-25 TABLES
COOLING SYSTEM .. . .... .. .. . . ...... .. . 03-26 a. Bolt tightening torques- general (in Nm) . . ... .. .. . . 03-10
Coolant level , checking .. .. ... . . . . . . ... . .. 03-27 b. Engine applications an d specifications ... ........ 03-15
Coolant I antifreeze concentration , checking . . 03-27 c. Transmission types . . . . ... .. .... .. .. . .... .. .. 03-18
d. Oil specifications .... . ... . .. ..... . .. . ....... . 03-24
Cool ing system hoses , inspecting . . . .. .. . ... 03-2S e. Oil capacities (approximate) .. ........ ... . .. . . . 03-24
BRAKE FLUID ... . ..... .. . . . . ... . ... .. .. 03-2S f. Cooling system capacities . .. ...... . .... . .. .... 03-27
Brake fluid level , checking .. .. .. .......... . 03-2S g. Spark plug applications . . ..... . . . . .. .. .... . ... 03-44
MAINTENANCE TABLES
POWER STEERING FLUID ..... . . ... .. . ... 03-29
h. 1999 scheduled maintenance .. ... . ... . ...... ... 03-54
Power steering fluid level , checking . . . . .. . .. 03-29 i. 2000 scheduled maintenance ... . ..... .. ... ..... 03-55
FUEL FILTER . . . ... .... . . . . .. . . ... . ... . . 03-30 j. 2001 scheduled maintenance . . . . . .... .. . ....... 03-56
Fuel filter, replacing . ................ . .... 03-31 k. 2002 scheduled maintenance .. . . .... ... ...... .. 03-57
I. 2003 scheduled maintenance ... .. . ... .. ....... . 03-58
Fuel fi lte r, replacing (RS6) . . . ....... . ..... 03-32 m. 2004 sched uled maintenance ........ ... ........ 03-59
BATTERY SERVICE . .... ... ... ... . . .. . . .. 03-33
Batte ry notes .. .......... . .. .. ... . ...... 03-34
 --

03-2 Maintenance
General I

GENERAL
This repair group explains the structure of this repair manual and
details basic information regarding your vehicle and repa ir
procedures for it. Included are service and maintenance
procedures.

Carry out the maintenance work described in this repair group at the
factory specified time or mileage interval shown in Maintenance
Schedules. Following these intervals helps ensure safe and
dependable operation .

The owner's manual, maintenance record and warranty booklet

originally supplied with the vehicle contain maintenance schedules
that apply to your Audi . Many of the maintenance procedures are
necessary to maintain warranty protection .

Audi is constantly updating their recommended mainten ance

procedures and requirements. The information contained here may
not include updates or revisions made by Aud i since the publication
of the documents supplied with the car. If there is any doubt about
what procedures apply to a specific model or model year, or what
intervals to follow, consult an authorized Audi dealer.

How to use this manual

This manual is divided into 12 main sections, or partitions:

0 General , Maintenance
1 Engine
2 Engine Management, Exhaust and Engine Electrical
3 Clutch and Transmission
4 Suspension , Brakes and Steering
5 Body- Assembly
6 Body-Components and Accessories
7 Body- Interior Trim
8 Heating and Air-conditioning
9 Electrical System
EWD Electrical Wiring Diagrams
08 0 On Board Diagnostics

A master listing of the 12 partitions and the corresponding specific

repair groups can be found on the inside front cover.

Thumb tabs are used on the first page of each repair group to help
locate the groups quickly. Page numbers throughout the manual are
organized according to the repair group system . A comprehensive
Index is at the end of the manual.
 Maintenance 03-3
General

Warnings, Cautions and Notes

Throughout th is manual , there are numerous paragraphs with the
headings WARNING, CAUTION or NOTE. These headings have
different meanings.

WARNING -
• Text under this heading warns of unsafe practices that are very
likely to cause injury, either by direct threat to the person(s)
doing the work or by increased risk of accident or mechanical
failure while driving.

CAUTION-
• Text under this heading also calls attention to important
precautions to be observed during the repair work to help
prevent accidentally damaging the car or its parts.

NOTE -
• A note contains information, tips, or pointers which help in doing a
better job and completing it more easily

Read WARNING , CAUTION and NOTE headings before you begin

repair work . See also 00 Warnings and Cautions .

TOWING AND TRANSPORT

Vehicle transport and towing eyes

~ The following information is to be used by a commercial flatbed tow
truck operator who knows how to operate equipment safely. To
prevent damage to the vehicle , re ad and understand all of the
following information before proceeding.

WARNING-
• Do not allow passengers to ride in a transported vehicle.
• To reduce the risk of accident and serious personal injury, stay
'
6 within manufacturer's rated equipment capacities. Exceeding
manufacturer's design specifications is dangerous .

CAUTION-
A604030 10 • To prevent damage to the vehicle, transport the Audi A6 with a
flatbed carrier, not by towing.
• Do not use conventional sling-type equipment or wheel dollies.
• Improper attachment of vehicle to the flatbed carrier may cause
damage to underbody components.

Towing eye mounts are located at right front and right rear of the
vehicle . A detachable towing eye is stored in the vehicle tool kit.

~ Front towing eye mount: Insert screwdriver in lower right grille slot.
Pry gently on lock tab (arrow) , then pull grille off.

Locate towing eye in tool kit.

A60403008
03-4 Maintenance
Raising Vehicle

~ Thread towing eye (arrow) fully into mounting hole and tighten with
wheel lug wrench (also from tool kit) .

- After use, unscrew towing eye , return to vehicle tool kit , and stow
tool kit in trunk.

- Reinstall cover.

~ Rear towing hook : Press cover up (arrow) to gain access to hook .

RAISING VEHICLE

CAUTIO~
• Do not lift or jack the vehicle underneath the engine oil pan,
transmission housing, front or rear axle or the body side
members. This could lead to serious damage.
• To avoid damage to the underbody or chassis frame , insert a
rubber pad between shop jack and lift points.
• Al/road quattro: To prevent damaging the shock absorbers
when lifting the vehicle with a lift or jack, set the ride height
selection to 'Jack mode". See allroad quattro "jack mode" in
this repair group.

Raising car safely using car jack

~ Raise the car safely and avoid damage by using the jack supplied
with the car and the front or rear side jacking lugs (arrows).

Park car on flat , level surface. Use chocks to block wheel opposite
to one being raised .

WARNING-
• Do not rely on the transmission or the parking brake to keep
the car from rolling.

If changing a tire , loosen lug bolts before raising car.

Remove jack and jack handle from jack compartment in trunk.

 Maintenance 03-5
Raising Vehicle

~ If changing a tire, remove large knurled nut at center of spare tire in

trunk and lift spare out.

~ Place jack in position and raise jack arm until jack claw fits under
jacking lug (arrow) securely. Make sure jack is resting on flat, solid
ground . Use a board or other support to provide a firm surface for jack,
if necessary.

~ Correct distance between jacking lug and wheel opening is as

follows :
•Audi A6 or S6 sedan ; allroad quattro
A = approx. 15 cm (6 in)
B =approx . 15 cm (6 in)
•Audi A6 or S6 Avant (station wagon)
A = approx . 15 cm (6 in)
B =approx . 25 cm (10 in)

WARNING -
• Watch the jack closely Make sure it stays stable and does not
shift or tilt.

Raise ca r slowly while constantly checking position of jack and ca r.

- Allroad quattro : See allroad quattro "jack mode" in this repair

group.
03-6 Maintenance
Raising Vehicle

Raising car safely with lift

WARNING -
• Before driving a vehicle on a lift, confirm that vehicle weight
does not exceed the allowable lifting capacity
• Lift vehicle only at points indicated in order to avoid damaging
vehicle floor pan and to prevent tipping.
• Do not start engine and engage a gear with vehicle lifted if any
drive wheel has contact with the floor. There is danger of an
accident due to possible vehicle movement.
• Exercise care while running the engine with the vehicle on a lift.
Engine vibration and vehicle movement could cause the vehicle
to slip off the lift.
• Before driving on a lift, be sure there is enough clearance under
the vehicle so that it does not drag the lift arms. Pay particular
attention to front spoilers and aprons.
• Observe the lift manufacturer's safety instructions and
guidelines before raising vehicle.

Use correct jacking points (arrows) to fift car safely and avoid
damage.

Front lifting point at longitudinal reinforcement of floor pan at area

marked for vehicle jack.

CAUTION-
• Do not raise vehicle at the vertical support on the rocker panel
at front of vehicle.

~ Rear lifting point at vertical reinforcement of lower sill.

 Maintenance 03-7
Raising Vehicle

Raising car safely using floor jack

Park car on flat , level surface. Use chocks to block wheel opposite
to one being raised .

WARNING -
• Do not rely on the transmission or the parking brake to keep
the car from rolling.

If changing a tire , loosen lug bolts before raising car.

Raising front wheel

-iiiiiii( Place floor jack under reinforced floor pan inboard of front jacking
point.

- Pl ace jack stand under front jacking point. Lower car slowly until it
rests firmly on jack stand.

Raising rear wheel

-iiiiiii( Place floor jack under rear trailing arm.

Place jack stand under rear jacki ng point. Lower car slowly until it
rests firmly on jack stand.

allroad quattro "jack mode"

Prior to jacking or lifting allroad quattro vehicle , set ride height
control to "jack mode" to protect suspension shock absorbers and
struts.

WARNING -
• Make sure that no one is lying under the vehicle or has head or
hands in the wheel housing while the ride height is changing.

Activatin g
-iiiiiii( Before lifting vehicle with jack or lift:
• Switch ignition ON .
• Press ri de height control buttons A and C in center dashboard for
at least 5 seconds.
• When system is in "jack mode", LEDs on control buttons (A and C) ,
yellow LED for manual mode on level indicator (B) and warning
light for level control in in strument cluster all illuminate .

- Switch ignition OFF and lift or jack vehicle .

Deactivating
Press contro l buttons 1 and 3 for at least 5 seconds. Warning light in
instrument cluster, LED for manual mode and control button LEDs
turn OFF.

"Jack mode" is automatically deactivated when vehicle speed

exceeds 3 mph (5 kph).
03-8 Maintenance
Raising Vehicle

Working under car safely

Jack stands When working under the car, observe the fol lowing points as a
matter of safety and good practice :
• Disconnect negative battery cable so that no one else can start
vehicle . Let others know that you will be under veh icle.
• Place at least two jack stands under vehicle . A jack is a temporary
lifting device. Do not use the jack alone to support vehicle while you
are under it. Use positively locking jack stand s th at are designed
for the purpose of supporting a veh icle.
• If you are using a lift, be sure that safety locks are engaged and
that vehicle weight is resting on the locks, not the hydrau lic system.
• Lower vehicle slowly until its weight is fully supported by jack
stands or safety locks. Watch to make sure that jack stands do not
tip or lean as vehicle settles on them , and that jack stands and lift
arms are placed solidly and will not move.
0024408 • Check to make sure vehicle is stable before working under car.
• Observe all jacking precautions again when raising vehicle to
remove jack stands .

WARNING-
• Use care when removing major (heavy) components from one
end of the vehicle. The sudden change in weight and balance
can cause vehicle to tip off lift or jack stands.
• Do not support vehicle at engine oil pan, transmission, fuel
tank, or on front or rear axle. Serious damage may result.

BASIC SERVICE INFORMATION

Diagnostic trouble codes (DTCs), accessing

Use Volkswagen I Audi diagnostic scan tool or equivalent to retrieve
diagnostic trouble codes.

- Place transmission selector lever in PARK or NEUTRA L. Engage

parking brake. Make sure ignition is OFF.

<liiiiiii( Connect scan tool (VAG 1551 or equ ivalent) to data link connector
(DLC, inset) , located under left side dashboard, to left of steering
column.

- Start engine and let idle.

Follow scan tool instructions as they appear on scan tool screen.

For more information , see 080 On Board Diagnostics.

Service reminder indicator (SRI), resetting

When the time for a service is reached , the needed service appears
in th e tri p odomete r display when the ignition is switched ON . The
display blinks for about 60 seconds after the engine is started:
•Service OIL indicates that oil change service is due .
•Service INSP indicates that inspection service is due .

A service that is due is displayed 1,000 km (625 mi) or 10 days in

advance.
 Maintenance 03-9
Raising Vehicle

Reset the SRI after each oil change or inspection se rvice . The SRI
can be reset in two different ways :
• Use the Volkswagen I Audi scan tool or equivalent .
• Use button s on the instrument clu ste r.

SRI, resetting using scan tool

~ Connect scan tool (VAG 1551 or equ ivalent) to data link connector
(DLC, inset), located under left side dashboard , to left of steering
column.

Switch ignition ON .

Follow scan tool instructions as they appear on scan tool screen .

SRI , resetting with iIBtrument cluster buttons

Switch ignition OFF.

~ Press and hold down trip odomete r reset button (8 ).

- Switch ignition ON while keeping button depressed :

•Service OIL appears in trip odometer display (C ).
• Release trip odometer reset button .

- Pull clock reset button (A) until Service OIL ind icato r is reset.
• - - - appears in trip odometer display (C ).

- Press trip odometer reset button (8) again to advance to next

service event.
• Release trip odometer reset button .
• Service INSP appears in trip odometer displ ay (C ).

- Pull clock reset button (A) until Service INSP indicator is reset.
• - - - appears in trip odometer display (C).

Switch ign ition OFF.

Non-reusable fasteners
Many fasteners used on the cars covered by this manual must be
replaced with new ones once they are removed. These include but
are not limited to : bolts, nuts (self-Jocking , nylock, etc .) , cotte r pins ,
studs, brake fittings , roll pins, clips and washers. Use genu ine Aud i
parts for this purpose .

Some bolts are designed to stretch during assembly and are

permanently altered , rendering them unreliable once removed.
These are known as torque-to-yield fasteners . Replace fastene rs
where instructed to do so. Failure to replace these fasteners could
cause vehicle damage and personal injury. See an authori zed Audi
dealer fo r applications and orde ring information.
 j

03-10 Maintenance
Raising Vehicle

Tightening fasteners
Tighten fasteners gradually and evenly to avoid misalignment or
over-stressing any one portion of the component. For components
sealed with gaskets, this method helps to ensure that the gasket
seals properly.

~ Where there are several fasteners , tighten them in a sequence

alternating between opposite sides of the component. Repeat the
sequence until all the bolts are evenly tightened to the proper
specification.

For some repairs a specific tightening sequence is necessary, or a

particular order of assembly is required . Such special conditions are
noted in the text , and the necessary sequence is described or
illustrated . Where no specific torque is listed , use Table a as a
general guide for tightening fasteners.

NOTE-
• Metric bolt classes or grades are marked on the bolt head.
B001FNI • Do not confuse wrench size with bolt diameter.

I
Table a. Bolt tightening torques-general (in Nm)

Bolt Bolt class (according to DIN 267)

diameter 5.6 5.8 6.8 8.8 10.9 12.9
M5 2.5 3.5 4.5 6 8 10
M6 4.5 6 7.5 10 14 17
MB 11 15 18 24 34 40
M10 23 30 36 47 66 79
M12 39 52 62 82 115 140
M14 62 82 98 130 180 220
M16 94 126 150 200 280 340
M18 130 174 210 280 390 470

CAUTIO~
•Table a is a general reference only The values listed are not
intended to be used as a substitute for torques specifically
called out in the text.

Buying parts
Many of the maintenance and repair tasks in this manual call for the
installation of new parts, or the use of new gaskets and other
materials when reinstalling parts. In most cases , make sure needed
parts are on hand before beginning the job. Read the introductory
text and the complete procedure to determine which parts are
needed .

For bigger jobs , partial disassembly and inspection are required to

determine a complete parts list. Read the procedure carefully and , if
necessary, make arrangements to get the necessary parts while
your car is disassembled .
 Maintenance 03-11
Raising Vehicle

Genuine Audi parts

Genuine replacement parts from an authorized Audi dealer are
designed and manufactured to the same standards as the original
parts. They are guaranteed to fit and work as intended by the
engineers who designed the car.

Many independent repair shops make a point of using genuine Audi

parts, even though they may at times be more expensive . They know
the value of doing the job right with the right parts. Parts from othe r
sources can be as good , particularly if manufactured by one of Audis
original equipment suppliers, but it is often difficult to know.

Audi is constantly updating and improving their cars , often making

improvements during a given model year. Audi may recommend a
newer, improved part as a replacement , and your authorized
dealer's parts department will know about it and provide it. The Audi
parts organization is best equi pped to deal with any Audi parts
needs .

Non-returnable parts
Some parts cannot be returned . The best example is electrical
parts. Buy electrical parts carefully, and be as sure as possible that
a replacement is needed , especially for expensive parts such as
electronic control modules. It may be wise to let an authorized Audi
dealer or other qualified shop confirm your diagnosis before
replacing a non-returnable part.

Audi service
Audi dealers are uniquely qualified to provide service for Audi cars .
Their authorized relationship with the large Audi service
organization means that they are constantly receiving special tools
and equipment, together with the latest and most accurate repair
information.

The Audi dealer's service technicians are highly trained and very
capable . Authorized Audi dealers are committed to supporting the
Audi product. On the other hand , there are many independent shops
that specialize in Audi service and are capable of doing high quality
repair work. Checking with other Audi owners for recommendations
on service facilities is a good way to learn of reputable Audi shops in
your area.

Tools
Most maintenance can be accomplished with a small selection of
the right tools. Tools range in quality from inexpensive junk, which
may break at first use , to very expensive and well-made tools for the
professional. The best tools for most do-it-yourself Audi owners lie
somewhere in between .

Many reputable tool manufacturers offer good quality, moderately

priced tools with a lifetime guarantee. These are your best buy. They
cost a little more, but they are good quality tools that will do what is
expected of them . Sears Craftsman® line is one such source of good
quality tools.

Some of the repairs covered in this manual require the use of special
tools , such as a custom puller or specialized electrical test
03-12 Maintenance -
Identification Plates and Labels

eq uipment. These special tools are called out in the text and can be
purchased through an authorized Audi dealer. As an alternative,
some special tools mentioned may be purchased from the following
tool manufacturers and/or distributors :

Assenmacher Specialty Ross-Tech

Tools, Inc. 920 South Broad Street
6440 Odell Place Lansdale, PA 19446
Boulder, CO 80301 215-361-8942
(800) 525-2943 www.ross-tech.com
www.asttool.com
Bau m Tools Unl imited , Inc. Samstag Sales
PO Box 5867 115 Main St. N. , Suite 216
Sarasota , FL 34277 Carthage , TN 37030
(800) 848-6657 (615) 735-3388
www.baumtools.com www.sam stagsales.com
Equipment Sol utions Shade Tree Software
P.O. Box 1450 4186 Culebra Ct.
Kenosha, VI/I 53141-1450 Boulder, CO 80301
(800) 892-9650 (303) 449-1664
(303) 940-2468
www.shadetreesoftware.com
Mac Tools Snap-On Technologies, Inc.
4635 Hilton Corporate Drive 2801 80th St .
Columbus, OH 43232 Kenosha , VI/I 53141-1 410
(800) 622-8665 (262) 656-5200
www.mactools.com www.snapon .com
Metal nerd Zelenda Automotive , Inc.
509 Crestview Drive, Su ite B 66-02 Austin St.
Greensburg , PA, 15601 USA Forest Hills, NY 11374
(412) 601-4270 (888) 892-8348
www.metal nerd .com www.zelenda.com

IDENTIFICATION PLATES AND LABELS

Information you need to know

Model. VI/hen ordering parts, it is important that you know the
correct model designation for your car. Audi A6 models include the
following:
• A6 and S6 (sedan)
• A6 and S6 Avant (station wagon)
• allroad quattro
• RS6

Model year. This is not necessarily the same as date of

manufacture or date of sale. A 1999 model may have been
manufactured in late 1998, and perhaps not sold until early 2000 . It
is still a 1999 model . Model years covered by this manual are 1998
to 2004 .

Date of manufacture. This information may be necessary when

ordering replacement parts or determining if any of the warranty
recalls are appl icable to your car. The label on the driver's door
below the door latch specifies the month and year that the car was
built.
 Maintenance 03-13
Identification Plates and Labels

Vehicle identification number {VIN) . This is a combination of

letters and numbers that identify the particular car. See Vehicle
identification number (VIN) in th is repair group. Also see 01
Vehicle Identification and VIN Decoder.

Engine code. Cars covered in this manual are powered by various

V6 and VB engines. For information on engine codes and engine
applications, see Engine identification in this repair group.

Transmission code. The transmission type with its identifying code

may be important when buying clutch parts, seals, gaskets, and
other transmission-related parts. For information on transmission
codes and applications, see 02 Audi A6 Familiarization .
Transmission identification code plates are illustrated in
Transmission identification in this repair group.

Vehicle identification number (VIN)

Vehicle year, model and engine type , along with other pertinent data
can be decoded from the vehicle identification number (VIN) . Data
plates and stickers containing the VIN are attached to the vehicle at
several locations.

~ United States federal law requires the VIN to be visible from outside
the vehicle and at a standard location. A plate with the complete 17
A60403040 digit VIN is attached to the padded dashboard at the base of the
windshield . See 01 VIN Decoder for detailed VIN decoding
information .

Other VIN locations include:

•Stamped on engine compartme nt bulkhead .
• Stamped into body in rear floor area under rear seat . Access to this
area requires lifting rear seat bottom (cushion).

~ B pillar certification sticker (inset) lists full VIN , vehicle weight

ratings , production date and emission compliance certification .
Airbag safety label is also attached to vehicle at this location.

Data labels
~ Vehicle data sticker is located in the trunk in the spare tire well. The
- ·• 1-·~ t 9( 444 UV sticker contains the following veh icle information :
WAUDA248 1 XN001612 1. Vehicle identification number (VIN)
485 4VZ SA9 2. Prod uction control number
3 A6 Ava quat. 2. 8
3. Model identification number
4 l47KW TLEV A5
4. Engine power, exhaust emissions classification , transmission
I
5 - . MOTORKB./ GETR. KB.
ENG.CODE/TRANS.CODE
tJ.H !>.
r"1
r •
CUB DPT type
6 -~f~~~'tf. 1~1~~:~~~1 LY7M /LY7M N1H/ BN 5. Engine and transmission code letters
M. · AUSST. t OPTIONS X9A BOA C6P GOQ H 4B 00 L
M10 G1A lBH 1 AH 1G7 2PR 6. Paint code , interior code
1N3 5RR 5SG T7F OJM 3 8 1 7. Option codes (optional equipment identification numbers)
4UB OYW OG7 BVQ 8GL
9VD 1 KD !LB 3 FE 1B H 8. Curb weight , fuel consumption , C0 2 emissions
: - - - - - 1818 9, 9 9, 9 9, 9 999

- - - 1 - - --

1
03-14 Maintenance
Identification Plates and Labels

~ Type plate (A) is affixed to plastic duct or other component at rear of

engine compartment.

8 is engine compartment bulkhead VIN stamping .

~ Tire pressure inflation sticker is attached to B or C pillar.

Recommended cold tire inflation pressures va ry from car to car due
to differing equipment levels. Usually, tire pressure information does
not appear in the owner's manual.

Engine identification
An Audi engi ne is identified by a three letter code (example: AHA)
followed by a 6-digit serial number. Engine code and engine serial
number are located on the engine block. A sticker with engine code
and serial number is often attached to the upper timing belt cover or
cylinder head cover. In addition , engine code may be stamped on
the cylinder head to allow for quick identification . Engine application
information is in Table b.

Engine type Engine codes

V6 5-valves per cylinder AHA , ATQ , APB , BEL, AVK
V8 5-valves per cylinde r ART, AWN , BBD, BAS, BCY
 Maintenance 03-15
Identification Plates and Labels

Table b. Engine applications and specifications

~ "E E E-
Q)
.::it.
c:
"E
Q) Q)-
a.- a.E o_ .Q
E E.=: ._ E ... a. .::: c:
(/) Q) (/)
Q) :J
e- Cl):.::,.
(/) E c: >-
Q)
Q)
u Q) Q) u u
c: m-
@ Q)@;
XE
...a.
Q)
Q) 8,.Q 0
Qi
... "O
c: ~
·- a. Q) .=:Cl"O
Q) ·-a.u Q; ;::@ 5-E..c ~E
.!: m ~Cl
mo C) (/) a.
c:._ >- c:
0)(/) u ~.::it. a. ... z, E.Q
o-
C) c: ·- Q)
c:mE'E
~E W"O- Wu
0 c: ·- c:
w "O ·-
a..
0 ___
c: .c:
·=
{!:. E.
0 c:
[J)._ (.)~ w E Q) u
V6 5-valves per cylinder

1998- 1999 AHA 2771 (169) 147 @ 6000 280 @ 3200 82.5 x 86.4 10.1 : 1 Motronic
A6 (200 @ 6000) (207@ 3200) (3.25 x 3.40) M5 .9.2
2. 8 liter
2000 - 2001 ATQ 2771 (169) 142 @ 6000 280 @ 3200 82.5 x 86.4 9.9 : 1 Motronic
A6 (193 @ 6000) (207@ 3200) (3.25 x 3.40) ME 7 .1

2000 - 2003 APB 2671 (163) 187 @ 5800 350 @ 1800- 4500 81 .0 x 86.4 9.3 : 1 Motronic
A6, allroad (254 @ 5800) (258 @ 1800 - 4500) (3 .19 x 3.40) ME 7.1
quattro 2.7 liter TLEV

2003 - 2004 biturbo BEL 2671 (163) 184 @ 5800 350@ 1800- 4500 81 .0 x 86.4 9.3 : 1 Motronic
A6, allroad (250 @ 5800) (258 @ 1800 - 4500) (3.19 x 3.40) ME 7.1
quattro LEV

2002 - 2004 3.0 liter AVK 2976 (182 ) 162 @ 6300 300 Nm @ 3200 82 .5 x 92 .8 10.5 : 1 Motronic
A6 (220 @ 6300) (221@ 3200) (3.25 x 3.65) ME 7.1.1
ULEV

VS 5-valves per cylinder

1999 - 2001 ART 4172 (255 ) 221 @ 6000 410 @ 3300 84.5 x 93 .0 Motronic
A6 (299 @ 6000) (302@ 3300) (3.33 x 3.66 ) ME 7.1

2002 - 2004 - - AWN 4172 (255) 228 @ 6000 413@ 3300 84.5 x 93.0 Motronic
A6 (299 @ 6000) (305 @ 3300) (3.33 x 3.66)
4.2 liter 11 : 1
2002 - 2004 BBD 4 172 (255 ) 250 @ 6000 400 @ 3500 84 .5 x 93.0 Motronic
S6 (340@ 6000) (295 @ 3500) (3.33 x 3 .66)

2003 - 2004 BAS 4163 (254) 220 @ 6200 380 @ 2600-4700 84.5 x 92.8 Motronic
allroad quatt ro (299 @ 6200) (280 @ 2600- 4 700) (3.33 x 3.65 ) ME 7.1 .1

2003 - 2004 4. 2 liter BCY 4172 (255) 331 @ 5700 - 6400 560 @ 1950 - 5600 84 .5 x 93 .0 9.3 : 1 Motronic
RS6 biturbo (450 @ 5700 - 6400) (413 @ 1950 - 5600) (3.33 x 3.66) ME 7 .1.1

2.7 liter and 2.8 liter V6 engine

~ Engine codes AHA , ATQ , APB , BEL: Engine code letters and serial
number are on flat surface of cylinde r block in front of ri ght cyl inder
head .

Engine code is also included on vehicle data sticker in trunk .

03-16 Maintenance
Identification Plates and Labels

3.0 liter V6 engine

<iiiiiii( To gain access to engine identification sticker, remove front eng ine
cover by pulling up (arrows).

<iiiiiii( Engine code AVK: Engine code , serial number and production
number are on sticker (arrow) on vacuum diaphragm housing of
intake manifold .

<iiiiiii( If sticker is not present, remove rear engine cover by pulling up

(arrows) .

<iiiiiii( Engine code AVK : Engine code and serial number are stamped on
left rear of cylinder block (a rrow).

Engine code is also included on vehicle data sticker in trunk.

 Maintenance 03-17
Iden tification Plates and Labels

4.2 liter V8 engine (AG, S6)

~ Engine codes ART, AWN , BBD : Engine code and serial number are
on left side of cylinder block (arrow).

Engine number is also listed on label on belt cover.

Engine code is also included on vehicle data sticker in trunk.

4.2 liter V8 engine (allroad quattro)

~ To gain access to engine identification stamping , remove front

engine cover by pulling up (2) and forward (1 ).

-----.,,.---- - ' - - - - - - , , - - - - - -

\,~
A1 0-15 14

~ Engine code BAS : Engine code and serial number are stamped on
front top of cylinder block (arrow).

Engin e code and serial numbe r is also on a sticker on right cylinder

head cover.

Engine code is also included on vehicle data sticker in trunk .

4.2 liter V8 engine (RS6)

~ Remove front engine cover:
• Undo quick-release fasteners (1 , 2) .

-- - r -~ --- -

"a I I
03-18 Maintenance
Identification Plates and Labels

<liiiiiii( Engine code BCY: Engine code and serial number is on top of
cylinder block (arrow) .

An engine code and serial number sticker is on the right tim ing belt
guard .

Engine code is also included on vehicle data sticker in trunk .

Transmission identification
A6 models were equipped with one of five different transmiss ion
types . See Table c. Each transmission type comes in numerous
versions , depending on engine type and front-wheel-drive (FWD) or
all-wheel -drive (AWD) requirements. For transmission applications ,
specifications and lubricants , see 02 Product Familiarization ,
34 Manual Transmission , 37 Automatic Transmission or 39
Final Drive.

Table c. Transmission codes

Description T ype
5-speed manual quattro (AWD) 01A
6-speed manual quattro (AWD ) 01E
5-speed automatic with Tiptronic® control quattro (AWD) 01L
5-speed automatic with Tiptronic® control FWD or quattro 01V

Multitronic® or continuously variable transmission (CVT) FWD 01J

Transmissions are identified by type , code , serial number,

manufacturer identification code and build date:
• Type denotes a family of transmissions that have generally simi lar
characteristics.
• Code is a specific group within the type and identifies individual
traits such as gear ratios .
•Serial number is a multi-digit string such as 0019967 .
• Manufacturer identification code may be a combination of
letters and numbers.
•Build date is a five digit number such as 15079. The digits indicate
day (15) , month (07 =July) and year (9 = 1999) transm ission was
built.

Transmission identification plates containing some or all of this

information are affixed to the transmiss·1on hous·ing .
 Maintenance 03-19
Identification Plates and Labels

5-speed manual transmission quattro (AWD)

~ Transmission type 1A: Code, serial number and date of manufacture

are on transmission as follows:
1. Top of bellhousing: Code letters and date of manufacture
2. Top of gear housing : Type and serial number
3. Bottom of gear housing : Code letters and date of manufacture

Transmission code letters are also included on vehicle data sticker in

trunk.

3
A34-0 130

6-speed manual transmission quattro (AWD)

~ Transmission type 1 E: Code, serial number and date of manufacture

are on transmission as follows :
1. Bottom of front final drive housing: Code letters and serial
number
2. Left side of bellhousing: Type and serial number

Transmission code letters are also included on vehicle data sticker in

trunk.

t1 V34-2733

5-speed automatic transmission quattro (AWD)

~ Transmission type 01 L: Identification plate (inset) , on bottom of

transmission at right front of transmission oil pan , contains
information as follows :
1. Transmission serial number
2. Part list number
3. Manufacturer identification code
4. Code letters

Transmission code letters are also included on vehicle data sticker in

trunk.

5-speed automatic transmission FWD or quattro (AWD)

~ Transmission type 01 V: Identification plate (arrow) is on bottom of
transmission at right front of transmission oil pan .

Another identification label (identical to the first one) is on the side of

the transmission. It is not accessible when the transmission is
installed.

A37-0056
03-20 Maintenance
Engine Compartment

~ Transmission identification plate contains information as fo llows:

1
1. Transmission serial number
2. Manufacturer identification code
3. Code letters

Transmission code letters are also included on vehicle data sticker in

trunk.

_________ 1 A37-0251

Multitronic® (CVT) transmission FWD

~ Transmission type 01 J: Identification plate (arrow) is on bottom of

transmission .

Transmission code letters are also included on vehicle data sticker in

trunk.

ENGINE COMPARTMENT

Fluid leaks, visual inspection

Remove upper and lower engine covers as requ ired and check
engine compartment for signs of fluid leaks. Fluid leaks attract dust
making them easier to spot. Many expensive repairs can be avoided
by prompt repair of minor fluid leaks.

Visually inspect for oil and ATF leaks at engine and transmission.
Also inspect cooling , fuel , heating and air-condition ing systems for
leakage. Visually inspect hoses and hose connections for leaks,
worn areas, porosity and brittleness. Also see Fluid and exhaust
leaks, visual inspection in this repair group.

Check that fluid levels are between MIN and MAX marks.

The following illustrations show representative engine compartment

layouts for the four major engine types. There may be minor differences
among model years, such as engine cover configuration .
 Mai ntenance 03-21
Engine Compartment

2.7 liter V6 biturbo engine

compartment
1. Battery (under plastic cover)
2. Brake fluid reservoir
3. Engine oil dipstick
4. Engine oil filler cap
5. Coolant expansion reservoir
6. Power steering fluid reservoir
7. Washer fluid reservoir

2.8 liter V6 engine

compartment
1. Engine oil dipstick
2. Battery (under plastic cover)
3. Brake fluid reservoir
4. Engine oil filler cap
5 . Coolant expansion reservoir
6. Power steering fluid reservoir
7. Washer fluid reservoir

3.0 liter V6 engine

compartment
1. Engine oil dipstick
2. Battery (under plastic cover)
3. Brake fluid reservoir
4. Engine oil filler cap
5. Coolant expansion reservoir
6. Power steering fluid reservoir
7. Washer fluid reservoir
03-22 Maintenance
Engine Compartment

4.2 liter va engine

compartment
1. Battery (under plastic cover)
2. Brake fluid reservoir
3. Engine oil filler cap
4. Engine oil dipstick
5. Coolant expansion reservoir
6. Power steering fluid reservoir
7. Windshield washer fluid reservoir

Engine covers, removing

A6 and S6 models are equipped with a variety of plastic noise
absorber panels in the engine compartment, both above and
underneath the engine. Following are some of the common types
and methods for removing them .

Engine upper cover

<iiiiii{ 2.7 liter V6 engine top covers :
•Loosen 6 fasteners (arrows) by turning each go 0 .
• Lift off covers A , B and C.

<iiiiii{ 2.8 liter V6 enginE~ top covers:

•Loosen 8 fasteners (arrows) by turning each go 0 •
• Lift off top (centE~r) cover, then cylinder head covers.
 Maintenance 03-23
Engine Compartment

-< 3.0 liter V6 rear engine cover :

•Lift cover at corners (arrows) and remove .

-< 3.0 liter V6 front engine cover:

•Lift cover at corners (arrows) and remove .

-< 4.2 liter V8 engine top cover:

• Remove air filter hose .
•Loosen 4 fasteners (arrows) and lift off cover.

Engine lower cover (splash shield)

-< V6 models : Loosen or remove quick-release fasteners (arrows).

Pull engine cover backward away from bumper cover to remove .

- V8 models are similar.

03-24 Maintenance
Engine Oil

ENGINE OIL
Lubricating oil for engines covered by this manual are req uired to
meet quality and performance standards specified by Aud i. These
standards are sufficiently high so that , generally, only synthetic oi ls
meet them.

Engine oils meeting specified performance standards are ava ilable

from Audi and other sources .

Current specifications for engine oil are shown in Tabled . If an oil

container is not marked with appropriate specification(s) , assume
that the oil is not suitable . Use of oils other than those specified may
cause engine damage.

Table d. Oil specific:ations

Type:
•American Petroleum Institute API service SJ
• European industry standard ACEA A2 or ACEA A3

Viscosity grade:
•New engine SAE OW30
• At oil change SAE 5W30
•High temperature service SAE 5W40
0024485 (above 40°C or 100°F)

Approximate refill capacities in Table e are listed by engi ne code .

Engine application information is in Table bin this repair group.

Table e. Oil capacities (approximate)

Oil capacity (includes oil
Engine (engine code) filter) in liters (US qt)

2.7 liter V6 (A6 , S6) (APB) 6.5 (6.9)

2.7 liter V6 (allroad quattro)(BEL) 6 .9 (7.3)

2.B liter V6 (AHA, ATQ) 5.7 (6 .0)

3.0 liter V6 (AVK) 6.4 (6.B)
4.2 liter VB (A6 , S6 , RS6) 7 .6 (B .O)
(ART, AWN , BBD, BCY)

4.2 liter VB (allroad quattro)(BAS) B.5 (B .9)

Engine oil level, checking

It is normal for any engine to consume a small amount of oil. The
rate of consumption depends on oil quality, viscosity, and operating
conditions . Check oil level at every fu el filling and especially before
starting out on a trip.

- Switch ignition OFF, then wait at least 3 minutes to allow oil to flow
back into oil pan .

- Remove dipstick, wipe with a clean cloth and fully reinsert into tube.
 Maintenance 03-25
Engine Oil

~ Remove dipstick again and read oil level :

•Oil at MIN (C) . Top off oil. After topping off, level is correct when it
is within normal area (8) .
•Oil at Normal operating range (8). Oil does not have to be topped
off, but can be as long as level does not exceed MAX mark (A) .
•MAX mark (A) . Do not top off.

B WARNING-
• Do not overfill engine oil. Overfilling can cause misfire
diagnostic trouble codes (OTCs) to be stored in engine control
module (ECM) .
• If engine oil level is above maximum mark, catalytic converter
0024757 may be damaged.

- When filling engine, note oil specification and capacity information in

Table d and in Table e in this repair group.

Engine oil and filter, changing

Procedures differ slightly by engine due to filter placement and design.
1999 A6 Quattro Avant with 2.8 liter V8 engine is illustrated .

- Warm car to normal operating temperature .

Shut engine OFF and apply parking brake.

Raise car and support safely. See Raising Vehicle in this repair
group.

WARNING -
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove engine lower cover. See Engine covers, removing in this

repair group.

~ Remove oil drain plug and allow oil to drain into waste oil pan .

WARNING -
• Hot oil scalds. Wear protective clothing, gloves and eye protection.
• Used oil is hazardous waste. Dispose of properly

- When oil has completely drained , reinstall drain plug with new
gasket and tighten .

Tightening torque
Drain plug to oil pan (replace gasket) 30 Nm (22 ft-lb)
I
Loosen and remove oil filter.

WARNING -
• Dispose of oil filter as hazardous waste.

RS6 model: Remove front stabilizer bar to subframe mounting bolts

for access to oil filter.
03-26 Maintenance
Cooling System

- When installing new filter:

•Clean oil filter flange on engine.
• Lightly lubricate rubber seal on new oil filter.
•Thread filter on and tighten by hand .

- Fill engine with oil of correct viscosity and rating. See Tabled in this
repair group.
• See Table e for approximate engine capacities .
•To prevent overfilling , fill to approximately % liter (112 US qt) less
than listed capacity. After vehicle is lowered and is sitting on a level
area, start engine, allow to run until operating temperature is
approximately 60°C (140°F) and switch OFF ignition . Wait
approximately 3 minutes, check dipstick, then carefully fill to MAX
mark.

Start engine and inspect oil filter housing and drain plug area fo r
leaks. Switch engine OFF.

Install lower engine cover.

Engine oil may also be changed using an extraction system . Th is

method involves siphoning oil out of engine through the dipstick
tube . In some instances this can save considerable time . When
using this type of device , follow the manufacturer's instructio ns.

COOLING SYSTEM
Cooling system maintenance consists of maintaining coolant level ,
checking coolant freezing point, and inspecting hoses. Cool ant
flushing is not part of Audi scheduled maintenance.

~ The coolant used in vehicles covered by this manual , called G12 and
identified by its purple color, is phosphate and silicate free .
Advantages of G12 over earlier types of coolant include
improvements in corrosion protection , thermal stability, heat transfe r
and control , hard water tolerance and environmental protection.

WARNING-
• Hot coolant can scald. Do not work on cooling system until it
has fully cooled.
• Use extreme care when draining and disposing of coolant.
Coolant is poisonous and lethal. Children and pets are
attracted to it because of its color, sweet smell and taste. See a
doctor or veterinarian immediately if any amount is ingested.

00246909
 Maintenance 03-27
Cooling System

CAUTION-
• Use Audi G 12 original antifreeze or equivalent when filling
cooling system. Use of other antifreeze types may be harmful
to the cooling system. Do not use antifreeze containing
phosphates.
• Do not mix green coolant (G 11 ) with purple coolant (G 12) .
Mixing can cause serious engine damage.
• Contamination of G 12 with other colored coolants is identifiable
by discoloration (brown, gray, etc.). This mixture may cause a
foamy deposit to appear in the expansion tank and radiator.
Drain and flush cooling system completely before refilling with
th e correct type of antifreeze.
• Make sure the cooling system is filled yea r- round with a mixture
of 40% antifreeze minimum. The antifreeze mixture provides
corrosion control and also raises the boiling point of the coolant.
• Do not use tap water in the cooling system. Use distilled water
to mix antifreeze.

Table f. Cooling system capacities

Cooling system capacity in
Engine liters (US qt)

2.7 liter V6 (APB , BEL) 6.0 (6.3)

2.S liter V6 (AHA, ATQ) S.O (S.5)

3.0 liter V6 (AVK) S.O (S.5)

4.2 liter VS (ART, AWN , BBD) 9.0 (9.5)

4.2 liter VS biturbo (RS6) (BCY) 12.0 (12.7)

Coolant level, checking

<liiiiii( A tran slucent expansion tank on left side of engine compartment
provid es easy monitoring of coolant level without opening the
system. Check coolant level when engine is cold because level rises
as en gi ne warms up. Make su re coolant level is between MIN and
MAX marks.

Coolant I antifreeze concentration, checking

<liiiiii( Use a coolant hydrometer to deter mine antifreeze concentration .

Coolant mixture recommendations

Concentration Cold protection

50% antifreeze -35°C (-31 °F)

60% antifreeze -40°C (-40°F)

Do not use a higher concentration of antifreeze than a 60% mixture,

as the heat transfer quality of the coolant decreases with higher
antifre eze concentrations.

PB0419048
03-28 Maintenance
Brake Fluid

Cooling system hoses, inspecting

Inspect hoses by first checking that all connections are tight and dry.
Coolant seepage indicates that either the hose clamp is loose , hose
is damaged , or conn ection is dirty or corroded . Dried coolant has a
chalky appearance.

Check hose condition by a visual and tactile inspection , making sure

they are firm and springy. Replace hoses that exh ibit conditions
noted below.
• Leakage : Dripping , moisture, or seepage near clamps or
connectors.
• Electromechanical degradation: Difficult to see , but detectable by

------,
Abrasion damage Ozone damage
squeezing hose and feeling for cracks , weak areas, and voids .
•Oil damage : Soft and spongy to touch , visible bulges and swelling .
, ...... , ~---
•Abras ion damage: Wea r, abrasion , or scuffing , often due to contact
l with components in engine compartment.
.... ..... ~.........~~·~ ........~ ~ -~~.:~,:"'-' -::;:::::;-~--==..;::;;;:;;;;;;;.~~---\
•H eat damage : Internal and external damage generally due to high
Oil damage Heat damage underhood temperatures or overheating. Internal heat damage is
89110 often indicated by swelling with external damage marked by
hardened and cracked areas.
•Ozone damage : Small , parallel cracks in outer layers, but without
hardening . Due to exposure to atmospheric conditions .

When installing or reinstalling hoses, use clamps specified by Audi .

Some clamp types do not allow for heat expansion and contraction
and often leak when hot or cold .

For additional cooling system information and repair procedures,

see 19 Engine-Cooling System .

BRAKE FLUID

Brake fluid level, checking

WARNING -
• Brake fluid is poisonous. Do not ingest brake fluid. Wash
thoroughly with soap and water if brake fluid comes into contact
with skin.

CAUTIO~
• Use only new, previously unopened brake fluid conforming to
US Standard FMVSS 116 DOT 4.
• Do not let brake fluid come in contact with paint. Wash
immediately with soap and water.
• Brake fluid absorbs moisture from the air. Store in an airtight
container.
•Do not use DOT 5 (silicone) brake fluid.
• Do not fill brake fluid above MAX in fluid reservoir.
• Do not mix mineral oil products such as gasoline or engine oil
with brake fluid. Mineral oil damages rubber seals in the brake
system.
• Observe hazardous waste regulations when disposing brake
fluid as a haza rdous waste.
 Maintenance 03-29
Power Steering

Routine mai ntenance of the brake system includes maintai ni ng an

adequate level of brake fluid in reservoir.

~ Check that fluid level in brake fluid reservoir at left rear of engine
compartment is between MIN and MAX marks. Fluid level drops
slightly as brake pad material wears.

~ Au di specifi es use of brake fluid that meets Departm ent of

Transportation (DOT) 4 Super specification in addition to Federal
Motor Vehi cle Safety Standard (FMVSS) 116 and Society of
Automotive Engineers (SAE) standard J1703. DOT 4 Super is also
known as DOT 4+ . Brake fluid meeting this specification is also
available in 30 and 50 liter containers for use in pressure bleeders.

Brake fluid specifications

Audi specification DOT 4 Super (DOT 4+)
Minimum wet boiling point 329°F (165°C)
Dry boiling point (exceeds) 500°F (260°C)

Additional service items include replacing brake fluid every 2 years ,

checking bra ke pads for wear, checking parking brake function and
inspecting system for fluid leaks or other damage. See also:
•Under Car Maintenance in this repair group for pad inspection
and brake system inspection .
• 46 Brakes-Mechanical for brake pad and disc service.
I 6024435 • 47 Brakes-Hydraulic for brake system bleeding and fluid change .

POWER STEERING

CAUTION-
• Use only Audi hydraulic oil in the power steering system. Do not
use ATF or other non-approved types of power steering fluid. If
the wrong fluid is used, power steering components may fail.
• Do not re use drained power steering fluid.

Power steering fluid

Audi specification G 002 000
I
Power steering fluid level, checking
Power steering hydraulic fluid can be checked when either hot or
cold .

Cold power steering fluid: Do not start engine . Turn front whee ls to
straight-ahead position.
03-30 Maintenance
Fuel Filter

- Power steering fluid at operating temperature (over 50°C or 122°F):

Start engine and steer front wheels to straight-ahead position .

-iiiii( Remove power steering fluid reservoir filler cap (inset). Dipstick is
attached to cap.

- Wipe dipstick with a clean lint-free shop cloth .

Screw on cap hand tight and remove.

Read level on stick:

•If fluid is cold , correct level is± 2 mm (± 0.08 in) of MIN mark
•If fluid is at operating temperature , correct level is between MIN
and MAX marks.

If cold fluid level is more than 2 mm (0 .08 in) above MIN mark ,
extract some fluid.

If fluid level is more than 2 mm (0 .08 in) below MIN mark, check
power steering hydraulic system for leaks. It is not sufficient to top
up with fluid .

FUEL FILTER
The fuel filter does not have a specified replacement interval.
Replace it as conditions or the situation dictates .

WARNING-
• The fuel system is designed to retain pressure even when the
ignition is OFF When working with the fuel system, loosen the
fuel lines slowly to allow residual fuel pressure to dissipate.
Avoid spraying fuel. Use shop towels to capture leaking fuel.
• Before beginning work on the fuel system, place a fire
extinguisher in the vicinity of the work area.
• Fuel is highly flammable . When working around fuel, do not
disconnect wires that could cause electrical sparks. Do not
smoke or work near heaters or other fire hazards.
• Wear eye protection and protective clothing to avoid injuries
from contact with fuel.
• Unscrew the fuel tank cap to release pressure in the tank before
working on fuel lines.
• Do not use a work light with an incandescent bulb near fuel.
Fuel may spray on the hot bulb causing a fire.
• Make sure the work area is properly ventilated.
 Maintenance 03-31
Fuel Filter

Fuel filter, replacing

The illustration in this procedure applies to all V6 engines and VS
engines for A6 , S6 and allroad quattro vehicles. Also see Fuel tilter,
replacing (RS6) .

~ In vehicles covered by this procedure , the fuel filter is underneath

the vehicle in front of the right rear wheel.

Raise car and support safely.

WARNING -
• Make sure the car is stable and well supported at all times.

---------------·----·---
~ Fuel filter mounting and layout for V6 and VS engines except VS
3 5 6 biturbo (RS6 models):
1. Clamping screw, tighten to 2 Nm (1 S in-lb)
2. Fuel supply to engine
3. Banjo bolt, tighten to 23 Nm (17 ft-lb)
4. Sealing 0-rings, replace
5. Fuel filter mounting bracket
6. Fuel line from fuel pump in tank
7. Fuel line flange
8. Banjo bolt, tighten to 23 Nm (17 ft-lb)
9. Sealing 0-rings , replace
10. Fuel filter, underneath vehicle , in front of right rear wheel
11. Fuel supply to engine

Before loosening fuel line banjo bolt, wrap a shop towel around
connection.

11 10 9 8 - Counterh old fuel filter, then loosen banjo bolts.

A60403020

CAUTION-
• Place fuel-resistant container underneath work area to catch
spilling fuel.

Remove fuel filter bracket clamping screw. Slide fuel filter out of
clamp.

- When installing:
• Note that arrow on fuel filter shows direction of fuel flow.
• Use new sealing 0-rings .
• Counterhold fuel filter when tig htening banjo bolts.

Tightening torques
Fuel filter clamping screw 2 Nm (1 S in-lb)
Fuel line to fuel filter 23 Nm (17 ft-lb)

- Check for fuel leaks upon completion of repair.

03-32 Maintenance
Fuel Filter

Fuel filter, replacing (RS6)

~ Fuel filter mounting and layout for V8 biturbo engine (RS6 models).
1. Hose clamp
• Attaches fuel filter to fuel tank
•Tighten to 0.8 Nm (7 in-lb)
2. Fuel filter
• Underneath vehicle , at right front of fuel tank , above fuel pump
3. Fuel line from fuel pump
4. Hose clamp
5. Hose clamp
1--~ 6. Fuel supply line to engine
A6040302

~ Remove fuel pump mounting screw (3 ) and pull fuel pump

downward. Do not disconnect fuel hoses (2 and 4) and fuel pump
electrical connector (1 ).

- Before loosening fuel line clamps , wrap a shop towel around

connection.

~ Loosen hose clamps (1 and 2) and separate lines from fuel filter
carefully.

CAUT/O~
• Place fuel-resistant container underneath work area to catch
spilling fuel.

- Loosen hose clamp (arrow) . Slide fuel filter out of clamp.

- When installing :
• Note that arrow on fuel filter shows direction of fuel flow.
• Use new hose clamps .

Tightening torques

Fuel filter mounting clamp 0.8 Nm (7 in-lb)

Fuel pump mounting bracket 1.2 Nm (11 in-lb)

- Check for fuel leaks upon completion of repair.

 Maintenance 03-33
Battery Service

BATTERY SERVICE
The battery is in the plenum chamber, behind the engine.

~ Open engine hood, release battery cover latches (arrows) and flip
cover up to gain access to battery.

Routine maintenance of the battery consists of visual checks of

battery hold-down bracket, cable clamps , and fluid (electrolyte)
level.

Some batteries have a charge indicator (magic eye) on top that

displays electrolyte level and charge condition.
•Green : Charge and electrolyte level are OK.
• Black : There is insufficient or no charge.
• Yellow or colorless : Electrolyte level is critically low. Top off with
distilled water immediately.

NOTE -
• If the battery is more than 5 years old and the charge indicators are
colorless, replace battery
•Air bubbles that occur normally during battery charging or during
vehicle operation may adversely affect charge indicator reading. To
obtain an accurate reading, gently tap the charge indicator with a
screwdriver handle to displace air bubbles that have formed.
• Maintenance-free batteries are equipped with sealing plugs with
plastic foil.
• When replacing battery, use a replacement battery with central gas
venting.

~ At high outside temperatures , check electrolyte level through

translucent battery housing. Make sure electrolyte level is just above
battery plates and separators.
• Remove filler caps to see battery plates. Make sure electrolyte
level aligns with internal electrolyte level indicator (lip). This
equates to external min and max markings on battery case.

~ For a battery with removable electrolyte caps:

• If electrolyte level is low, use battery filling bottle VAS 5045 or
equivalent to replenish it.
• Add distilled water only. Distilled water prevents electrolyte
impurities which cause self-discharging.
• Make sure battery cell caps are equipped with 0-ring seals.

CAUTION-
• Do not overfill battery Overfilled batteries can boil over.
• Too little electrolyte reduces the service life of the battery
• Extract excess electrolyte using a hydrometer.
• Dispose of electrolyte (sulfuric acid) as hazardous waste. Refer
A60403023
to local regulations pertaining to electrolyte disposal.
03-34 Maintenance
Engine Accessory Belt

During battery service, check the following :

•Battery securely bolted down .
• Battery terminal clamping bolts tight.

Tightening torques

Bolts, positive and negative cable clamps 9 Nm (80 in -lb)

Bolt, battery hold-down bracket 20 Nm (15 ft-lb )

Make sure battery vent hose is routed correctly.

See 27 Battery, Alternator, Starter for battery testing and

installation procedures.

Battery notes
If the battery is disconnected and reconnected , reset or reinitialize
the following systems or components :
•Clock
• Power window motor limit position (one-touch operation)
• Seat and outside rear view memory
•Heating and A/C automatic setting
•Radio

See Battery reconnection notes in 27 Battery, Alternator,

Starter for procedures necessary to reinitialize compon ents.

ENGINE ACCESSORY BELT

The engine uses one multi-ribbed belt (serpentine belt) to drive
engine accessories. Although belts of this design are known fo r the ir
smooth running , high efficiency and long life, periodic inspection is
required.

Accessory belt, checking

Remove upper and lower engine covers . See Engine covers ,
removing in this repair group.

1 ~ Cross section of accessory belt.

2 1. Top layer, cover
2. Tension cords
3. Base material (substrata)
3 - Check belt periodically. Manually turn engine at vibration damper or
pulley with a suitable wrench. Inspect belt from above or below for
the following conditions:
• Splits, core fractures and cross section fractures.
0024409 • Separation between layers, especially between top cover and
tension cord layers.
• Chunking or breaking of base or lower layer material.
• Fraying of tension cords.
• Flank (side) wear including flaking , fraying , chunking , glazing ,
hardening , and surface cracking.
•Oil and grease contamination .
 Maintenance 03-35
Engine Accessory Belt

If any of above conditions exist, replace belt. Also, consult

maintenance tables at end of this repair group for appropriate
routine replacemen t intervals.

Accessory belt, replacing

(2.7 liter or 2.8 liter V6 engine)
Remove lower engine cover. See Engine covers , removing in this
repair group.

~ Use dual pin tool (Aud i spec ial tool 3212 or equivalent) (in set) to
counterhol d viscous fan pulley. Use 32 mm open end wrench (Audi
special tool 3312) to loosen (arrow) viscous fan.

CAUTION-
• Viscous fan threads are left-handed. Turn clockwise to remove.

- Lift out visco us fan.

~ Use 17 mm box wrench to rotate tensioner in direction of arrow.

When hole in tensioner lines up with front engine cover, insert steel
drift to lock tensioner in re leased mode .

If belt is to be reused, such as for an emergency spare , mark

direction of rotation prior to removal .

- Remove belt.

~ When reinstalling belt:

• Note correct belt routing as illustrated.
• If reusing be lt, install in direction of rotation marked previous ly.
•Be sure belt is seated correctly in pulley grooves.
• Position belt on A/C compressor pulley last.

Use 17 mm box wrench to release tension and remove steel locking

drift.

Reinstall vi scous fan. Note that visco us fan threads are left-handed .

Tightening torque
A13 -00 18
Viscous fan to fan pulley:
•Using 3312 open end wrench 37 Nm (27 ft-lb)
• Without 33 12 open end wrench 70 Nm (52 ft-lb)

Run engin e briefly to make sure belt routing is correct. Then reinstall
engine covers.
03-36 Maintenance
Engine Accessory Belt

Accessory belt, replacing

(3.0 liter V6 engine)
~ Remove cover (1) in engine compartment (left side) .

~ Remove air filter housing cover (1) in engine compartment (right

side) .

~ Remove air duct mounting bolts (arrows) at lock carrier (radiator

support frame) . Remove air duct (1).

~ Remove front engine cover (arrows).

 Maintenance 03-37
Engine Accessory Belt

.;;;;;( Use special tools 3299 and 3299/ 1 to swing belt tensioner in
direction of arrow to release belt te nsion .

- If belt is to be reused , such as for an emergency spare, mark

direction of rotation prior to removal.

- Remove belt from pulleys .

.;;;;;( When installing belt:

• First install belt on crankshaft pull ey (5) .
• Slide belt on tensioner (6) last.
• Note correct belt routing as illustrated.
2 • Be sure belt is seated correctly in pulley grooves .
1. Alternator (generator)
2. Accessory belt
3. Power steering pump
4. A/C compressor
5. Crankshaft pulley
A27-0 100 I 6. Tensioner

- Run engine briefly to make sure belt routing is correct. Then reinstall
engine covers .
03-38 Maintenance
Engine Accessory Belt

Accessory belt and

4 5 6 7 8 10 11 12 13 components (VB engine,
not allroad quattro)
14 1. Engine accessory belt (serpentine
belt), mark direction of rotation
before removing
2. Alternator mounting bolt, 22 Nm
(16 ft-lb)
3. Alternator mounting bolt, 45 Nm
(33 ft-lb)
4. Alternator
5. Belt tensioner mounting bolt, 43 Nm
(32 ft-lb)
6. Upper idler mounting bolt, 10 Nm
(7 ft-lb)
7. Upper idler pulley
8. Upper idler bearing
9. Upper idler bearing mounting bolt
•Apply thread locking compound when
installing . Tighten to 22 Nm (16 ft-lb).
10. Belt tensioner
• Rotate clockw ise with 19 mm wrench
to release tension
11 . Vibration damper mounting bolt,
22 Nm (16 ft-lb)
12. Front pulley (vibration damper)
13. Lower idler pulley
14. Power steering pump pulley
27 26 25 24 23 22
A 13-0524 15. Spacer (shim)
16. Power steering pump
17. Power steering pump mounting bolt
• 22 Nm (16 ft-l b)
18. Power steering pump mounting
bracket bolt, 40 Nm (30 ft-lb)
19. Power steering pump bracket
20. Dowel sleeve
21 . A/C compressor mounting bolt,
22 Nm (16 ft-lb)
22. A/C compressor
23. Mounting bolt, 22 Nm (16 ft-lb)
24. Dowel sleeve
25. Power steering pump pulley
mounting bolt, 22 Nm (16 ft-lb)
26. Lower tensioner pulley mounting
bolt, 23 Nm (17 ft-lb)
27. Trim cover
 Maintenance 03-39
Engine Accessory Belt

Accessory bE~lt, replacing

(VB engine, not allroad quattro)
To gain access to Emgine accessory belt (serpentine belt) , remove
front bumper cover and place lock carrier (radiator mounting frame
in front of engine) in service position

Raise car and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove lower engine cover. See Engine covers , removing in this

repair group.

Remove front bumper and bumper cover. See 63 Bumpers .

Place lock carrier in service position. See 50 Body-Front.

~ Remove mounting screws (a rrows) for viscous fan outer housing .

Remove housing .

Remove electric fan .

~ use Audi special tool 3212 (pin wrench) to counterhold viscous fan
pulley. Use open end wrench (special tool 3312) to loosen viscous
fan .

CAUTION-
• Viscous fan threads are left-handed. Turn clockwise to remove.

Lift out viscous fan .

~ Use 19 mm box wrench to rotate tensioner in direction of arrow.

When hole in tensioner lines up with hole in front engine cover, insert
steel drift (special tool 3204) to lock tensioner in released mode.

- If belt is to be reused , such as for an emergency spare, mark

direction of rotation prior to removal.

- Remove belt.
03-40 Maintenance
Engine Accessory Belt

When reinstalling belt

• Note correct belt routing in illustration .
• If reusing belt, install in direction of rotation marked previously.
•Be sure belt is seated correctly in pulley grooves .
•Place belt on vibration damper and idler pulleys first. Position belt
on tensioner pulley ~ ast.

- Use 19 mm box wrench to release tension and remove steel drift.

- Reinstall viscous fan . Note that viscous fan threads are left-handed .

Tightening torques
A1 3-0230 Fan shroud to radiator 10 Nm (7 ft-l b)
Viscous fan to fan pulley:
• Using 3312 open end wrench 37 Nm (27 ft-lb)
•Without 3312 open end wrench 70 Nm (52 ft-lb)

- Run engine briefly to make sure belt routing is correct. Then reinstall
lock carrier, front bumper and eng ine covers.

5 6 7 9 10 1 12 13 Alternator belt and

components (VS engine,
allroad quattro)
14 1. Belt tensioner mounting bolt, 22 Nm
(16 ft-lb)
2. Belt tensioner lock bolt, 22 Nm
(16 ft-lb)
3. Belt tensioner
4. Alternator mounting bolt, 22 Nm
(16 ft-lb)
5. Alternator
6. Alternator bracket mounting bolt,
MB: 22 Nm (16 ft-lb), M10: 46 Nm
(34 ft-lb)
7. Bushing
8. Alternator bracket
9. Idler pulley mounting brac ket bolt, 10
Nm (7 ft-lb)
10. Idler pulley mounting bracket
11. Front pulley (vibration damper)
12. Vibration damper mounti ng bolt, bolt
class 12.9, 42 Nm (31 ft-\b)
13. Idler pulley
14. Idler pulley mounting bolt, 22 Nm
(16 ft-lb)
15. Trim cover
16. Alternator belt (serpentine belt),
27 26 25 24 23 22 mark direction of rotation before
A 13-0524 removing
17. Threaded bushing
 Maintenance 03-41
Engine Accessory Belt

Alternator belt, removing and installing

(V8 engine, allroad quattro)
To gain access to alternator accessory belt (se rpentine belt) ,
remove front bumper cover and place lock carrier (radiator mounting
frame in front of engine) in service position.

Raise car and support safely.

WARNING -
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands design ed for the
purpose. A floor jack is not adequate support.

Remove lower engine cover. See Engine covers , rem ovi ng in this
repair group.

Remove front bumper and bumper cover. See 63 Bumpers.

Place lock carrier in service position. See 50 Body-Front.

<Oiiii{ Loosen tensioner lock bolt (arrow) and remove belt.

- If reusing belt, install in direction of rotati on marked previously.

<Oiiii{ Place belt over pulley in specified sequence:

1. Alternator
2. Belt
3. Idler pulley
4. Vibration damper
5. Tensioner pulley

- Be sure belt is seated correctly in pulley grooves.

1 5
A13-0550

<Oiiii{ Use torque wrench (special tool VAG 1332 or equivalent) to rotate
tensione r and pretension alternator belt. Then tighten tensioner lock
bolt.

Tightening torques

Alternato r belt pretension 72 ± 2 Nm

(54 ± 2 ft-lb)
Tensione r lock bolt 22 Nm (16 ft-lb)

- Run engin e for a short time and make sure belt routing is correct.

- Reset belt pretension . Then reinstall lock carrier, front bumper and
A1 3-0577 I engine covers.

. - l -~-
03-42 Maintenance
Timing Belt (Toothed Belt)

TIMING BELT {TOOTHE D BELT)

For timing belt replacement interval , see Maintenance Schedules
in this repair group.
Timing belt replacement is covered in 13 Timing Belt, Engine
Pulley, Rear Main Seal.

CAUTION-
• To avoid costly damage caused to engine mechanical
components if the timing belt breaks, periodically inspect the
timing belt for wear, cracks or other damage every 50,000
miles.

SPARK PLUGS
Audi specifies spark plugs made by several different manufacturers .
High voltage
co nnection Table g is a listing of current spark plug recommendations . Engines
are referred to by configuration (V6 or VS) , displacement and engine
Al uminum Oxide code. For a listing of engine codes and applications, see Table b in
insula tor this repair group.

Because specifications and part numbers can change , check with an

authorized Audi dealer parts department or aftermarket parts special-
ist for the latest application information.
Shell
Hea t shrin kage
zone
Spark plugs, replacing
Co nductive glass
seal Remove upper engine cover. See Engine covers , removing in th is
Captive o uter repair group.
gasket

Cen ter electrode

(sil ver, platinum, or copper)
Ground electrode(s)

00244 38

"'iiiiii( Engine with spark plug wires: Use special plastic puller (stored
under cylinder head plastic cover) to pull spark plug wire ends off
spark plugs.
 Maintenance 03-43
Spark Plugs

~ Engine with coils over spark plugs : Attach special tool T 40039
(puller) to uppermost thick rib (arrow) of each coil. Pull coils off

0 spark plugs.

CAUTION-
• Lower ribs of coil may be damaged if they are pried for removal.

If special coil removal tool is not available, use 2 screwdrivers to

gently pry each coil off spark plug .

I A02-0392
~ Disconnect harness connectors (4, 5, 6) and pull all connectors out
of ignition coils simultaneously.

- Pull coils out of spark plug holes and set aside.

A28-0057 I
~ Remove and install spark plugs with 16 mm or 5/s inch spark plug
socket (special tool 31228 or equivalent) . See Table g for spark plug
applications.

Tightening torque
Spark plug to cylinder head 30 Nm (22 ft-lb)

Engine with spark plug wires : Reinstall wires on spark plugs. Press
firmly for a positive connection.

- Engine with coils over spark plugs: Insert ignition coils loosely into
spark plug shafts.

~ Align ignition coils to connectors (arrows) and connect all

connectors to ignition coils simultaneously.

- Align ignition coils to recesses in cylinder head cover.

Press ignition coils evenly on spark plugs by hand .

Install upper engine cover.

03-44 Maintenance
Air Filter

Table g. Spark plug applications

Year, engine plug NGK spark plug Gap 1
199S - 2001 V6 2.S liter (AHA, ATQ) F7LTCR , F 7DQE0 2 BKR6EKUB AHA: 1.6 mm (0.064 in)
ATQ : 0.4 - 0.6 mm (0 .016 - 0.024 in )
2000 - 2002 V6 2.7 liter (APB) BKR6ES O.S mm (0 .032 in)
2002 - 2003 V6 2.7 liter (BEL) FR7DPP222 BKR6ES 3 O.S mm (0 .032 in)
2004 V6 2.7 liter (BEL) FR7DPP33 BKR6ES O.S mm (0. 032 in)
2002 - 2003 V6 3.0 liter (AVK) 4
FR7DPP332 BKR6ES-11 1.1 mm (0.044 in)
2004 V6 3.0 liter (AVK) FR7DPP22 BKR6ES-11 1.1 mm (0.044 in)
2000 VS (ART) HGR7KQC BKR6EKUB 1.6 mm (0.064 in)
2001 - 2003 VS (AWN , BAS) FGR7KQE BKR6ES Not adjustable
2002 - 2004 vs (BBD) FGR6KQE BKR6ES Not adjustable
2004 VS (AWN , BBD, BAS) FGR7KQEO BKR6ES Not adjustable
2003 - 2004 VS biturbo (BCY) BKR7E 3 O.S mm (0.032 in)
Notes:
1. Spark plugs gapped by the manufacturer during produ tion ; However, check gaps before installation .
2. Part numbers current at time of publication , but can ch nge due to supersessions, etc.
3 . -11 at end of part number indicates that spark plug is regapped at factory to 1.1 mm (0 .044 in).
4. Standard NGK spark plug listed. See NGK web site fo additional listings.

AIR FILTER

Air filter element, replacing

The air filter housing is in the right front corner of the engine
compartment. In the procedure that follows , 1999 2.S liter V6 engine
compartment is illustrated . Layout of other engine compartments is
similar.

~ Where applicable, pull up cover (A ).

- Detach intake air duct (2).

~ Unsnap air filter housing cove r retaining clips (arrows) and swing
cover to side. If necessa ry remove intake air duct.

- Remove old air filter element and discard .

- Clean air filter housing and install new filter element.

NOTE -
• Make sure sealing surfaces on inner and outer parts of air filter
housing are positioned flush and seated correctly

- Snap filter housing halves together using retaining clips .

 Maintenance 03-45
Under Car Maintenance

UNDER CAR MAINTENANCE

Transmission and final drive oil

For transmission and final drive lubricant information see the
following repair groups :
• 34 Manual Transmission
• 37 Automatic Transmission
• 39 Final Drive

Brake system, visual inspection

Brake system items to check:
•Check power brake servo (booster) and brake master cylinder.
• Check ABS hydraulic unit.
• Check front and rear brake cali pers, hoses and brake lines for
leaks and damage .
• Inspect parking brake cables and handle for proper operation and
damage.
• Check that brake hoses are not twisted .
• Ch eck that brake hoses do not touch any part of the vehicle when
steerin g is at full lock and suspension is at lim its.
• 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.

Brake pads, checking

Periodic maintenance of the brake system includes inspection of
front and rear brake pads for th ickness.

Outer brake pad thickness can usually be estimated by looking

through wheel openings . For in ner brake pad thickness , use
flashlight and mirror to inspect. If in doubt , remove wheel for more
thorou gh inspection.

~ Front disc brake outer pad .

Brake pad wear limit (incl. pad backing plate)

Minimum pad thickness (a) 7 mm (0 .28 in)
I
~ With front wheel off, check inner front pad thickness (A) through
calipe r opening .

Brake pad wear limit (friction material only)

Minimum pad thickness (A)
• A6 , 86 , allroad quattro approx. 2 mm (0 .08 in)
• RS6 approx .3 mm (0.12 in)
03-46 Maintenance
Under Car Maintenance

~ Rear disk brake outer pad .

Brake pad wear limit (incl. pad backing plate)

Minimum pad thickness (a)
l 7 mm (0.28 in )

(\ \\
\

~
~ With rear wheel off, check rear pad thickness (A) through rear
caliper opening .

Brake pad wear limit (friction material only)

Minimum pad thickness (A)
• A6 , S6 , allroad quattro approx . 2 mm (0.08 in)
• RS6 approx .3 mm (0.12 in)

- Replace pads if they are below min imum thickness . See

46 Brakes-Mechanical.

Tire and wheel service

Tire maintenance

Inspect tires at least as often as every maintenance service. Check

tire pressures more often . Remember that tire pressures change
with temperature changes. Check tire pressures when the tires are
cold due to the normal pressure rise associated with heat generated
by driving . Tire pressures vary among vehicles with different engine
types and between different model years . Refer to data label on B or
C pillar for proper inflation pressures. See Identification Plates and
Labels at the beginning of this section. Be sure to also check spare
tire pressure.

Replace dust caps on tire valves after checking tire pressures . If

valve extensions are used (as on steel wheels and wheel covers) ,
inspect extensions for damage and replace as required .

Tire inspection includes the following:

•Check tire tread surface and side walls for signs of damage.
Remove foreign objects from tread .
• Check that tires are the same type , size, and tread pattern .
•Measure tread depth . If tread wear has exceeded minimum
specification listed , replace tire.
•Check for scuffing , cupping , feathering , irregular tread wear,
sidewall checking , dry rot , cuts and fractures .
•Also check rims (both steel and alloy) for damage.
 Maintenance 03-47
Under Car Maintenance

~ Tires have tread wear indicators (TWI) spaced around the tire ,
perpendicular to the tread , at marked intervals (arrows). Note bold
TWI letterin g and location triangle on sidewall at location of TWI
bands .

When the TWls start to become visible , the tire is reaching the wear
limit. When the tops of the tread wear indicators are even with the
tread , repl ace the tire .

Some tire manufacturers use symbols in place of TWI lettering on

sidewalls ; however, TWI bands are still at that location on tire.

New summer and all-season tires generally have 10h2 of an inch

tread depth while snow tires generally have 14132 of an inch (tread
depth is measured in 32nds of an inch). Tread depth can , however,
vary con sid erably among different designs and manufacturers.

Specifications below are minimum as specified by vehicle and tire

manufacturers . State, provincial , and local laws may specify a
different tread depth minimum .

Tire wear limit

Tire tread depth , minimum remaining:
•Summ er & all-season 1.6 mm (0.063 or 2/32 in)
•Snow 4.0 mm (0.157 or %2 in)

Snow tires (or winter tires) have a deep lug tread pattern. Be sure to
use on all 4 wheels. They are not generally suitable for warm
weather use and have different speed ratings .

Because winter tires improve vehicle handling on snow and ice , use
them wh en temperatures below 45°F (7°C) are expected. Also,
increase tire pressure by 3 psi (0.2 bar) . Consult the tire
manufacturer and owner's manual for additional information and
applications .

If irregular wear patterns are identified , determine causes by

checking wheel alignment (front and rear) and inspecting
suspension for damage and worn components.

Vibrati ons felt through the steering wheel may be an indication of tire
out of balance condition. This can shorten tire life , cause wear on
steering and suspension components , and often results in an
uncomfortable ride. Tire balancing is the usual solution.

Old tires (6 years or more) may experience internal tread separation

1. Manufacturers brand and not function or perform as originally intended . Use such old tire
2. Tire dimensions (size) with caution. Audi specifies replacement after this time period
3. Type (tubeless) regardl ess of tread wear.
4. Country of origin
5. Load index and speed rating ~ Overview of typical information found on tire sidewall that complies with
United States Federal Motor Vehicle Safety Standard (FMVSS) 109.
6. Load range (A , B , C)
7. Tread & sidewall ply and construction
When installing new tires , observe the following :
8. Maximum cold inflation pressure
•Audi specifies that only radial tires be used.
9. Treadwear index number
10. Tra ction index number (AA , A , B , C) • For safety reasons , replace tires in pairs and on the same axle.
11 . Temperature index number (A , B, C ) However, replacement of all tires at the same time is preferred.
12 . USA DOT compliant • Balance new tires and fit rims (wheels) with new valve stems.
I 13 . Manufacturers production coding •New tires tend to be slippery and require a break-in period of at
L 0024416 least 350 miles (560 km) .

-- I ---·-
, ,.
 \

03-48 Maintenance
Under Car Maintenance

•Acquire new tires of the same size as originally installed . If you

change sizes , be aware that gear ratios and speedometer readings
will change.
• For safety reasons , install tires of the same type and tread pattern
on a vehicle.
•On quattro (AWD) vehicles , be sure to use the same size tires on
all four wheels.
• Do not use tires of a lesser speed rating or load range than
originally installed .
•Rebalance wheel and tires as they accumulate mileage due to
settling and wear.
• Make sure that wheel covers are installed correctly so as to not cut
valve stems and extensions.

~------
-
+,- -
,, Tire rotation

Rotate tires periodically for maximum service life and quiet runn ing .
Tire rotation also equalizes wear between tires . This keeps rolling

1 r---·---~r-·--~ -'2:'.:7\~
L/L-·-· ·-- circumference the same which is important to some vehicle
f
........ g '"··..:.::'.'~- ... ~

I -- ·i\ / ,~'
- - ·- ·- - . -- · - -· systems, especially in quattro (AWD) models.

'.
( ( ,I )!
Audi specifies tire rotation at the first 5000 mile service and then
defers to the tire manufacturers recommendations from that point

_ \ ~~= -=-=--~- -:-=J{._J

. ...., . . !'\'\---·--~"IL---;.,.~· . ~ ~-
on. These recommendations can vary slightly among
manufacturers, but generally, rotation at 5000 to 7500 mile intervals
~
results in optimal wear.

l Jj
~ Audi specifies that under most conditions , tires remain on the same
A60403025 side of vehicle when they are rotated (front to back) .

Wheel maintenance

Visually inspect steel and alloy wheels for damage such as dents
and missing balance weights . Ensure that all wheel bolts are present
and tight.

When removing and installing road wheels (alloy and steel) , note the
following points to be sure that wheels remain secure at all times:
•Tighten wheel bolts in crisscross pattern and to specified torque .
Excessive torque can distort wheel bolt seat in wheel.
•When installing a wheel , do not torque down first wheel bolt
immediately (for instance, with an impact wrench) . This may
prevent other bolts from centering the wheel properly when they
are threaded in . The rim could then come loose, even though bolts
have been tightened to specified torque .
• Do not apply grease or oil to wheel bolt threads.
•Before installing wheels , examine seats of wheel bolts and contact
surfaces between rims and hubs for rust, corrosion and paint.
Clean off these parts if necessary.

WARNING-
• If the procedures above are not observed, wheel mountings can
come loose and wheel bolt seats can become distorted. This dis-
tortion may be very slight and not visible to the naked eye. Even
this slight distortion of wheel bolt seats can prevent rims from be-
ing held firmly and cause the wheels to come loose.
 Maintenance 03-49
Under Car Maintenance

Suspension components, checking

Raise car and support safely.

WARNING -
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Check wear in front suspension components :

• Move wh eels and tie-rods and check for free play.
•Any play indicates wear. Repair as necessary.

~ Check tightness of tie-rod lock nut.

Tightening torque
Lock nut to tie-rod end 40 Nm (30 ft lb)
I
- Check dust boot for damage and correct installation .

Inspect shock absorbers for excessive oil leakage past seals.

Inspect coil springs for cracks and damage .

Inspect front and rear suspension bushings for cracks or

deterioration.

Inspect front and rear inner and outer constant velocity (CV) joint
boots for leakage , cuts and damage. Ensu re that boots are correctly
seated.

See 40 Front Suspension and 42 Rear Suspension for

suspensi on component replacement.

Underbody visual inspection

Inspect the following for leaks or damage :
•Engine
•Transmission (manual and automatic)
• Fuel system
• Cooling and heating systems
• Brake system
• Exhaust system

A small amount of dampness is considered normal in some cases ,

especially around axle and pulley seals since the leaking fluid helps
the seal work properly. On the other hand , expensive repairs can be
avoided by prompt repair of minor fluid leaks. Judgement and
experien ce are required to distinguish among the different kinds of
fluid leaks.

Inspect underside of vehicle for damage caused by normal wear and

tear or by driving over road debris. Whenever vehicle is raised on a
lift, inspect underbody, wheel we lls and sill or rocker panels for
damage to underbody sealants and coatings. Also inspect after
major repairs to vehicle systems.

- I - -
03-50 Maintenance
Body and Interior Maintenance

Repair damage or defects found. Only 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 applied
protection. Check with an authorized Audi dealer's parts
department .

BODY AND INTERIOR MAINTENANCE

Airbags, visual inspection

-<iiiiii( Airbags are installed in several locations in passenger
compartment:
•Driver and passenger side front airbags.
• Side airbags built into front seat backrests.
• Side curtain airbags.
•Side airbags built into rear seat backrest bolster (optional) .

Inspect padded airbag covers on steering wheel and instrument

panel for signs of external damage . Ensure that they are not covered
over or have any objects attached to them such as stickers, etc.

Inspect seats front and rear. Do not use seat covers that obstruct or
- - - - - - - _ _ _ _ _ _ _ _ _ _ _0=0=
24~7-=-
8 1'-"l l hinder proper deployment of side airbags.

Inspect covers along roof line for side curtain airbags for objects that
may hinder proper deployment of side airbag .

Do not apply any chemical treatment to airbag unit covers. Clean

with a dry or water moistened cloth only.

Observe airbag warning light in instrument cluster when starting vehi-

cle. It should come on for a few seconds when engine is started, as an
electronic systems self-test, and immediately go off and stay off. It
should only illuminate during this self-test or if there is a system mal-
function.

Door check strap and hinges, lubricating

-<iiiiii( Lubricate door check strap and hinges at places indicated by
arrows using G 000 150 lubricant.
 Maintenance 03-51
Body and Interior Maintenance

Door lock service

Lock and unlock left and right front doors . Make sure lock buttons
move up when unlocking and down when locking each door.

Press lock buttons down on right front and rear doors and close
doors. Make sure doors are locked .

- Make sure that lock button on driver door cannot be pressed down
while door is open .

Move child safety lever on each rea r door lock down (in direction of
arrow on door lock) . Check to make sure that inside door lever is
inoperative while lock button is in unlocked position .

Lubricate lock cylinders using G 000 400 01 lubricant.

Sunroof service
- Check sunroof for leaks.

- Clean guide rails , then spray with D 007 000 00 silicone lubricant.

CAUTIO~
• Do not allow silicone spray lubricant to contact painted areas.

Dust and pollen filter element, replacing

The dust and pollen filter (interior ventilation microfilter) is in the
plenum chamber on the right-side .

~ Remove plenum chamber cover :

• Pull rubber gasket forward and off.
• Remove plenum chamber cover toward front.

~ Working inside plenum chamber :

• Press filter retaining clip forward (arrow) .
• Remove filter from housing by pulling forward and up.
• Insert new filter element with air flow arrow (inset) aligned
correctly.

Reinstall plenum chamber cover and rubber gasket.

CAUT/O~
• When installing, place the plenum chamber cover carefully
into the water deflector below the windshield so that no water
can run into the dust and pollen filter and the climate control
system.

- - I - ·- -~-
03-52 Maintenance
Body and Interior Maintenance

Interior motion detector, checking

Test function of ultra-sonic interior motion detector:

- Open door window approx . 10 cm (4 in).

- Lock vehicle to set alarm and activate interior monitoring .

- Wait 30 seconds until indicator light blinks steadily, approx. once

every two seconds.

- Reach through window opening and place hand directly on sensor

cover in center of head liner.

If motion detector is OK, alarm is triggered.

Unlock vehicle to switch alarm OFF.

Windshield wiper blade, replacing

- Fold wiper arm away from windshield .

~ Remove wiper blade:

• Rotate blade on arm approximately 14 turn.
•Squeeze plastic retainer and slide blade off arm.

CAUTIO~
• Do not allow wiper arm to snap back against windshield

Installation is reverse of removal.

For windshield wiper troubleshooting or wiper arm replacement , see

92 Wiper and Washers .

Washer fluid, topping off

~ Fill windshield washer reservoir.
•When adding windshield washer fluid , be sure freeze protection is
adequate for your climate.
•Some windshield washer fluid brands are used as-is, straight from
container. Some are in concentrate form and require mixing with
water. Refer to product label for proper freeze protection levels.
• Most windshield washer fluids contain additives that help remove
insect residue.
 Maintenance 03-53
Maintenance Schedules

Headlights, adjusting
For proper adjustment of headlights:
•Tires inflated to correct pressures.
•Vehicle on level surface.
•Headlight lenses and reflecto rs clean and undamaged with correct
type and wattage bulbs.
•Vehicle loaded with approximately 75 Kg (165 lb) on driver's seat.
•Vehicle at curb weight with tool kit , jack, spare tire , etc . and 90%
fuel load. If fuel tank is not at least 90% full , add weight to
compensate.

Before manually adjusting xenon (HID) headlights , use VAG scan

tool or equivalent to check OTC memory, then erase OTC memory.

<iii( Left headlight:

•Height adjustment screw (1 ).
•Lateral and height adjustment screw (2).

Right headlight adjustment is the reverse .

MAINTENANCE SCHEDULES
1998Aucti Ae Aside from keeping your Audi in the best possible condition , scheduled
Owner's Manuat maintenance plays a role in maintaining full coverage under Audi's ex-
tensive warranties. If in doubt about terms and conditions of your vehicle
warranty, consult an authorized Audi dealer.

Maintenance schedules list routine maintenance specified by Aud i,

as well as time and/or mileage intervals.

Audi continually updates maintenance schedules to suit changing

.' conditions through the issuance of Maintenance Schedule Service
Circulars. If in doubt about any of the requirements for your vehicle ,
consult an authorized Audi dealer.

Maintenance tables on the following pages are year specific.

Maintenance tables may only list service intervals through 100,000

miles (160,000 km) . For continued service, repeat intervals listed for
the first 100,000 (160 ,000 km) miles for remaining life of vehicle .

Routine maintenance operations within each engine group can vary

depending on vehicle equipment level ; not all operations apply to all
vehicl es.

CAUT/O~
• To avoid costly damage caused to engine mechanical
components if the timing belt breaks, periodically inspect the
timing belt for wear, cracks or other damage every 50,000
miles.
03-54 Maintenance
Maintenance Schedules

a:ro
Au on
1998 Ma ntenance Schedule

VG & V8- Miles 7.5 15 22 .5 37 .5 45 52 .5 60 67 .5 75 82 .5 90 97 .5 105 112.5 120 127 .5 135 142 .5 150
A4 , AG & AS Ki lometers 12 24 36 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228 240

Engin e Oil - change

Engine Filter - replace
Fluid Levels - check
Auto-Sh ift Lock - check
Manual Trans - check shift and
clutch interlock
Wheels - rotate*
Plenum Water Valve - clean **
Service Rem inder - reset
Battery - chec k level
Du st/Poll en Filter - replace
Cooling System - check level
W/W System - check , add fluid
Sliding Roof - clean , lubricate
rails
ATF - replace* **
Transmission - check for leaks
Trans Final Drive(s) - check
lu bricant
Brake System - check
Drive Shafts - check boots
Wheelsrrires/Spare - check
condition , pressure
OBD - check OTC memory
Exterior Li ghts - cl1eck, adjust
Door Hinge Mechanism -
lubricate
Roof Mechanism - lubricate****
During Road Test
After Road Test
Air Cleaner - re pl ace
Front End - check dust sea ls,
ball joints, tie rod ends
Brake Fluid - re place r

Spark Plugs - replace

V-Belt - replace
Ribbed Belt - rep lace
Timing Belt - re place
V6 , VB
Spark Plugs - replace
Ribbed Belt - replace
Timing Belt - rep lacett

'F irst service on ly ·· AG Wagon on ly · •·cabriolet. AG Wagon nly ·'''Cabriolet only

'Every 2 years . regarcll ess of mi leage "Except Cabriolet

CAUTIO~
• To avoid costly damage caused to engine mechanical
components if the timing belt breaks, periodically inspect the
timing belt for wear, cracks or other damage every 50, 000
miles.
 Maintenance 03-57
Maintenance Schedules

2001 Maintenance Schedule

Engine Filter - replace

Service Reminder - reset
Wheels - rotate
Fluid Levels - check
Auto-Shift Lock - check
Brake System - check
Manual Trans - check shi ft and
clutch interlock
Cooling System - check level
Exhaust System - check
OBD - check OTC memory
Door Hinge Mechanism - lubricate
Battery - check level
W/W System - check , add fluid
Wheels/Tires/Spare - check
condition, pressure
Drive Shafts - check boots
Road Test
Lights - check
Engine - check for leaks
Front End - check dust seals,
ball joints, tie rod ends
Haldex Clutch - change oil & filter*
Transmission - check for leaks
Trans Final Drive (man/auto) -
check lubricant
Dust/Pollen Filter - replace
Head Lights - adjust
Sliding Roof - clean, lubricate ra ils
Power Steering Fluid - check
Air Cleaner - replace element
Spark Plugs - replace
Ribbed Belt - replace
V-Belt - replace* *
Timing Belt - replace **
Timing Belt - replace*••
Timing Belt and
Tensioner Roller - re place••>+
Brake Fluid - replace

· IT ciuattro • 1 81 Turbo • • 2 71 VG and 4.21 V8 ' .. ' 2.BL VG

CAUTION-
• To avoid costly damage caused to engine mechanical
components if the timing belt breaks, periodically inspect the
timing belt for wea r, cracks or other damage every 50, 000
miles.
 I

03-58 Maintenance
Maintenance Schedules

cmD 200:~ Maintenance Schedule

Audc A6/S6/allroad
Miles
ilometers ,_1~ ;"! ~m a!1 tllP t~
··,,,. ,,J~l .:·""' %
~ I
" a
ill) ,,, ()I!J :xm
I
~ .11 I
Engine Oil - change • • • • • • • • • •
Engine Oil Filter - replace • • • • • • • • • •
Engine - check for leaks • • • • •
Cooling System - check level, add if nee issary • • • • • • • • • •
Exhaust System - check for damage. le< ks • • • • • • • • • •
Engine OBD - check memory, purge • • • • • • • • • •
Door Hinge Mechanisms - lubricate • • • • • • • • • •
Battery - check electrolyte, add if nece s~ ary • • • • • • • • • •
Wiper/Washe r - check fluid , add if nec e~ ;ary • • • • • • • • • •
Automati c Shift Lock - check • • • • • • • • • •
Manual Transmission - check shift and ir erlock • • • • • • • • • •
Tires and Spare - check condition , press ire • • • • • • • • • •
Se rvice Remi nd er Display - reset • • • • • • • • • •
Brake System - check • • • • • • • • • •
Drive Shaft Boots - check • • • • • • • • • •
Road Test • • • • • • • • • •
Lights - check • • • • • • • • • •
Front Ax le - check dust seals, ball joints.
ti e-rod end s • • • • •
Automatic Transmission - check for leaks • • • • •
Automatic Transmission Final Drive - che k
for leaks • •
Manual Transmission - check for leaks • • • • •
Manual Transmission Final Drive - check fc leaks • • • • •
Multitronic™ Transmission - change ATF • •
Power Stee rin g Flu id - check, add if nece sary • •
Du st and Pollen Filter - replace • • • • •
Headl ights - inspect, adjust if necessary • • • • •
Sl iding Roof - clean, lubricate rails • • • • •
Air Cleaner - replace filter element • •
Spark Plugs - replace • •
Ribbed Bel t - replace •
Ribbed Belt - chec k~ ·
•
Timing Belt - replace" ... •
Timing Belt and Tensione r Roller - replace •
Brake Fluid - replace every 2 yea rs. rega rdless of r ileage. '2 .7L '" 3.0L '"'4 .2L
W42AUMAINT2002A4S4 A6S6 Printed October 20C

CAUTIO~
• To avoid costly damage caused to engine mechanical
components if the timing belt breaks, periodically inspect the
timing belt for wear, cracks or other damage every 50,000
miles.
 Maintenance 03-59
Maintenance Schedules

2003 Maintenance Schedule

A6/S6/allroad

~h
i I ~1
i· ~ ~
Miles
Kil ometers , 'I I I· UfI!J 1.liE!l
·' ml
Engine Oil - change • • • • • • • • • •
Engine Oil Filter - replace • • • • • • • • •
Engine - check for leaks • • • • •
Cooling System - check level , add if necessa ry • • • • • • • • •
Exhaust System - check for damage. leaks • • • • • • •
Engine OBD - check memo ry, pu rge • • • • • • • • • •
Door Hinge Mechanisms - lubricate • • • • • • •
Battery - check elect rolyte , add if necessary • • @
• • • • • • •
Wiper/Washer - check fluid, add if necessa ry • • • • • • • •
Automatic Shift Lock - check • • • • • • • •
Manual Transmission - check shi ft and interlock • • • • • • • • •
Tires and Spare - check condition , pressure • • • • • • •
Service Reminder Display - reset • • • • • • • •
Brake System - check • • • • • • • •
Drive Shaft Boots - check • • • • • • • •
Road Test • • • • • • • • •
Lights - check • • • • • • • • • •
Front Axle - check dust sea ls, ball joints,
tie -rod ends • • • •
Automatic Transmission - check for leaks • • • •
Autom atic Transmission Final Drive - check
for leaks • • •
Manual Transmission - check for leaks • • • •
Manual Transmission Final Drive - check for leaks • • • •
Multitronic™ Transm ission - change ATF •
Power Steering Fluid - check , add if necessa ry •
Dust and Pollen Fi lter - rep lace • • •
Headlights - inspect, adjust if necessary • • •
Sliding Roof - clean, lubricate rails • • • •
Air Cleaner - replace filter element • •
Spark Plugs - rep lace (except allroad 4.2L) •
Spark Plugs - replace (a llmad 4.2L) •
Ribbed Belt - replace •
Ribbed Belt - cl1eck' - •
..
Timing Belt - replace··
... -~

•
Timing Belt and Tensioner Roller - rep lace' •
Brake Fluid - replace every 2 years. rega rdless of mileage. '2 .7L .. 3.0L ... 4 .2L

CAUTION---
• To avoid costly damage caused to engine mechanical
components if the timing belt breaks, periodically inspect the
timing belt for wea r; cracks or other damage every 50, 000
miles.
 -

03-60 Maintenance
Maintenance Schedules

@ID 2004 M :iintenance Schedule

A uo1 AG/all road
Miles
Kilometers i
i'.i~.m
i",o ll ;
.
·I ma m
J!J ~
: I m G'J
I
I
Engine Oil - change oil and replace filter • • • • • • • • • •
Wiper/Washer/ Headlight washer -
check adjust. and function • • • • • • • • • •
Tires and Spare - check condition , pressure • • • • • • • • • •
Tires - rotate •
Service Reminder Display - reset • • • • • • • • • •
Road Test • • • • • • • • • •
Cool ing System - check level, add if necessary • • • • •
Exhaust System - check for damage, leaks • • • • •
Eng ine OBD - check memory, purge • • • • •
Engine - check for leaks • • • • •
Battery - check electrolyte, add if necessary • • • • •
Dust and Pollen Filte r - rep lace • • • • •
Automatic Transmission and Final Drive -
check for leaks • • • • •
Manual Transmission and Final Drive -
check for leaks • • • • •
Sunroof - clean, lubricate rails • • • • •
Front Axl e - check dust seals, ball joints.
tie rods, tie rod ends • • • • •
Tire Repa ir Set - check renewal date • • • • •
Lights - check • • • • •
Headlights - inspect. adjust if necessary • • • • •
Brake System - check • • • • •
Drive Shaft Boots - check • • • • •
Door Hin ge Mechani sms - lubricate • • • • •
Spark Plugs - replace (except allroad 4.2L) • •
Spark Plugs - replace (al lroad 4.2L) •
Multitronic™ Transmission - change ATF • •
Power Steering Fluid - check , add if necessary • •
Air Cleaner - clean housing , replace filter eleme t • •
Ribbed Belt - replace (except 3.0) •
Ribbed Belt - check (3.0) •
Timing Belt - replace (3.0 and 4.2L) •
Timing Belt and tensioner - replace (2.7T) •

Brake Fluid - replace every 2 years. regardless of mileagE

CAUTIO~
• To avoid costly damage caused to engine mechanical
components if the timing belt breaks, periodically inspect the
timing belt for wea r, cracks or other damage every 50,000
miles.
 13-1

13 Timing Belt, Crankshaft Pulley,

Rear Main Seal

GENERAL .. . ....... .. .......... . . ..... .. 13-1 Crankshaft pulley , removing and installing
(VB engine) ........ . ... . . ...... .... . . . 13-B
TIMING BELT ........ . .......... . ........ 13-1
REAR MAIN SEAL ...... . .......... . ..... 13-B
Timing belt, removing .. ... .... ........ ... . 13-2
Timing belt, installing ...... . ............... 13-4 Rear main seal , removing and installing
(2.B liter V6 engine) . .... . ........... .. .. 13-9
FRONT CRANKSHAFT PULLEY .. .. ........ 13-6 Rear main seal , removing and installing
Crankshaft pulley , removing and installing (2. 7 liter or 3.0 liter V6 engine; VB engine
(2 .7 liter or 2 .B liter V6 engine) ...... . ... .. 13-6 notallroad quattro) ........... . . .. . .. .. 13-10
Crankshaft pulley , removing and installing Rear main seal, removing and installing
(3.0 liter V6 engine) ... ........... ...... . 13-7 (VB engine allroad quattro) ... ....... .... 13-13

GENERAL
This repair group covers camshaft tim ing belt (toothed belt) , front
crankshaft pulley (vibration damper) and rear main (crankshaft) seal
replacement.

Engin e accessory belt service is covered in 03 Maintenance .

Camshaft sprockets
TIMING BELT
/ Securing plates
~ Teeth on the timing belt (or toothed belt) mesh with teeth on
crankshaft and camshaft sprockets and maintain precise valve
timing .

Each camshaft sprocket is pressed on the camshaft . When

loosened , the sprocket spins freely on the camshaft. An oval
securing plate is keyed to the camshaft. The sprocket is securely
attached to the camshaft only when the securing plate is torqued .

Preci se camshaft timing is achieved by lining up the oval securing

A6041 3007 plates on the camshaft ends with each other, using a special tool.
Camsh aft sprockets are then tightening in that position .

~ Prior to removing the timing belt, proceed as follows :

• Rem ove engine cooling fan and viscous clutch .
• Rem ove front bumper and place front lock carrier (radiator
mounting frame in front of engine) in service position . See
50 Body-Front.
• Remove accessory belt. See 03 Maintenance.
• Remove accessory belt tensioner.
• Re move timing belt covers .
• Remove front crankshaft pulley. See Crankshaft pulley,
removing and installing (2.7 liter or 2.8 liter VG engine) in this
repair group.
13-2 Timing Belt, Crankshaft Pu ley, Rear Main Seal
Timing Belt

CA U TIO~
• To avoid costly damage caused to engine mechanical
components if the timing belt breaks, periodically inspect the
timing belt for wear, cracks or other damage every 50, 000
miles.
• When replacing the timing belt, be sure to use crankshaft
locking pin and camshaft locking bar as described in the
procedure.
• When the timing belt is off, any rotation of the camshafts or
crankshaft may lead to valve damage.

Timing belt, removing

In the procedure that follows , timing belt replacement is described
for 2.7 liter or 2.8 liter V6 engine. Timing belt replacement requires
several special tools and procedures. Read the procedure through
before starting the job.

Raise car and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove upper and lower engine covers. See 03 Maintenance.

Remove viscous fan and accessory belt. See 03 Maintenance.

NOTE-
• If belt is to be reused, mark direction of rotation prior to removal.

Remove front bumper. Place lock carrier (radiator mounting frame in

front of engine) in service position . See 50 Body-Front.

2.7 liter turbo engine: Loosen hose clamps (arrows) and remove
pressure hoses between intercoolers and turbo pressure lines on
left and right sides.

2.7 liter turbo engine : Remove turbo pressure lines (1 ). Note

position of retaining strips (2) .

A13-0177 I
 Ti ming Belt, Crankshaft Pulley, Rear Main Seal 13-3
Timing Belt

~ Working at front of engine :

• Remove accessory belt tensioner (1 ) .
• Unclip (2) timing belt covers on both sides and remove .
• Remove center timing belt cover (3) .

A1 3-0 178 I

~ Using wrench on crankshaft pulley, rotate crankshaft until marks

(arrows ) on crankshaft pulley and lower crankcase cover align . This
is crankshaft top dead center (TDC) .

~ Check position of camshafts:

•M ake sure larger holes (arrows) of oval securing plates on
camshaft sprockets face each other.
• If not, turn crankshaft another full rotation until crankshaft pulley
TDC marks line up and larger holes on securing plates face each
other.

~ Working underneath engine, above oil drain plug , remove sealing

~-- plug from left side of cylinder block and install special tool VAG 3242
(crankshaft locking pin) into opening . If necessary, rock crankshaft
back and forth gently to facilitate insertion of lock tool.

- Remove crankshaft pulley (vibration dampener) . See Crankshaft

pulley, removing and installing (2.7 liter or 2.8 liter V6 engine)
in this repair group. Do not loosen or remove pulley center bolt.

V13-083 1
13-4 Timing Belt, Crankshaf Pulley, Rear Main Seal
Timing Belt

<Oiiii( Working at front of engine :

•Remove accessory belt idler mounting bolts (top arrows) and lift
out idler pulley bracket.
• Remove timing belt cover bolts (lower arrows) and take off cover.

<Oiiii( Remove timing belt tensioner.

• Use 8 mm Allen wrench to rotate belt tensioner roller (1) clockwise
(direction of broken arrow). Apply slow pressure to oil-dampened
tensioner.
•When tensioning lever (2) compresses tensioner (3), insert pin with
2 mm diameter (VAG special tool 2024A or equivalent) into bore.
This releases timing belt tension .

NOTE -
• If belt is to be reused, mark direction of rotation prior to removal.
• Crankshaft pulley is shown installed.

A1 3-0032 Remove timing belt.

CAUTIO~
• Do not allow camshafts to rotate once timing belt is off.

Timing belt, installing

- Prior to reinstalling timing belt, spin timing belt tensione r and listen
for worn bearing . Replace if necessary.

Tightening torque
Timing belt tensioner to crankcase I 20 Nm (15 ft-lb)

<Oiiii( Working at camshafts :

•Install camshaft locking bar, special tool VAG 3391 , into oval
securing plates.
• Loosen camshaft sprocket bolts and back out approx. 5 turns .
• Remove camshaft locking bar.
Timing Belt, Crankshaft Pulley, Rear Main Seal 13-5
Timing Belt

"'iiii( Working at each camshaft:

• Remove camshaft sprocket bolt.
•Use puller VAGT 40001 to pull off camshaft sprocket.
• Rein stall camshaft sprocket togethe r with oval securing plate and
hand-tighten.
•Make sure camshaft sprocket is just loose enough to be rotated but
not so loose as to wobble on camshaft .

NOTE -
• Once the camshaft sprocket bolt is loosened sufficiently, as an
alternative to using puller VAG T40001 , tap the sprocket gently
with a soft-faced hammer to break free press fit at camshaft.

"'iiii( Install timing belt on all sprockets, as shown. If reusing belt, install in
direction marked previously.

- Reinstall camshaft locking bar, special tool VAG 3391 , into oval
securing plates.

Use 8 mm Allen wrench to back off timing belt tensioner, then

remove tensioner locking pin . Release tensioner slowly.

"'iiii( Pretension timing belt as follows : Using torque wrench with 8 mm

Allen bit, apply 15 Nm (11 ft-lb) counterclockwise tension to belt
(broken arrow) . This ensures tensioner expands completely and
engages timing belt correctly.

- Tighten camshaft sprocket bolts.

Tightening torque

Camshaft sprocket to camshaft 55 Nm (40 ft-lb)

I
Remove camshaft locking bar and cra nkshaft locking pin .

- Remainder of installation is reverse of removal.

Tightening torques
Accessory belt idler to crankcase 45 Nm (33 ft-lb)
Crankshaft pulley to timing belt sprocket 25 Nm (18 ft-lb)
Timing belt tensioner element to bracket 10 Nm (7 ft-lb )
13-6 Timing Belt, Crankshaft Pu ley, Rear Main Seal
Front Crankshaft Pulley

FRONT CRANKSHAFT PULLEY

The front crankshaft pulley is also referred to as vibration damper or
harmonic balancer. It is bolted to front of timing belt crankshaft
sprocket.

V6 models with 2.7 litE!' or 2.8 liter engine: Remove lower engine
cover, viscous fan and accessory belt to gain access to front pulley.

V6 models with 3.0 liter engine : Remove engine covers and front
bumper. Place lock carrier (radiator mounting frame in front of
engine) in service position . Remove accessory belt to gain access to
engine pulley.

VB models: Remove lower engine cover and front bumpe r. Place

lock carrier (radiator mounting frame in front of engine) in service
position. Remove viscous fan and accessory belt to gain access to
engine pulley.

CAUTIO~
• Do not loosen or remove the timing belt sprocket mounting bolt
in the center of the pulley

Crankshaft pulley, removing and installing

(2.7 liter or 2.8 liter VG engine)
- Raise car and support safely.

WARNING -
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

- Remove lower engine cover. See 03 Maintenance.

- Remove viscous fan and accessory belt. See 03 Maintenance.

NOTE -
• If belt is to be reused, mark direction of rotation prior to removal.

Remove pulley mounting bolts (arrows). Do not loosen or remove

center bolt.

- Lift pulley off timing belt sprocket.

When installing pulley, make sure notches (arrows) in pulley are

aligned with locating lugs on timing belt sprocket.

Tightening torque
Crankshaft pulley to timing belt sprocket 25 Nm (18 ft-lb)

Reinstall belt in direction of rotation marked previou sly. Reinsta ll

viscous fan . See 03 Maintenance.

J
A1 3-003 1 I
- Run engine briefly to make sure belt routing is correct. Then reinstall
engine cover.
Timing Belt, Crankshaft Pulley, Rear Main Seal 13-7
Front Crankshaft Pulley

Crankshaft pulley, removing and installing

(3.0 liter VG engine)
Raise car and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove engine covers. See 03 Maintenance.

Remove front bumper cover and bumper. See 63 Bumpers.

- Place lock carrier in service position. See 50 Body-Front.

Remove accessory belt. See 03 Maintenance.

NOTE -
• If belt is to be reused, mark direction of rotation prior to removal.

~ Remove front pulley mounting bolts (1 ). Do not loosen or remove

center bolt.

- Lift pulley (2) and thrust washer (3) off timing belt crankshaft
sprocket.

NOTE -
• Thrust washer is only installed on sprocket with part no.
06C 105 063. If sprocket part no. is 06C 105 063 B, do not install
thrust washer.

- When installing , make sure convex side of thrust washer rests

against pulley.

A1 3-0439 I

~ When installing pulley, make sure notches (arrows) in pulley are

aligned with locating lugs on timing belt sprocket.

Tightening torque
Crankshaft pulley to timing belt sprocket / 25 Nm (18 ft-lb)

Reinstall belt in direction of rotation marked previously.

J
A13-003 1 I
Run engine briefly to make sure belt routing is correct. Then reinstall
lock carrier, front bumper and engine covers.
13-8 Timing Belt, Crankshaft ulley, Rear Main Seal
Rear Main Seal

Crankshaft pulley, removing and installing

(VS engine)
Raise car and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove lower engine cover. See 03 Maintenance.

Remove front bumper and bumper cover. See 63 Bumpers.

Place lock carrier in service position . See 50 Body-Front.

Remove viscous fan (if equipped) and accessory belt . See 03

Maintenance.

NOTE-
• If belt is to be reused, mark direction of rotation prior to removal.

Remove pulley mounting bolts. Do not loosen or remove cente r bolt.

Lift pulley off timing belt sprocket or crankshaft.

~ When installing pulley, make sure notches (arrows) in pulley are

aligned with locating lugs on timing belt sprocket.

Tightening torque
Crankshaft pulley to timing belt sprocket 25 Nm (18 ft-lb )
(not allroad quattro)

Crankshaft pulley to crankshaft 42 Nm (31 ft-lb)

(allroad quattro VS , engine code BAS)

J
A13-0031 I
- Reinstall belt in direction of rotation marked previously. Reinstall
viscous fan (if equipped). See 03 Maintenance.

Run engine briefly to make sure belt routing is correct. Then reinstall
lock carrier, front bumper and engine covers.

REAR MAIN SEAL

Oil drips at the engine-to-transmission seam are usually evidence of
crankshaft rear main seal leak. The rear main seal is accessible
after removal of transmission and dual-mass flywheel or torque
plate .

V6 models with 2.B liter engine:Replace seal by prying out of seal

flange .

~ V6 models with 2.7 liter or 3.0 liter engine, VB models not

allroad quattro: Audi recommends replacing rear main seal with
seal flange . When removing flange , sealing of flange against oil pan
gasket is disturbed. Remove upper oil pan and replace gasket if it is
damaged .

Allroad quattro models with VB engine {engine code BAS):

Replace seal by prying out of timing chain cover.
Tim ing Belt, Crankshaft Pulley, Rear Main Seal 13-9
Rear Main Seal

Rear main seal, removing and installing

(2.8 liter V6 engine)
<fiiiii( With transmission removed , set crankshaft at top dead center
(TDC). Install special tool 3242 (crankshaft lock) . Mark position of
flywheel or torque plate opposite crankcase flange (arrows) .

- Remove flywheel or torque plate and set aside. Discard mounting

bolts.

<fiiiii( Automatic transmission: Mark positions of shim (1) and washer (2)
in front of and behind torque plate as plate is removed .

<fiiiii( Pry out rear main seal using special tool 10-221 or equivalent.

CAUTION-
• Work carefully to avoid damaging aluminum seal flange or
flywheel sealing surface.

- Clean sealing surfaces.

- Install new seal over end of crankshaft. Use installation sleeve

supplied with new seal.

CAUTION-
• Do not lubricate seal lip or seal outer edge before installation.

<fiiiii( Use special tool 2003 I 3 (seal installer) to press seal in up to stop.
Use flywheel or torque plate installation bolts for pressing .

- Using new bolts, install flywheel or torque plate. Use previously

made marks to line up with crankcase .

Tightening torque
Flywheel to crankshaft
•Stage 1 60 Nm (44 ft-lb)
•Stage 2 +Y2 turn (180°)

Torque plate to crankshaft

•Stage 1 60 Nm (44 ft-lb)
•Stage 2 + % turn (90°)
13-10 Timing Belt, Cranksh t Pulley, Rear Main Seal
Rear Main Seal

~ After installing torque plate , measure torque plate offset (a) from
crankcase bellhousing flange. Measure at three different spots and
calculate average value .

Torque plate offset

a = offset of torque plate from engine block approx . 12.3 mm

(0.484 in)

~ If offset is incorrect, install different shim (arrow) between flywheel

and crankshaft. Shim thickness is as follows:
• Part no. 054 105 30 = 3.00 mm (0.12 in)
• Part no. 054 105 20 = 4.00 mm (0 .16 in)

- Remainder of installation is reverse of removal. Bear in mind :

•Automatic transmission : Check ATF level and top off.
•Cooling system: Check coolant level and top off.
• Engine: Check oil level and top off.

Rear main seal, removing and installing

(2.7 liter or 3.0 liter V6 engine; VB engine not
allroad quattro)
~ With transmission removed , set crankshaft at top dead center
(TDC). Install special tool 3242 (crankshaft lock). Mark position of
flywheel or torque plate opposite crankcase flange (arrows).

- Manual transmission: Remove flywheel and set aside. Discard

mounting bolts.
Timing Belt, Crankshaft Pulley, Rear Main Seal 13-11
Rear Main Seal

~ Automatic transmission : Using wrench on crankshaft pulley, rotate

crankshaft until marks (a rrows ) on crankshaft pulley and lower
crankcase cover align . This is crankshaft top dead center (TDC) .

~ Check position of camshafts:

• Make sure larger holes (arrows) of oval securing plates on
camshaft sprockets face each other.
• If not, turn crankshaft another full rotation until crankshaft pulley
TDC marks line up and larger holes on securing plates face each
other.

~ Working underneath engine, above oi l drain plug , remove sealing

plug from left side of cylinder block and install special tool VAG 3242
(crankshaft locking pin) into opening . If necessary, rock crankshaft
back and forth gently to facilitate insertion of lock tool.

- Remove torque plate mounting bolts and discard.

~ Autom atic transmission : Mark positions of shim (1 ) and washer (2 )

in front of and behind torque plate as plate is removed.
13-12 Timing Belt, Crankshaft P lley, Rear Main Seal
Rear Main Seal

Remove seal flange (arrow) with seal . Separate carefully from oil
pan gasket.

CAUT/O~
• If oil pan gasket is damaged during this procedure, remove oil
pan and replace gasket.

A1 3-0460 I
Apply bead of silicone sealant approx. 1.5 mm (0.06 in) to sealing
surface of new flange. Install new seal and seal flange over end of
crankshaft. Use instal lation sleeve supplied with new seal.

CAUTIO~
• Be sure to install seal flange within 5 minutes after application
of silicone sealant.

Using new bolts, install flywheel or torque plate. Use previously

made marks to line up with crankcase.

Tightening torque
A13-046 1 Flywheel to crankshaft (use new bolts) :
•Stage 1 60 Nm (44 ft-lb)
•Stage 2 +% turn (180°)
Torque plate to crankshaft (use new bolts) :
•Stage 1 60 Nm (44 ft-lb)
•Stage 2 + 14 turn (90°)

After installing torque plate, measure torque plate offset (a) from
crankcase bellhousing flange . Measure at three different spots and
calculate average value .

Torque plate offset

a ~ offset of torque plate from engine block I approx . 12.3 mm

(0.484 in)

If offset is incorrect, install different shim (arrow) between flywheel

and crankshaft. Shim thickness is as follows:
• Part no. 054 105 30 = 3.00 mm (0.12 in)
• Part no. 054 105 20 = 4.00 mm (0.16 in)

- Remainder of installation is reverse of removal. Bear in mind :

•Automatic transmission : Check ATF level and top off.
•Cooling system : Check coolant level and top off.
• Engine: Check oil level and top off.
Timin g Belt, Crankshaft Pulley, Rear Main Seal 13-13
Rear Main Seal

Rear main seal , removing and insta lling

(VB eng ine allroad quattro)
- Raise car and support safely.

WARNING -
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

~ W ith transmission removed , use special tool 10-201 to counterhold

torque plate while loosening mounting bolts . Mark position of torque
plate and washer for reinstallation. Set torque plate aside and
discard bolts.

~ Pull shim (arrow) off end of crankshaft. Mark its position for
reinstallation .

~ Pry out seal using special prying tool T20 143/2.

13-14 Timing Belt, Cranksha Pulley, Rear Main Seal
Rear Main Seal

"iii( Insert assembly sleeve T10122/1 on pull sleeve T10122/2. Sl ide

new seal on pull sleeve.

- Remove assembly sleeve.

X:- T10122/1

N13-0782 I

"iii( Install pull sleeve with seal on end of crankshaft.

"iii( Use special tool T10122/3 to press in seal evenly until it is flush with
surface of cover. Remove pull sleeve.

- Reinstall torque plate, washer and shim according to marks made

previously. Use new bolts.

Tightening torque

Torque plate to crankshaft (use new bolts) :

•Stage 1 30 Nm (22 ft-lb )
•Stage 2 + 1,1i turn (90°)

- Remainder of installation is reverse of removal. Bear in mind :

•Automatic transmission: Check ATF level and top off.
•Cooling system : Check coolant level and top off.
• Engine : Check oil level and top off.
 15-1

15 Cylinder Head Cover

GENERAL . ..... . ... . ... ... .............. 15-1 Left cylinder head cover, removing and installing
Warnings and Cautions ............... . ... 15-1 (3.0 liter engine) ....... . ....... . .... . .. 15-5
Right cylinder head cover, removing and installing
CYLINDER HEAD COVER (V6 MODELS) ... . 15-2 (3.0 liter engine) . . . . . . . . . . . . . . . . . . . . . . . 15-7
Left cylinder head cover, removing and installing
(2.7 liter or 2 .B liter engine) ... .. .... . ..... 15-2 CYLINDER HEAD COVER (VS MODELS) 15-9
Right cylinder head cover, removing and installing Left cylinder head cover,
(2.7 liter or 2.B liter engine) . ... ........ .. . 15-4 removing and installing (VB models) 15-9
Right cylinder head cover,
removing and installing (VB models) .. . . . . . 15-10

GENERAL
This repair group contains information on cylinder head cover
removal and installation.

If engine oil leaks are detected or if spark plug wells are filling with
oil , remove the cylinder head cover and replace both the outer
gasket and the inner spark plug well gasket.

Warnings and Cautions

WARNING -
• To avoid personal injury, be sure the engine is cold before
beginning any procedure in this repair group.
• The fuel system is designed to retain pressure even when the
ignition is OFF When working with the fuel system, loosen the
fuel lines slowly to allow residual fuel pressure to dissipate.
Avoid spraying fuel. Use shop towels to capture leaking fuel.
• Before beginning work on the fuel system, place a fire
extinguisher in the vicinity of the work area .
• Fuel is highly flammable. When working around fuel, do not
disconnect wires that could cause electrical sparks. Do not
smoke or work near heaters or other fire hazards.
• Wear eye protection and protective clothing to avoid injuries
from contact with fuel.
• Unscrew the fuel tank cap to release pressure in the tank
before working on fuel lines.
• Do not use a work light with an incandescent bulb near fuel.
Fuel may spray on the hot bulb causing a fire.
• Make sure the work area is properly ventilated.
15-2 Cylinder Head Cover
Cylinder Head Cover (V6 Models)

CAUTION-
• When working on internal engine components, mainta in
absolute cleanliness.
• To prevent damage to vehicle body or paint, use protective
body covers.
• Lay removed engine parts on a clean surface and cover
immediately Even small dirt particles can block oil passages.
• Place matching marks on harness connectors, hardware and
other components for ease of assembly

CYLINDER HEAD COVER (V6 MODELS)

The illustrations in this section illustrate work on a 2000 A6 with
2.7 liter turbocharged engine . The procedures are similar on other
models.

Left cylinder head cover, removing and

installing (2.7 liter or 2.8 liter engine)
Remove top engine cover(s) . See 03 Maintenance.

~ Loosen or remove turbo ram air duct clamps and remove air duct
mounting fasteners (arrows). Lift off air duct.

~ Remove coolant reservoir mounting fasteners (arrows).

• Disconnect electrical connector from coolant level sensor at
bottom of reservoir.
• Move reservoir aside. Leave coolant hoses connected .

- Remove cover panel from left cylinder head cover.

 Cylinder Head Cover 15-3
Cylinder Head Cover (V6 Models)

~ Working at left side of engine:

•Loosen hose clamp (a rrow ).
• Remove intake line (1 ).
• Disconnect hose (2) .
• Detach coolant line (3).
• Plug lower section of intake line.

~ Wo rk in g above left cylinder head cover:

• Disconnect crankcase breather (1) from cylinder head cover.
• Di sconnect electrical connectors from ign ition coils and remove
coils . See 28 Ignition System .

NOTE -
• 2 .8 liter engine: Remove spark plug wires.

Rem ove cylinder head cover.

~ Installation is reverse of removal; note the following:

• Replace cylinder head cover gasket and spark plug well gasket.
•Seal end points of joints (arrows) between bearing caps and
cylinder head. Apply small quantity of sealant (D 454 300 A2 or
equivalent) at four end points.
•Tighten cylinder head cover fasteners in crissc ross pattern ,
starting from middle fasteners.

Tightening torque
Cylinde r head cover to cylinder head (M6) 10 Nm (7 ft-lb)

A15-0097 I
15-4 Cylinder Head Cover
Cylinder Head Cover (V6 Models)

Right cylinder head cover, removing and

installing (2.7 liter or 2.8 liter engine)
- Remove top engine cover(s). See 03 Maintenance.

- Remove cover above air filter housing.

~ Loosen or remove turbo ram air duct clamps and remove air duct
mounting fasteners (arrows). Lift off air duct.

~ Wrap shop towel around fuel connections , then disconnect fuel

supply and return lines (1 and 2) and move fuel lines clear.

WARNING-
• The fuel system is designed to retain pressure even when the
ignition is OFF. When working with the fuel system, loosen the
fuel lines slowly to allow residual fuel pressure to dissipate.
Avoid spraying fuel. Use shop towels to capture leaking fuel.

- Disconnect hose from fuel tank evaporative control (EVAP)

valve (3) .

~ Working at right side of engine :

• Disconnect electrical connector (1) from mass air flow sensor.
• Disconnect electrical connectors (2) from ignition output stages
and move wiring clear.

- Remove air filter housing.

~ Loosen fasteners (arrows) and remove cover panel from right

cylinder head cover.

i
A2 1-004
 Cylinder Head Cover 15-5
Cylinder Head Cover (V6 Models)

<fiiiili( Working at right side of engine :

• Disconnect hose (1 ).
• Loosen hose clamp (2) .
•Detach upper section of intake line (3).
•Plug lower section of intake line.

Remove bolt securing timing belt guard from cylinder head cover.

Disconnect electrical connectors from ignition coils and remove

coils . See 28 Ignition System.

NOTE-
• 2.8 liter engine: Remove spark plug wires.

- Detach crankcase breather from cyl inder head cover.

- Remove cylinder head cover.

<fiiiili( Installation is reverse of removal ; note the following :

• Replace cylinder head cover gasket and spark plug well gasket .
•Seal end points of joints (arrows) between bearing caps and
cylinder head . Apply small quantity of sealant (D 454 300 A2 or
equivalent) at four end points.
•Tighten cylinder head cover fasteners in crisscross pattern ,
starting from middle fasteners.

Tightening torque
Cylinder head cover to cylinder head (M6) I 10 Nm (7 ft-lb)

Left cylinder head cover, removing and

installing (3.0 liter engine)
- Remove front and rear engine upper covers . See 03 Maintenance.

<fiiiili( Remove cover (1) in engine compartment (left side).

15-6 Cylinder Head Cover
Cylinder Head Cover (V6 Models)

~ Remove coolant reservoir mounting fastene r (arrow).

• Disconnect electrical connector from coolant level sensor at
bottom of reservoir.
•Move reservoir aside. Leave coolant hoses con nected .

~ Remove timing belt guard mounting fasteners (arrows) from left

cylinder head cover.

- Disconnect electrical connectors from ignition co ils and remove

coils . See 28 Ignition System .

~ Working above left cylinder head :

• Detach crankcase breather (arrow) from cylinde r head cover.
•Unscrew cylinder head cover bolts in sequence, 12 to 1.
• Remove cylinder head cover.

- Installation is reverse of removal; note the following:

• Replace cylinder head cover gasket and spark plug we ll gasket.
• Use new self-locking fasteners .
•Tighten cylinder head cover fasteners in sequence, 1 to 12 .

Tightening torques
A15-0679 I Cylinder head cover to cylinde r head (M6) 10 Nm (7 ft-lb)
(use new fasteners)
Timing belt guard to cylinde r head cover (use 6 Nm (53 in-lb)
new fasteners)
 Cylinder Head Cover 15-7
Cylinder Head Cover (V6 Models)

Right cylinder head cover, removing and

installing (3.0 liter engine)
- Remove front and rear engine upper cover(s) . See 03
Maintenance.

~ Remove air filter housing cover (1) in engine compartment (right

side).

~ Remove air duct mounting bolts (arrows) at lock carrier (radiator

support frame). Remove air duct (1 ).

~ Workin g in right side of engine compartment:

• Disconnect fuel tank evaporative control (EVAP) valve (1) at air
filter housing .
•Disconn ect electrical harness connector (2) at mass air flow (MAF)
sensor.
• Remove engine intake air duct (3) together with MAF sensor.
• Unclip air filter housing clips (arrows) . Lift air filter housing out.
15-8 Cylinder Head Cover
Cylinder Head Cover (V6 Models)

Working above right cylinder head :

• Remove dipstick mounting bolts (1 and 3).
• Disconnect secondary air injector hose (4).
•Pull dipstick guide tube (2) out of oil pan. Swing forward for
removal .

A 15-0752 I
~ Remove timing belt guard mounting fasteners (arrows) from rig ht
cylinder head cover.

- Disconnect electrical con nectors from ignition coils and remove

coils. See 28 Ignition System .

~ Working above right cylinder head:

•Detach crankcase breather (arrow) from cylinder head cove r.
• Unscrew cylinder head cover bolts in sequence , 12 to 1.
• Remove cylinder head cover.

- When reinstalling cylinder head cover, note the following :

• Replace cylinder head cover gasket and spark plug well gasket.
• Use new self-locking fasteners .
•Tighten cylinder head cover fasteners in sequence , 1 to 12.

Tightening torques
10 4 6 12 A1 5-0682 I Cylinder head cover to cylinder head (M6) 10 Nm (7 ft- lb)
(use new fasteners)
Timing belt guard to cylinder head cover (use 6 Nm (53 in-lb)
new fasteners)
 Cylinder Head Cover 15-9
Cylinder Head Cover (VB Models)

Raise car and support safely.

WARNING -
• Make sure the car is stable and well supported at a ll times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove engine lower cover. See 03 Maintenance.

Replace dipstick guide tube 0-ring gasket. Insert guide tube into oil
pan , then secure fasteners to cylinder head cover.

Tighteni ng torque

Dipstick guide tube to cylinder head cover 10 Nm (7 ft-lb)

CYLINDER HEAD COVER (V8 MODELS)

The illustrations in this section illustrate work on a 2000 A6 with VS
engine. The procedures are similar on other normally aspirated VS
models.

On the biturbo RS6 engine (engine code BCY), the left cylinder head
cover can be removed with the engine installed. Right cylinder head
cover removal , however, requires engine rem oval.

Left cylinder head cover,

removi ng and installing (VB models)
Remove top engine cover(s). See 03 Maintenance .

<fiiiiii( Remove coolant reservoir mounting fasteners (arrows).

• Disconnect electrical connector from coolant level sensor at
bottom of reservoir.
•Move reservoir aside. Leave coolant hoses co nnected .

<fiiiiii( Working above left cylinder head:

• Detach breather hoses (1 and 2 ).
• Remove ignition coil bracket mounting bolts (3).
• Disconnect ignition coil connectors (4 ) .
• Remove ignition coil mounting bolts (5 ) and remove coils.

- Remove cylinder head cover.

15-10 Cylinder Head Cover
Cylinder Head Cover (VB Models)

~ Installation is reverse of removal ; note the following :

• Replace cylinder head cover gasket and spark plug well gasket.
• Apply small quantity of sealant (D 454 300 A2 or equivalent) to
cylinder head cover sealing points (arrows) .

~ Tighten cylinder head cover fasteners in sequence, 1 to 12 .

Tightening torques

Cylinder head cover to cylinder head 10 Nm (7 ft-lb)

Ignition coil to cylinder head cover 10 Nm (7 ft-lb)

A15-0389

Right cylinder head cover,

removing and installing (VB models)
Remove top engine cover(s). See 03 Maintenance.

- Remove intake air duct for air cleaner.

~ Wrap a shop towel around fuel connections , then disconnect fuel

supply and return lines (1) and move fuel lines clear.

WARNING-
• The fuel system is designed to retain pressure even when the
ignition is OFF When working with the fuel system, loosen the
fuel lines slowly to allow residual fuel pressure to dissipate.
Avoid spraying fuel. Use shop towels to capture leaking fuel.

Disconnect hose from fuel tank evaporative control (EVAP)

valve (2).
 Cylinder Head Cover 15-11
Cylinder Head Cover (VB Models)

~ Working above right cylinder head :

1 •Disconnect ignition coil connectors (1 ).
• Remove ignition coil bracket mounting bolts (2).
• Remove ignition coil mounting bolts (3) and remove coils.

Disconnect crankcase breather hose.

Remove cylinder head cover.

A1 5-0344 I

~ Installation is reverse of removal ; note the following:

• Replace cylinder head cover gasket and spark plug well gasket .
• Apply small quantity of sealant (D 454 300 A2 or equivalent) to
cylinder head cover sealing points (arrows) .

~ Tighten cylinder head cover fasteners in sequence , 1 to 12 .

Tightening torques
Cylinder head cover to cylinder head 10 Nm (7 ft-lb)
Ignition coil to cylinder head cover 10 Nm (7 ft-lb)

A15-038 9
 17-1

17 Engine-Lubrication System

GENERAL .. ... ... ... .. . . . . . ...... .. .. . . . 17-1 Oil pump .. . . . ... . .. .. ...... . ... .. .. ... . 17-5
Oil filter ...... . . . .. . .. . . . ... . .. . .. ... . . . 17-5
ENGINE OIL . ....... . ...... . ..... ... .. . .. 17-1
Oil cooler .... . .... . . .. . . .. . . . . . . . ... . .. 17-5
OIL PRESSURE . .... . .. . ... .. ........ . ... 17-2 Oil level sensor . .. ..... .. . .. ... . ....... .. 17-6
Oil pressure and oil pressure switch , testing .. . . 17-2 Oil passages and valves . ....... ... .. . ... . 17-6
Integrated oil supply . ..... .. .. . .. . . . . . . . .. 17-6
LUBRICATION SYSTEM . . .. . .. . . ... .. . .. .. . 17-3
2.7 liter engine lubrication system 17-3 TABLES
3.0 liter engine lubrication system . . ... . ... . . 17-4 a. Oil specifications ... . .. . .. . . .... . .. . .. . .. . .... . 17-1
VB engine lubrication system ..... . ..... .. .. 17-4 b. Oil capacities (approximate) . ..... . ...... . ....... 17-1

GENERAL
The rep air group covers the A6 engine lubrication system.

ENGINE OIL
Lubricating oil for engines covered by this manual are required to
meet quality and performance standards specified by Audi. These
standards are sufficiently high so that , generally, only synthetic oils
meet them . Current specifications for engine oil are shown in
Table a. For oil change procedures, see 03 Maintenance.

Table a. Oil specifications

Type:
•American Petroleum Institute API service SJ
• European industry standard ACEA A2 or ACEA A3
Viscosity grade:
•New engine SAE OW30
• At oil change SAE 5W30
• High temperature service SAE 5W40
(above 40°C or 100°F)

Approxim ate refill capacities in Table b are listed by engine code .

For engin e application and code information , see 03 Maintenance.

Table b. Oil capacities (approximate)

Oil capacity (includes oil
Engine (engine code) filter) in liters (US qt)

2.7 liter V6 (A6 , S6) (APB) 6.5 (6 .9)

2.7 liter V6 (allroad quattro)(BEL) 6.9 (7 .3)

2.8 liter V6 (AHA, ATO) 5.7 (6 .0)

3.0 liter V6 (AVK) 6.4 (6 .8)

17-2 Engine-Lubrication Syste
Oil Pressure

Table b. Oil capacities (approximate)

Oil capacity (includes oil
Engine (engine code) filter) in liters (US qt)
4.2 liter VB (A6 , S6 , RS6) 7. 6 (B.O)
(ART, AWN , BBD, BCY)
4.2 liter VB (allroad quattro)( BAS) B.5 (B.9)

CAUTIO~
• Lubricant specifications are subject to change. Consult your
authorized dealer for the latest information regarding lubricant
applications and specifications.

OIL PRESSURE
~ The oil pressure switch (F1 ) is in the oil pan at the base of the oil filter
housing .

Oil pressure and oil pressure switch, testing

~ Remove oil pressure switch and screw into oil pressu re tester
(special tool VAG 1324) .

- Screw tester into oil pan in place of oil pressure switch .

- Connect brown wire of tester to ground.

- Connect LED voltage tester (special tool VAG 15278 ) to B+ (battery

positive terminal) and to oil pressu re switch .

- Start engine and gradually increase engine speed .

•Make sure LED lights up at 1.2 - 1.6 bar (17.4 - 23. 2 psi) . If not,
replace oil pressure switch .
I V 17-0540 I
- Warm up engine so that oil pressu re is at least B0°C (1 76°F) . Read
off oil pressure at 2000 rpm and compare to specification.

Oil pressure specification

Oil pressure at 2000 rpm , oil at B0°C (176°F) I min 2.0 bar (29 psi )
 Engine-Lubrication System 17-3
Lubrication System

LUBRICATION SYSTEM

2.7 liter engine

lubrication system
1. to Oil filter and oil cooler
2. Oil pressure re lief valve
4 3. Oil retention valve
4. Restrictor
5. Oil distributor
6. Turbochargers

9 10 7. Camshaft bearing cap

-~]~
8. Oil groove

' I

~~~.!~
9. Oil retention valve
I I 10. Oil filter element
- ,~ I
11. from Oil filter and oil cooler
12. Chain tensioner
22
13. Oil pressure control valve
21
18 14. Oil pickup filter
A6041 7 005
15. Duocentric oi l pump
16. Oil pressure relief valve
17. to Oil f ilter and oil cooler
18. from Oil filter and oil cooler
19. Oil temperatu re sender
20. Oil pressure switch
21. Bypass valve
22. Bypass filter

NOTE -
• 2.8 liter engine lubrication system is similar.
17-4 Engine-Lubrication Sy tern
Lubrication System

3.0 liter engine

lubrication system
1. Camshaft bearing caps
2. Piston cooling jets
3. Oil filter housing
4 . Oil pump drive chain t ensioner
5. Balance shaft
• Driven by oil pum p gear
6. Duocentric oil pump

va engine lubrication system

1. Variable camshaft timing assemblies
2. Camshafts
3. Piston cooling jets
4. Oil filter
5. Bypass valves
6. Oil cooler
7. Oil pressure control valve
8. Duocentric oil pump

I 7

I
.ru1
8

t
A60417001
 Engine-Lubrication System 17-5
Lubrication System

Oil pump
~ V6 engine : Duocentric oil pump, chain-driven from the crankshaft, is
attached to the bottom of the crankcase and projects into the oil
sump. It is immersed completely in engine oil when oil level is
correct. This prevents the pump fro m running dry.

This oil pump design, in combination with the extremely short intake
path , assures that oil pressure builds up quickly, particularly during
cold starts.

The sheet metal chain guard encapsulates the oil pump drive chain
and sprocket and sharply reduces oil frothing .
Chain gua rd
A60417003

~ V8 engine: Oil pump is similar in design and placement.

A604 17008

Oil filter
V6 engine : Oil filter unit contains oil retention valve , filter element,
bypass filter and filter bypass valve. If filter element becomes
clogged or if oil is too thick (high viscosity), bypass valve maintains
engine lubrication .

~ V8 engine: Oil filter housing and function is similar to V6 engine , but

for space reasons a filter cartridge is used instead of paper insert.

Oil filter Alternator

cartridge bracket

A60417006

Oil cooler
2.7 liter turbocharged engine : Oil cooler unit is integrated into the
primary oil flow. The capacity and flow resistance are optimized to
allow all the oil to flow through the cooler, unlike in the normally
aspirated engine, where an oil bypass line is required .
17-6 Engine-Lubrication Sy .tern
Lubrication System

Oil level sensor

~ V8 engine : Oil level sensor functions as oil quality sensor as well .
This allows oil service interval to be calculated. An oil level warning
is displayed in the instrument cluster.

A6041 70

Oil passages and valves

Oil pressure control valve is integrated in the oil pump housing .
The oil diverted by the control valve is fed to the suction side of the
pump, thus optimizing oil pump efficiency.

Oil pressure limiting valve is another internal pressure control

valve which opens when oil pressure rises too high , as during a cold
start.

Oil retention valves prevent oil running out of the oil filter and the
cylinder heads and back into the oil sump while the engine is not
running .

Oil passage restrictorspreven t oil flooding of the cylinder heads at

high engine speeds.

Control valve for piston cooling oilopens once the oil pressure is
above 26 psi (1 .8 bar). This allows the low-viscosity engine oil to
maintain high pressure. Also, at low engine speeds piston cooling is
not necessary.

Integrated oil supply

Transverse passage
~ V6 engines installed in A6 models feature the integrated oil supply
concept. Each camshaft bearing is supplied via a passage
stemming from the cylinder head main oil gallery. The oil is fed along
a bolt bore to a transverse passage. A lubrication groove distributes
the oil throughout the camshaft bearing.

A6041 4004
 19-1

19 Engine-Cooling System

GENERAL ... .. .... . ... . .... ... ..... . .. . 19-1 3.0 LITER ENGINE COOLING SYSTEM . . . . . . 19-9
Coolant and antifreeze . . . . . . . . . . . . . . . . . . . . 19-1 Coolant pump and thermostat (3.0 liter engine) . 19-9
Warnings and Cautions ........... . ...... . 19-2 Coolant hoses and pipes (3.0 liter engine) .. .. 19-10
Coolant hose schematic (3.0 liter engine ) . . ... 19-10
2. 7 LITER ENGINE COOLING SYSTEM ...... 19-4
Cooling system components on body V8 ENGINE COOLING SYSTEM . . . . . . . . . . . 19-11
(2 .7 liter engine) . ....................... 19-4 Coolant hose schematic
Cooling system components , front of engine (4.2 liter engine , codes ART, AWN , BBO) ... 19-11
(2.7 liter engine) . ................ . ..... . 19-5 Coolant hose schematic
Cooling system components , rear of engine (4.2 liter RS6 biturbo, engine code BCY) ... 19-11
(2.7 liter engine) .... . .. .... ...... . . ... .. 19-6
COOLING SYSTEM SERVICE . . . . . . . . . . . . . 19-12
Coolant hose schematic (2.7 liter engine) ..... . 19-7
Cooling system draining , filling and bleeding .. 19-12
2.8 LITER ENGINE COOLING SYSTEM ...... 19-7 Radiator, removing and installing . .... ... ... 19-14
Cooling system components on body Coolant pump , removing and installing ...... 19-16
(2.8 liter engine) ... ....... ...... .... . ... 19-7 Coolant thermostat, removing and installing 19-17
Cooling system components on engine
(2.8 liter engine) .. .. ....... . .. . . ...... . . 19-8 TABLE
Coolant hose schematic (2 .8 liter engine) .. .. .. 19-9 a. Cooling system capacities .... ........... .. . . . ... 19-1

GENERAL
This rep air group covers the engine cooling system .

See 87 Heating and Air-conditioning for cooling system relay and

fuse locations.

Coolant and antifreeze

Cooling system capacity depends on a variety of options and
configurations. If a repair procedure includes opening the sealed
cooling system, make sure to fill and bleed the system after repairs .
See Cooling system draining, filling and bleeding in this repair
group.

Table a. Cooling system capacities

Cooling system capacity in
Engine liters (US qt)
2.7 liter V6 (APB, BEL) 6.0 (6.3)
2.S liter V6 (AHA, ATQ) S.O (S.5)
3.0 lite r V6 (AVK) S.O (S.5)

4.2 liter VS (ART, AWN , BBD) 9.0 (9 .5)

4.2 liter VS biturbo (RS6) (BCY) 12.0 (12 .7)
19-2 Engine-Cooling System
General

The cooling system is factory filled with a lifetime coolant mixture of

50% silicate-free antifreeze and 50% water. If topping up or
replacing coolant , use fresh antifreeze mixture . Aud i recommends
using G12 low-phosphate silicate-free coolant yea r-round . In an
emergency, use clear water.

~ Use a coolant hydrometer to determine antifreeze concentration .

Coolant mixture recommendations

Concentration Cold protection
50% antifreeze -35°C (-31 °F)

60% antifreeze -40°C (-40°F)

Antifreeze concentration may also be tested with a refractomete r,

special tool T10007

Do not use a higher concentration of antifreeze than a 60% mixture ,

as the heat transfer quality of the coolant decreases with higher
A604 19048
antifreeze concentrations.

Do not allow antifreeze concentration to drop below 40%.

Warnings and Cautions

Observe the following warnings and cautions when working on the
cooling system.

WARNING-
• At normal operating temperature the cooling system is
pressurized. Allow the engine to cool thoroughly (a minimum
of one hour), then cover the overflow tank pressure cap with a
cloth and open carefully to relieve system pressure slowly
• Releasing cooling system pressure lowers the boiling point of
coolant and it may boil suddenly Use heavy gloves and wear eye
and face protection to guard against scalding.
• Use extreme care when draining and disposing of engine
coolant. Coolant is poisonous and lethal to humans and pets.
Pets are attracted to coolant because of its sweet smell and
taste. Seek medical attention immediately if coolant is ingested.
 Engine-Cooling System 19-3
General

CAUTION-
• Replace sealing 0-rings and gaskets when working on cooling
system.
• When installing coolant hoses, make sure they are free of
stress and do not come into contact with other components.
Make sure arrows embossed on coola nt pipes and coolant
hoses face each other.
•Avoid adding cold water to the cooling system while the engine
is hot or overheated. If it is necessary to add coolant to a hot
system, do so only with the engine running and coolant pump
turning.
• To avoid excess silicate gel precipitation in the cooling system
and loss of cooling capacity, use Audi coolant G 12 or equivalent
silicate-free antifreeze.
• G 12 coolant is red in color. Do not mix with other coolant types.
• If the fluid in the expansion tank is brown, G 12 coolant has been
mixed with another coolant. Flush cooling system and change
coolant. See Cooling system draining, filling and bleeding
in this repair group.
• Dispose of coolant in an environmentally safe manner.
• If oil enters the cooling system, flush with cleaning agent.
• Fill the cooling system year round with frost and corrosion
protection additives included in approved coolant.
• Be sure to protect the engine against freezing to approx. -25°C
(-13 °F) . In an arctic climate, protect to -35°C (-31 °F) .
• In summe r, do not reduce antifreeze concentration below 40 %.
• In extreme a rctic conditions, do not increase the antifreeze
concen tra tion above 60%.
• Mix antifreeze with clean drinking water.
• If the radiator, heater core, cylinder head, cylinder head gasket
or engine block is replaced, completely replace the engine
coolant. Do not re use old coolant.
• Prior to disconnecting the battery, read the battery
disconnection precautions given in 00 Warnings and
Cautions .
19-4 Engine-Cooling Syste
2. 7 Liter Engine Cooling System

2.7 LITER ENGINE COOLING SYSTEM

Cooling system components

on body (2.7 liter engine)
1. Radiator
2. Mounting clip
3. Rubber insulator
4. Sealing 0-ring
5. Lower radiator hose
6. Rubber washer
7. Self-tapping screw
8. Nut, 10 Nm (7 ft-lb)
9. Fan shroud
10. 2-pin harness connector
11. Engine cooling fan (V7)
12. Fan switch 4-pin connector (F18)
13. Fan switch (F54), 35 Nm (26 ft-lb)
• Stage 1 switching temperatures:
6
on : 92° - 97° C (198° - 207° F)
off: 84 ° - 91 °C (183° - 196°F)
•Stage 2 switching temperatures :
on: 99° - 105°C (210° - 221 °F)
off: 91 ° - 98°C (196° - 208°F)
9
12
14. Sealing 0-ring
10
15. Radiator drain screw, 10 Nm (7 ft-lb)
11
A6041900 1 16. Upper radiator hose
17. Bolt, 5 Nm (44 in-lb)
18. Mounting bracket
19. Guard plate
20. Nut, 5 Nm (44 in-lb)
21. Bracket
22. Electric fan shroud
23. Electric cooling fan
 Engine-Cooling System 19-5
2. 7 Liter Engine Cooling System

Cooling system components,

1 2 3 4 front of engine (2. 7 liter
engine)
1. Thermostat cover and coolant duct
2. Sealing 0-ring
3. Thermostat
•Starts to open at 86 °C (187°F)
4. Bolt, 10 Nm (7 ft-lb)
5. Filler cap , 1.4 - 1.6 bar (20 - 23 psi)
6. Sealing 0-ring
7. Bolt, 10 Nm (7 ft-lb)
8. Coolant expansion tank
9. to Rear coo lant line
1o. Top radiator hose
11. Coolant line
12. Timing belt guard
13. Coolant pump gasket
14. Coolant pump
15. to Front coolant line
16. Bolt, 1O Nm (7 ft-lb)
17. Bolt, 25 Nm (18 ft-lb)
18. Lower coolant line
19. Oil cooler
21 20 17 19 18 17
20. Bolt, 25 Nm (18 ft-lb)
21. Bolt, 10 Nm (7 ft-lb)
A19-0093
22. Accessory belt pulley
23. Bolt, 10 Nm (7 ft-lb)
24. Viscous fan
25. Viscous fan clutch
• Left-hand threads
• 37 Nm (27 ft-lb) using special spanner
3312
26. Bolt, 25 Nm (18 ft-lb)
27. Viscous fan bracket
28. Lower rad iator hose connection

- ' -

' j
19-6 Engine-Cooling System
2. 7 Liter Engine Cooling System

Cooling system components,

1 2 4 5 6 7 8 rear of engine (2. 7 liter
engine)
1. to Front coolant hose
2. Front coolant hose
3. Bleeder, 20 Nm (15 ft-lb)
4. Coolant line
5. Auxiliary coolant pump
6. Coolant hose
7. Right coolant line
8. Banjo bolt, 35 Nm (26 ft-lb)
•Replace coppe r sealing 0 -rings
9. Engine coolant temperature (ECT)
sensor (G62)
10. Retaining clip
11. to Heater core
21
12. Rear coolant line
20 13. Bolt, 10 Nm (7 ft-lb)

19 14. Right coolant line

15. Banjo bolt, 35 Nm (26 ft-lb)
18
• Re place copper seali ng 0 -rings
16. Banjo bolt, 35 Nm (26 ft-lb)
• Rep lace copper seali ng 0 -rings
17. Left coolant line
18. from Heater core
17 A 19-0094 19. to Front coolant hose
20. Coolant line
21. Bleeder, 20 Nm (15 ft-lb)
22. Banjo bolt, 35 Nm (26 ft-lb)
• Repl ace coppe r sealing 0 -rings
23. Left coolant line
24. Auxiliary coolant pump sensor, 2-pin
25. to Oil cooler
26. Retaining clip
 Engine-Cooling System 19-·7
2.8 Liter Engine Cooling System

2 3 Coolant hose schematic (2.7 liter engine)

1. Lower radiator hose
2. Cylinder head and engine block
3. Right turbocharger
4. Auxiliary coolant pump
5. Heater core
6. to Heater core
7. Left turbocharger
8. Rear coolant line
9. Coolant expansion tank cap
10. Coolant expansion tank
11. Oil cooler
12. Radiator
13. Coolant pump
14. Thermostat cover and duct

11 10 9 A 19-0092

2.8 LITER ENGINE COOLING SYSTEM

Cooling system components on body
(2.8 liter engine)
1. Radiator
2. Mounting clip
3. Rubber insulator
4. Sealing 0-ring
5. Lower radiator hose
6. Rubber washer
7. Self-tapping screw
8. Nut, 10 Nm (7 ft-lb)
9. Fan shroud
10. 2-pin harness connector
11. Engine cooling fan (V7)
12. Fan switch 4-pin connector (F18)
13. 2-stage fan switch (F54) , 35 Nm (26 ft-lb)
• Stage 1 switching temperatures:
on: 92° - 97°C (198° - 207°F)
off: 84° - 91 °C (183° -196°F)
11 •Stage 2 switching temperatures :
N19-0177
on : 99° - 105°C (210° - 221 °F)
off: 91 ° - 98°C (196° - 208°F)
14. Sealing 0-ring
15. Radiator drain screw, 10 Nm (7 ft-lb)
16. Upper radiator hose
19-8 Engi ne-C oolin g Syste
2. 8 Liter Engine Coolin g System

Coolin g system compo nents

1 2 3 4 5 2 on engin e (2.8 liter engine )
1. Thermo stat cover and coolant duct
2. Sealing 0-ring
3. Thermo stat
• Starts to open at 86°C (187° F)
•Openin g travel: min. 7 mm ( ~ in)
12 4. Cooling system bleeder
10 5. Bolt, 25 Nm (18 ft-lb)
6. Retainin g clip
7. Engine coolant tempera ture (ECT)
sensor (G62)
8. Rear coolant distribu tor pipe
9. Engine lifting eye
10. Bolt, 10 Nm (7 ft-lb)
11. Coolant pipe
12. Front coolant pipe
13. Cooling expansi on tank pressur e
cap
14. Sealing 0-ring
15. Coolant expansi on tank

23 16. Upper radiator hose

17. Coolant hose
18. Timing belt guard
19. Coolant pump gasket
10 5 22 21 5 N19-017 6
20. Coolant pump
21. Lower coolant pipe
22. Oil cooler
23. Belt pulley
24. Viscous fan
25. Viscous fan clutch
• Left-han d threads
• 37 Nm (27 ft-lb) using special spanner ,
VAG 3312
26. Viscous fan bracket
27. Lower radiator hose connect ion
 Engine-Cooling System 19-9
3. 0 Liter Engine Cooling System

1 2 3 4 Coolant hose schematic (2.8 liter engine)

1. Lowe r radiator hose
2. Cylinder head and engine block
+- _:1

rr
I' \_2 \ 3)

I 3. Intake manifold

::~Jti'
4. from Heater core

+(i - 5. Heate r core

:: ±-1llJ ~!' ®l6)

6. to Heater core

1lf _l
7. Rear coolant pipe
8. Cool ant expansion tank
IJ-\ 'J.
JI(' Y.y:""-,,
9. Oil cooler
- I
- «· I - - I 10. Cool ant line
- , IT~, I
[1 <· ! 11. Uppe r radiator hose
I
12. Radi ator
i
13. Cool ant pump
14. Lower coolant pipe
15. Thermostat cover and duct
1 7 6 5
N 19-0 178

3.0 LITER ENGINE COOLING SYSTEM

Coolant pump and thermostat (3.0 liter engine)

5~ 1.
2.
3.
Nut, 10 Nm (7 ft-lb)
Bolt, 1 o Nm (7 ft-lb)
Cool ant pump
4. Coolant pump gasket
5. Sealing 0-ring
6. Cool ant thermostat integral with housing
7. Bolt, 1O Nm (7 ft-lb)
r,

. 'J····"
\
I j I.

4
.,

1,

I;
I A19-03 14 I
19-10 Engine -Cooling Syste
3.0 Liter Engine Cooling System

Coolant hoses and pipes (3.0 liter engine)

1. Bolt, 10 Nm (7 ft-lb)
2. Front coolant pipe
3. Bolt, 22 Nm (16 ft-lb)
4. Sealing 0 -ring
5. Right coolant pipe
6. Bolt, 1O Nm (7 ft- lb)
7. Sealing 0-ring
8. Bolt, 10 Nm (7 ft- lb)
9. Sealing 0-ring
10. Engine coolant temperatur e (ETC) sensor (G2, G62)
11. Retaining clip
12. to Heater core
13. to Coolant expansion tank
14. Connector, 20 Nm (14 ft-lb)
15. Seal
16. to Heater co re
17. Bolt, 1O Nm (7 ft-lb)
I A19-0315 I 18. Rear coolant pipe
19. Sealing 0-rings
20. Top radiator hose
21. to Oil cooler

Coolant hose schema tic (3.0 liter engine)

7 --------'-
1. Radiator
2. Bleeder, 15 Nm (1Oft-lb)
3. Coolant thermostat
4. Cylinder head and engine block
5. Throttle valve control module (J338)
6. Bleeder hole
7. Heater core
8. Coolant expansion tank
9. Oil cooler
10. Coolant pump

I A19-0268 I
 Engine-Cooling System 19-11
VB Engine Cooling System

2 3 va ENGINE COOLING SYSTEM

Coolant hose schematic
(4.2 liter engine, codes ART, AWN, 880)
1. Rear coo lant pipe
2. from Heater core (with bleeder valve)
3. to Heater core (with bleeder valve)
4. Return hose
13
5. Coolant expansion tank cap
12 6. Coolant expansion tank
11 7. Filler hose
10 8. Coolant thermostat
8 9. Radiator
10. Coolant hoses bracket
f--- 9 11. Coolant pipe between oil cooler and engine block
---~~-----------< I----

12. Oil cooler

13. Coolant pipe
14. Coolant pipe , to oil cooler
I A1 9-0002 I

Coolant hose schematic

(4.2 liter RS6 biturbo engine, code BCV)
1. Right intercooler
2. Check valve
3. Oil filter
4. Right turbocharger
5. Coolant overflow tank
6. Heate r core
7. Left turbocharger
r---:::::::::::i====i--- 8 8. After-run coolant pump (V51)
9 9. Engine
10. Check valve
11. Coolant pump
12. Coolant circulation valve
13. Left intercooler
14. Coolant thermostat
15. Radiator

15 14 I A1 9-056 1
19-12 Engine-Cooling Syste
Cooling System Service

COOLING SYSTEM SERVICE

In the procedures that follow, the 2.8 liter V6 engine is illustrated .
Other models are similar.

Cooling system draining, filling and bleeding

WARNING-
• To avoid personal injury, be sure the engine is cold before
opening the cooling system.

Remove coolant expansion tank filler cap.

- Raise car and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

- Remove lower engine cover (splash shield) . See 03 Maintenance.

- Place 5 gallon pail underneath engine.

~ Loosen hose clamp (arrow) at bottom radiator hose. Detach hose

from radiator and allow coolant to drain into pail.

~ If front bumper is off, turn drain tap (arrow) at left bottom of radiator
(left side) counter-clockwise to drain coolant.

~ Drain coolant from engine block at block drain screw (arrow).

- Using new sealing 0-ring , replace and tighten drain screw.

Tightening torque
Block drain screw to engine block 20 Nm (15 ft-lb)

Reattach lower hose to radiator. Alternatively, shut off coolant drain

tap on radiator.
 Engine-Cooli ng System 19-13
Cooling System Service

~ Thread adapter (VAG 1274/8) to coolant expansion tank and insert

extension (VAG 1274/ 10).

~ Working at heater core coolant connection:

• Loosen coo lant hose clamp at heater core
•Pull hose far enough so that bleeder hole (arrow) in coolant line is
not covered by hose.
• Fill coolant at tank until it comes out at bleeder.
• Push coolant hose on connection and tighten clamp.

~ Loosen bleeder screw on rear coolant line (arrow) below expansion

tank .
• Fill coola nt at tank until it comes out at bleeder.
• Tighten bleeder screw.

Tightening torque
Coolant bleeder screw 20 Nm (15 ft-lb)
I

~ Loosen bleeder screw on front coolant line (arrow) between power

steering pump and left cylinder head.
• Fill coolant at tank until it comes out at bleeder screw.
• Tighten bleeder screw.

Tightening torque
Coolant bleeder screw 20 Nm (15 ft-lb)
19-14 Engine-Cooling Syste
Cooling System Service

~ Remove special tools from coolant expansion tank and fill coolant to
MAX mark. Close filler cap on expansion tank.

- Set heater controls to maximum heat setting .

- Start engine and let it idle for about 10 minutes .

•Maintain engine speed of about 2000 rpm for about 5 minutes .
• Allow engine to run at idling speed until lower radiato r hose
becomes hot.

- Check coolant level and top off if necessary.

WARNING-
• When the engine is hot, the cooling system is under pressure.
Releasing cooling system pressure lowers the boiling point of
coolant and it may boil suddenly
• Cover the filler cap with a cloth and remove it carefully
• Use heavy gloves and wear eye and face protection to guard
against scalding.

Normal coolant level

Engine at operating temperature MAX

Engine cold between MIN and MAX

Radiator, removing and installing

Raise car and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove front bumper and bumper cover. See 63 Bumpers .

Drain coolant. See Cooling system draining, filling and bleeding

in this repair group.

WARNING-
• To avoid personal injury, be sure the engine is cold before
opening the cooling system.

~ Loosen hose clamps (arrow) and detach upper and lower hoses
from radiator.
 Engine-Cooling System 19-15
Cooling System Service

~ Disconnect electric cooling fan switch connector (arrow) at bottom

right of radiator.

~ Workin g in front of radiator :

• Remove electric cooling fan mounting fasteners (upper arrows), if
applicable.
• Detach power steering fluid cooler mounting screw (lower arrow).
• Use stiff wire to suspend these components in front of engine
compartment.

CAUTION-
• Do not kink steering fluid line.
• Do not disconnect steering fluid line.

~ Workin g at A/C condenser :

• Detach air cowls from radiator on left and right sides.
• Remove condenser securing bolts (hidden by cowl in photo)
•Discon nect A/C pressure switch connector.
• Lift condenser out of bracket, turn sideways and secure with stiff
wire .

CAUTION-
• Do not kink or stretch A/C refrigerant lines.
• Do not disconnect refrigerant lines.

~ Use small screwdriver tip to release two radiator retaining pins

(arrows ).

- Tip radiator forward and out.

Installation is reverse of removal.

Tightening torques
A/C condenser to radiator 10 Nm (7 ft-lb)
Electric cooling fan to radiator 10 Nm (7 ft-lb)
Power steering cooling line to radiator 10 Nm (7 ft-lb)

- After completing assembly, fill cooling system and bleed. See

Cooling system draining , filling and bleeding in this repair group.

~
I

!
19-16 Engine-Cooling System
Cooling System Service

Coolant pump, removing and installing

This procedure applies to engines with camshaft timing belt. The
timing belt drives the coolant pump. When replacing the pump, mark
both accessory belt and timing belt with direction of rotation before
removal for correct reinstallation .

CAUTIO~
• Do not allow coolant to contaminate belts.

Raise car and support safely. Remove front bumper. Place lock
carrier (radiator mounting frame in front of engine) in service
position . See 50 Body-Front.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove viscous fan and accessory belt. See 03 Maintenance.

NOTE -
• If belt is to be reused, mark direction of rotation prior to removal.

Remove timing belt. See 13 Timing Belt, Crankshaft Pulley, Rear

Main Seal.

NOTE-
• If belt is to be reused, mark direction of rotation prior to removal.

Drain coolant. See Cooling system draining, filling and bleeding

in this repair group.

WARNING-
• To avoid personal injury, be sure the engine is cold before
opening the cooling system.

~ Working at front of engine, remove timing belt tensioner (1) and idler
pulley (2).

~ Working at coolant pump :

• Remove timing belt guard mounting nuts (1) (2 nuts) .
•Remove coolant pump mounting bolts (2) (9 bolts).
• Remove coolant pump.

- Prior to installing new pump, clean gasket and sealant residue off
sealing surface of engine block.

- Installation is reverse of removal. Use new coolant pump gasket.

Tightening torques
Timing belt guard to coolant pump 10 Nm (7 ft-lb)
Timing belt idler to engine block 40 Nm (28 ft-lb)
Timing belt tensioner to engine block 20 Nm (14 ft-lb)
 Engine-Cool ing System 19-17
Cooling System Service

Coolant thermostat, removing and installing

Mark both accessory belt and timing belt with direction of rotation
before removal for correct reinstallation.

CAUTION-
• Do not allow coolant to contaminate belts.

Raise car and support safely.

WARNING -
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove front bumper. Place lock carrier (radiator mounting frame in

front of engine) in service position . See 50 Body-Front.

Remove viscous fan and accessory belt. See 03 Maintenance.

NOTE -
• If belt is to be reused, mark direction of rotation prior to removal.

Remove timing belt. See 13 Timing Belt, Crankshaft Pulley, Rear

Main Seal.

NOTE -
• If belt is to be reused, mark direction of rotation prior to removal.

Drain coolant. See Cooling system draining , filling and bleeding

in this repair group.

WARNING -
• To avoid personal injury, be sure the engine is cold before
opening the cooling system.

<oiiiiii{ Remove thermostat cover mounting bolts (1) and remove

thermostat (4 ).

2
1
1 N1 9-0 143

<oiiiiii{ Installation is reverse of removal. Make sure of the following :

• Lubricate new thermostat sealing 0-ring with coolant.
• Install thermostat with bleeder valve (arrow) at top.

Tightening torque
Thermostat cover to engine block 10 Nm (7 ft-lb)

- Afte r completing assembly, fill cooling system and bleed. See

Cooling system draining , filling and bleeding in this repair group.

- I

' i
)
 Engine-Cooling System 19-17
Cooling System Service

Coolant therm ostat, removing and installing

Mark both accessory belt and timing belt with direction of rotation
before removal for correct reinstallation.

CAUTION-
• Do not allow coolant to contaminate belts.

Raise car and support safely.

WARNING -
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove front bumper. Place lock ca rrier (radiator mounting frame in

front of engine) in service position . See 50 Body-Front.

Remove viscous fan and accessory belt. See 03 Ma intenance.

NOTE -
• If belt is to be reused, mark direction of ro tation prior to removal.

Remove timing belt. See 13 Timing Belt, Crankshaft Pulley, Rear

Main Seal.

NOTE -
• If belt is to be reused, mark direction of rotation prior to removal.

Drain coolant. See Cooling system draining, filling and bleeding

in this repair group.

WARNING -
• To avoid personal injury, be sure the engine is cold before
opening the cooling system.

~ Remove thermostat cover mounting bolts (1) and remove

thermostat (4).

~ Installation is reverse of removal. Make sure of the following :

• Lubricate new thermostat sealing 0-ring with coolant.
• Install thermostat with bleeder valve (arrow) at top.

Tightening torque

Thermostat cover to engine block

10 Nm (7 ft-lb)

- After completing assembly, fill cooling system and bleed. See

Cool ing system draining, filli ng and bleeding in this repair group.
 20-1

20 Fuel Storage and Supply

GENERAL . ... . ...... . . .. . ........ . ...... 20-1 FUEL SYSTEM COMPONENTS . ... ..... .. . 20-10
Fuel tank capacity . ... .. . .............. .. 20-1 Fuel tank components (front-wheel drive) . . .. 20-10
Fuel pump and fuel level sender(s) . . . .. ..... 20-1 Fuel filler neck components (front-wheel drive) 20-11
On-Board Diagnostics . . . . . . . . . . . . . . . . . . . . 20-2 Fuel pump and fuel level sender components
Warnings and Cautions . ..... .... .... ..... 20-2 (front-wheel drive) ...... . ..... . . . ...... 20-11
Fuel tank components
FUEL DELIVERY TESTS . ..... . ... . . . ...... 20-3
(V6 quattro, allroad quattro) 20-12
Fuel pump power supply ......... . .. . ..... 20-4
Fuel filler neck components
Fuel pump , electrical testing ... .... ...... . . 20-4 (V6 quattro, allroad quattro) ........ ..... 20-13
Relieving system fuel pressure . .... . . ... ... 20-5 Fuel level sender components (quattro) . . .... 20-13
Fuel pump wiring (in tank) , checking .. ....... 20-5 Fuel pump components (quattro) ..... . . . ... 20-14
Fuel delivery volume , checking . . . ...... .. .. 20-6
Fuel pressure , checking .. .. .. ...... . .... .. 20-8
Residual pressure , checking . . ............. 20-9

GENERAL

This repair group covers repair information for the fuel pump and
related fuel storage and supply components.

For additional information , see :

• 03 Maintenance for fuel filter replacement
• 24 Fuel Injection
• OBD On-Board Diagnostics

Fuel tank capacity

Audi A6 models vary in body style and running gear. This affects fuel
tank capacity. The accompanying table gives approximate fuel
capacity figures for most models.

Fuel tank capacity

Front wheel drive V6 engine , allroad quattro 18 .5 US gal (70 liters)

V8 engine (not allroad quattro) 21 .6 US gal (82 liters)

Fuel pump and fuel level sender(s)

Front-wheel drive model. Fuel pump and fuel level sender are
combined in one unit in fuel tank .

Quattro model. There are three fuel level senders. Right fuel level
sende r and fuel pump are combined in one unit in fuel tank.

A604 20003
20-2 Fuel Storage and Supp y
General

On-Board Diagnostics
The fuel supply system is an integral part of the operation of the fuel
injection system. Problems such as a no-start condition , hesitation ,
or stalling may be due to poor fuel delivery. The fuel pump itself is not
directly monitored by on-board diagnostics, but the fuel pump relay
is monitored.

In case of poor fuel delivery, the fuel injection system 's attempt to
adjust for the resultant lean running condition may exceed the
system's ability to compensate. This stores diagnostic trouble codes
(DTCs) in the engine control module (ECM) memory.

~ Investigate suspected fuel pump problems with Volkswagen scan

tool or equivalent plugged into to DLC plug (inset) under left side
dashboard. See OBD On-Board Diagnostics for more information .

Warnings and Cautions

Read the following warnings and cautions before starting work on
you r fuel system .

WARNING -
• Disconnect negative (-) battery cable and cover terminal with
insulated material when working on fuel related components.
• Gasoline is dangerous to your health. Wear suitable hand, skin
and eye protection when working on fuel system. Do not
breathe fuel vapors. Work in a we/I-ventilated area .
• Fuel and fuel vapors may leak during many operations
described in this repair group. Do not smoke or create sparks.
Be aware of pilot lights in gas operated equipment (heating
systems, water heaters, etc.). Have an approved fire
extinguisher handy
• The fuel system is designed to maintain pressure in the system
after the engine is turned off. Fuel is expelled under pressure
when fuel lines are disconnected. This is a fire hazard,
especially if the engine is warm. To prevent fuel from spraying,
wrap a clean shop rag around fuel line fitting before loosening
or disconnecting it.
• Exercise extreme caution when using spray-type cleaners on a
warm engine. Observe all manufacturer recommendations.
• Prior to working on fuel-related components, unscrew the fuel
filler cap to release pressure in the tank.
 Fuel Storage and Supply 20-3
Fuel Delivery Tests

CAUTION-
• Cleanliness is essential when working on any part of the fuel
system. Thoroughly clean fuel line unions and hose fittings
before disconnecting them. Use only clean tools.
• Keep removed components clean. Seal or cover them with
plastic or paper, especially if repair cannot be completed
immediately Seal open fuel supply and return lines to prevent
contamination.
• When replacing parts, install only new, clean components.
Replace seals and 0-rings.
• Prior to disconnecting the battery, read the battery
disconnection cautions in 00 Warnings and Cautions .
• Before making any electrical tests with the ignition turned ON,
disable the ignition system. Be sure the battery is disconnected
when replacing components.
• To prevent damage to the ignition system or other OME
components, including the engine control module (ECM) ,
always connect and disconnect wires and test equipment
with the ignition OFF
• Only use digital multimeter for electrical tests.

NOTE -
• Audi identifies electrical components by a letter and/ or a number in
the electrical schematics. See EWD Electrical Wiring Diagrams.
These electrical identifiers are listed in parentheses as an aid to
electrical troubleshooting.

FUEL DELIVERY TESTS

The fuel pump delivers fuel at high pressure to the fuel injection
system . During starting , the fuel pump runs as long as the ignition
switch is in the START position and continues to run once the engine
starts. If an electrical system fault interrupts power to the fuel pump,
the eng ine does not run .

Checking fuel delivery is a fundamental part of troubleshooting and

diagnosing the DME system . Fuel pressure directly influences fuel
delivery. An accurate fuel pressure gauge is needed to make the
tests .

There are three significant fuel delivery values to be measured:

• Fuel del ivery volume-created by the fuel pump and affected by
rest rictio ns , such as clogged fuel filter.
• Fuel pressure-created by the fuel pump and maintained by the
pressure regulator.
• Residual pressure-the pressure maintained in the closed
system after the engine and fuel pump are shut off.
20-4 Fuel Storage and Suppl
Fuel Delivery Tests

Fuel pump power supply

<liiiiii( The fuel pump is powered by fuse 28 (arrow) in fuse panel at left
end of dashboard .

Fuel pump fuse ratings

1998 - 2000 fuel pump 15 A
2001 - 2004 fuel pump 20 A

<liiiiii( The fuel pump relay (arrow) is on micro central electric panel , under
left side dashboard . See 97 Fuses, Relays, Component
Locations for additional information.

Fuel pump, electrical testing

Make sure battery has at least 12 volts charge .

- Visually check fuel pump fuse and relay. See Fuel pum p power
supply in this repair group.

<liiiiii( Remove fuse 28 (arrow). Connect VAG1348/3A remote switch and

VAG1348/32 adapter cable to opening for fuse 28. Con nect other
end of adapter to battery.
• Listen carefully for fuel pump to start running . If necessary, lift up
rear seat bottom to hear fuel pump.

- Alternatively, crank engine and listen carefully for fuel pu mp to start

running.
• Fuel pump runs quietly. If necessary, lift up rear seat bottom to hear
fuel pump.

If fuel pump does not run , remove rear seat bottom , see 72 Seats .

<liiiiii( Remove fuel pump cover. Pull off (arrow) fuel pump electrical
connector.
 Fuel Storage and Supply 20-5
Fuel Delivery Tests

.;;;;;;{ Connect digital multimeter across terminals 1 and 4 of harness

connector.

- Crank engine and check voltage at fuel pump connector. If battery

voltage (12 volts) is not present , locate and repair open circuit in
wiring . See EWD Electrical Wiring Diagrams.

- If battery voltage is present, fuel pump power supply is OK . To

continue , testing , see Fuel pump wiring (in tank) , checkingin this
repair group.

4
A24-0094 I

Relieving system fuel pressure

The fuel system retains fuel pressure in the system when the engine
is OFF. To prevent fuel from spraying on a hot eng ine , relieve system
fuel pressure before disconnecting fuel lines . One method is to
tightly wrap a shop towel around fuel line fitting and loosen or
disconnect the fitting .

Fuel pump wiring (in tank), checking

Loosen fuel tank filler cap .

.;;;;;;{ Remove fuel pump cover. Mark fuel supply (A) and return (8) lines.

- Loosen or cut hose clamps and detach fuel lines from pump
assembly.

WARNING -
• Fuel will be expelled under pressure. Wrap a cloth around
fu el line to absorb any leaking fuel .

.;;;;;;{ Use special tool VAG 3217 (front-wheel drive model) or VAG 3087
(quattro model) to loosen and remove fuel tank plastic collar.

WARNING -
• Open fuel tank cap only if the tank is below J'4 full. Otherwise
large quantities of fuel escape.

A20-0121 I
20-6 Fuel Storage and Sup ly
Fuel Delivery Tests

~ Pull up fuel pump assembly flange and make sure electrical

connections between flange and fuel pump are intact.

- Reattach fuel lines using new hose clamps.

Fuel delivery volume, checking

Make sure battery has at least 12 volts charge and fuel tank is at
least % full. Make sure fuel filter is not plugged . Fuel filter
replacement is covered in 03 Maintenance.

Loosen fuel tank filler cap.

- Remove upper engine cover. See 03 Maintenance.

~ 2.7 liter V6 turbo engine: Disconnect fuel return line from fuel rail.
Connect test hose (arrow) and hold end of hose in measuring
container.

WARNING-
• Fuel will be expelled under pressure. Wrap a cloth around
fuel line to absorb any leaking fuel.

2.8 liter V6 engine: Disconnect fuel return line from fuel rail. Connect
test hose (arrow) and hold end of hose in measuring container.

WARNING-
• Fuel will be expelled under pressure. Wrap a cloth around
fuel line to absorb any leaking fuel.
 Fuel Storage and Supply 20-7
Fuel Delivery Tests

~ V8 engine with timing belt: Disconnect fuel return line from fuel rail.
Connect test hose (arrow) and hold end of hose in measuring
container.

WARNING-
• Fuel will be expelled under pressure. Wrap a cloth around
fuel line to absorb any leaking fuel.

~ VS engine with non-return fuel loop : Disconnect fuel return line from
fuel rail. Connect test hose (arrow) and hold end of hose in
measuring container.

WARNING-
• Fuel will be expelled under pressure. Wrap a cloth around
fuel line to absorb any leaking fuel.

~ Remove fuse 28 (arrow) . Connect VAG1348/3A remote switch and

VAG 1348/32 adapter cable to opening for fuse 28 . Connect other
end of adapter to battery. Operate fuel pump in this manner for 15
seconds.

- Compare quantity of fuel delivered with correct quantity indicated in

graphs below.

~
~-1- - - - -- - -
2.8 liter V6 engine : Fuel delivery plotted vs . battery voltage .
~-, - - - - - - - - -- - 500 •Minimum delivery in milliliters I 15 seconds.

-i --
- -
--
- - --
,.,.,...-
~
7
~ - _,.. ~ 400

300
• Engine stationery during test.

Fuel delivery volume (battery @ 12 volts)

- ~~ ·- ~ -
200
2.8 liter V6 engine I approx . 375 ml (13 oz) I 15 sec
i,.....----
I
-+- I

I
- - f--- ~ - - 100

9 10 11 12 13 V**)
A20-0260 I
20-8 Fuel Storage and Suppl
Fuel Delivery Tests

3
cm / 15s*)
~ 2.7 liter V6 engine, VS engine : Fuel delivery plotted vs . battery
- - ~

i
~
-

600
voltage.
•Minimum delivery in milliliters I 15 seconds.
,__.
- - - .....-:: 1 500
• Engine stationery during test .

__.. ............ -~ I
400 Fuel delivery volume (battery @ 12 volts)
L..--'"' - -
I -
I 2. 7 liter, 3.0 liter, VS engine / approx . 525 ml (18 oz) I 15 sec
300
----- I
- - - - - - -L
I
200 If fuel delivery volume is below specifications :

I
• Check for fuel line obstructions.
9 10 11 12 13 V**) • Replace fuel pump.
A20-0296 I
Fuel pressure, checking
- Make sure battery has at least 12 volts charge and fuel tank is at
least 1,4 full. Make sure fuel filter is not plugged. Fuel filter
replacement is covered in 03 Maintenance.

Loosen fuel tank filler cap.

Remove upper engine cover. See 03 Maintenance.

- Make sure fuel delivery volume is correct. See Fuel delivery

volume, checking in this repair group.

~ Connect fuel pressure tester (VAG 131 Sor equivalent) between fuel
supply line and fuel rail using adapters 131 S/7, 131S/10 and
131S/1 3.
•Make sure VAG 131 S shut off valve is between fuel supply line and
gauge.

WARNING-
• Fuel will be expelled under pressure. Wrap a cloth around
fuel line to absorb any leaking fuel.

- Open pressure tester shut-off valve (lever parallel to direction of

flow) .

Detach and plug vacuum line from fuel pressure regulator to intake
manifold.

CAUTIO~
• During the following test, do not let the engine run
unnecessarily with the vacuum hose removed, since the higher
fuel pressure causes enrichment of the fuel air mixture. The
richer mixture could exceed the oxygen sensor control limits
and set a OTC.

- Switch off electrical consume rs (rear defrost, A/C, etc.) .

- Start engine and allow it to idle. Measure fuel pressure.

NOTE -
• If, during the pressure test, fuel leaks from the fuel pressure
regulator vacuum connection, replace the regulator.
 Fuel Storage and Supply 20-9
Fuel Delivery Tests

Fuel pressure specification s

2. 7 liter biturbo V6 , all VS idling :

• Fuel pressure regulator vacuum line approx. 3 .5 bar (51 ps i)
connected
• Fuel pressure regulator vacuum line approx . 4 .0 bar (58 psi)
discon nected

2.8 liter or 3.0 liter V6 idling :

•Fuel pressure regulator vacuum line approx. 3 .2 - 3 .8 bar
connected (46 - 55 psi)
• Fuel pressure regulator vacuum line approx . 3 .8 - 4.2 bar
disconnected (55 - 61 psi )

If specified value is not obtained , replace fuel pressure regulator and

repeat pre ssure test.

If specifi ed value is still not attained , check the following and replace
if necessary:
• Fuel pump strainer in fuel tank
•Fuel pump
• Fuel filter
• Fuel su pply lines (check for damage or kinking)

If specified value is exceeded , check return line for damage or

kinking ; replace if necessary.

Reattach vacuum hose to fuel pressure regulator and check for fuel
pressu re drop when vacuum is applied.
•Check that fuel pressure drops by about 0.5 bar (7 psi) .

If pressure does not change , proceed as follows :

•Check vacuum line for leaks, cracks or damage.
•Check vacuum line for obstruction ; remove hose at fuel pressure
regul ator and blow into it.
• If th ere is no leak and vacuum connection has no obstruction ,
repl ace fuel pressure regulator.

Residual pressure, checking

After fue l pressure test is finished , leave pressure gauge attached .

- Check residual pressure 10 minutes after shutting off engine .

Residual pressure specification s

Warm engine approx. 3 .0 bar (44 psi )
Cold engine
• 2.7 liter biturbo V6 , all VS approx . 2.5 bar (36 ps i)
• 2.8 liter or 3.0 liter V6 approx . 2.2 bar (32 psi )

NOTE -
• The higher pressure with a warm engine, caused by fuel
expansion, is normal.
20-10 Fuel Storage and Suppl
Fuel System Components

- If specified value is not attained :

• Start engine and , after fuel pressure stabil izes , switch ignition OFF.
•Close shut-off valve on VAG 1318 pressure tester.

- If residual pressure does not drop, check for the following :

• Leak at connection between pressure gauge and fuel lines
• Leak at fuel reservoir line
• Fuel pump malfunctioning

- If the residual pressure drops excessively, check for the following :

• Fuel pressure regulator malfunction
• Injectors leaking
• Pressure gauge leaking behind shut-off valve

- To remove pressure gauge, close shut-off valve , loosen VAG 1318/7

adapter and drain excess fuel by opening shut-off valve into fuel-
resistant container.

FUEL SYSTEM COMPONENTS

Fuel tank components

9 10 11 (front-wheel drive)
1. Fuel return line
2. Fuel supply line
3. M8 x 35 mm bolt with washer
• Secures fuel tank filler neck and
ground wire
4. Overflow hose
5. Rubber cup
6. Retaining ring
7. Fuel tank filler cap
8. Seal
3 ---~ 9. Filler neck ground wire
•Make sure wire end contacts bare
metal of body
• Resistance to ground approx . OD
10. Vent line
11. Vent line
12. Vent line
13. Fuel tank
1 -~
14. Mounting straps
15. M8 x 28 mm bolt with washer
• 23 Nm (17 ft-lb)

A20-0516
 Fuel Storage and Supply 20-11
Fuel System Components

Fuel filler neck components (front-wheel drive)

4 5 6 7
1. Filler neck and expansion tank
2. 0-ring
3. Gravity valve
4. Tank protection valve
5. Filler neck ground wire
6. Sealing ring
7. 0 -rin g
8. Vent valve
9. Hose coupling
10. to Fuel tank evapo rat ive canister

I A20-0517 I

Fuel pump and fuel level sender components

8
(front-wheel drive)
1. Fuel level sender

~ 9
2.
3.
Fuel strainer
Fuel pump module
4. Fuel tank flange
5. Fuel return line
4 6. Fuel supply line
7. Ru bber sea l
8. Fuel tank flange collar nut
3 9. Harness connector
10. Seali ng 0-rings
11. Fuel return line
~ 10
2 12. Accumulator housing
11

I A20-0 579 I
20-12 Fuel Storage and Sup ly
Fuel System Components

Fuel tank components

~---------15 (V6 quattro, all road quattro)
11'-----tt------ 16 1. MB x 2B mm bolt with washer

~~~~~~~~~17
• 23 Nm (17 ft-lb)
2. Speed nut

12--------
~~TL-.>-18 3. Heat shield
4. Support bracket
5. Mounting strap
11---------- 6. Fuel return line

10-------. 7. Vent line

rJ;~~<®» '?;j/j~~~--- 20
•to Fuel tank evaporative control
canister valve (N80)
9-------~
• Remains attached when tank is
removed
8--- B. Fuel supply line

7-~ 9. Nut
• 2 Nm (18 in-lb)
10. Filler neck heat shield

21 11. Vent line

•to Fuel tank evaporative control
canister
• Remains attached when tank is
removed
12. MB x 2B mm bolt with washer
• 25 Nm (18 ft-lb)
• Secures fuel tank filler neck and
ground wire
A20-0225 I 13. Overflow return hose
14. Fuel tank filler cap
15. Seal
16. Retaining ring
17. Rubber cup
1B. Filler neck ground wire
•Make sure wire end contacts bare
metal of body
• Resistance to ground approx . 00
19. Filler neck and expansion tank
20. Vent line
21. Fuel tank
 Fuel Storage and Supply 20- 13
Fuel System Components

6 7
Fuel filler neck components
(V6 quattro, allroad quattro)
1. Nut, 2 Nm (18 in-lb)
2. Heat shield
3. Hose
4. Hose connections for vent lines
5. Hose connection
f - - - - - - -13
6. Hose connection for fuel tank vent
7. Grou nd connection
8. Ru bber cup
9. Retai ning ring
10. Seal insert
11. Seal
12. Fu el tank filler cap
13. Overflow return line
14. Fill er neck and expansion tank
15. M8 x 30 mm bolt with washer, 23 Nm (17 ft-l b)

I A20- 0227 II

Fuel level sender components (quattro)

5
1. Fu el supply line to accumulator
4 2. Accu mulator
3. Fu el distributor
• Attached to accumulator with 3 tabs
• Push toward left to release
4. Left side fuel level sender wire
5. Ri ght side fuel level sende r (G)
•Attached to accumulator with tabs
6. W ire ties
7. Fu el tank flange coll ar lock
8. Ru bber seal
9. Fu el tank flange and left side fuel level sender (G169)
10. Sucti on jet pump

I A20- 0226 I
20-14 Fuel Storage and Suppl
Fuel System Components

Fuel pump components (quattro)

1. Fuel distributor
• Attached to accumulator with 3 tabs
• Push toward left to release
2. Accumulator
3. Left side fuel level sensor wire
4. Right side fuel level sensor wire
5. Harness connector
6. Fuel return line
7. Fuel supply line
8. Fuel tank flange collar lock
9. Rubber seal
10. Fuel tank flange
11. Fuel pump module (G6)
•To remove:
-Release fuel distributor
-Disconnect return line from distributor
12. Sealing 0 -rings
13. Fuel return line
14. Fuel strainer

/
J ...,

;(/
 21-1

21 Tu rbocharger and lntercooler

GEN ERAL . . .. ... .... .. ... .. . . . . .. . . . .... 2 1-1 Turbocharger cooling circuit .... . .. ..... . ... 21 -2
Turbocharger system .. . .. .. .... .. ... .. .. . 21 -1 Warnings and Cautions . .. . .. . .... .. ... . ... 21-2

GEN ERAL
This repair group provides basic turbocharger and intercoole r
info rmation.

Tu rbocharger boost pressure is not adjustable and separate parts

for the turbocharger are usually not available from Audi .

Turbocharger system
<iiiiii( Major com ponents of the turbocharger system in 2.7 liter biturbo V6
engine are as follows :
1. Air filter housing
2. Mass airflow sensor
3. Turbocharger
4. Air distributor
5. Charge air intercooler
6. Fresh air intake
7. Throttle valve control module

A6042 1001

<iiiiii( The exhaust-driven turbocharger turbine spins at very high speed

V Oil supply
and is precisely balanced. The turbine bearings are cooled and
lubricated by engin e oil with additional cooling supplied by a
connection to the engine cooling system .

Turbo boost pressure is controlled by the wastegate bypass

regulator valve operated by the engine control module (ECM) . When
boost pressure exceeds programmed values , the ECM opens the
wastegate to bypass some of the exhaust gases around the turbine .
21-2 Turbocharger and lnterc ler
General

Turbocharger cooling circuit

5
I 1. Coolant thermostat
3 4 6 8
2. Right turbocharger
3. Engine coolant temperature (ECT)
sensors (G2, G62)
4. After-run coolant pump (V51)
5. Heater core
6. After-run coolant pump switch (F95)
7. Left turbocharger
8. Coolant overflow reservoir

------ 9. Coolant fan switch (F18 , F54)

10. Coolant pump
11. Engine oil cooler
t l 12. Radiator

A6042 1003

<Oiiiiii( The electric after-run coolant pump (V51) keeps coolant from
overheating under high thermal load.

The after-run pump is in the engine V-angle. The after-run function is

activated only if the engine is not running . It cycles OFF after 10
After-run
- coolant minutes.
pump
switch
(F95) Warnings and Cautions
After-run
coolant WARNING-
pump
(V51) • The turbocharger and related components operate at very high
temperature. Prior to working on these components, allow the
system to cool thoroughly
_ _ _ _ _A60421004

CAUT/O~
• To prevent dust and dirt contamination, cover turbocharger
components with dust-free paper or seal them in plastic bags.
Do not use cloth material. Avoid nearby use of compressed air.
• Do not move the car or work in dusty conditions while the
turbocharger is open or removed.
• Make sure turbocharger air lines, hoses and connections are
free of oil and grease before reinstalling. When reinstalling air
connection 0 -rings, use water as an assembly lubricant.

I ,!
 24-1

24 Fuel Injection

GENERAL 24-1 3.0 LITER ENGINE MANAGEMENT

Engine management systems . .. . . ... . . .. . . 24-1 COMPONENTS . . . . ..... . ... ... . ... . . . . . . 24-14
Bosch Motronic 7.1 sensors and actuators Engine compartment (3.0 liter V6 engine) .. . . 24-14
(2.7 liter turbo V6 engine) ... . ....... . . .. . 24-3 Electrical connectors
Evaporative control system (EVAP) ....... . . . 24-4 (3.0 liter V6 engine compartment) . .. . . ... . 24-16
On-board diagnostics . ... .. . .. . .. . .... .... 24-5
Warnings and Cautions . . .... . .. .... . .... . 24-5
va ENGINE MANAGEMENT COMPONENTS
(ENGINE CODES ART, AWN, BBD) .. . .. . 24-18
ENGINE MANAGEMENT FUSES AND RELAYS 24-6 Engine compartment
(VS engine , codes ART, AWN , BBD) . .. ... 24-1 S
ENGINE CONTROL MODULE (ECM) ..... . .. 24-7
ECM , access ing 24-7 va ENGINE MANAGEMENT COMPONENTS
(ENGINE CODE BAS, ALLROAD QUATTRO) 24-20
PEDAL SENSORS AND SWITCHES .. .... . . . . 24-S
Engine compartment (VS engine , code BAS) . 24-20
Accelerator pedal sensors . . . . . . . . . . . . . . . . . 24-S
Engine management component details
Cruise control switches .. .. . . .. . .. . ... . .. . 24-S (VS engine , code BAS) . . . .. . ... . .. . . .. . 24-21
2. 7 LITER ENGINE MANAGEMENT va ENGINE MANAGEMENT COMPONENTS
COMPONENTS .. . ... . ........ .. . . . .... ... 24-9 (ENGINE CODE BCV , RS6) . .... .. ...... 24-22
Engine compartment (2 .7 liter turbo V6 engine) 24-9 Engine compartment (VS engine , code BCY) . 24-22
Engine management component details Additional engine compartment components
(2.7 liter tu rbo V6 engine) ... ... ... .. . ... 24-11 (VS engine, code BCY) ...... . . ......... 24-24
2.8 LITER ENGINE MANAGEMENT Engine management component details
COMPONENTS . . ... . ........ . .......... . 24-12 (V8 engine , code BCY) ..... .... .. .. . . . . 24-26
Engine compartment (2.S liter V6 engine) . ... 24-12

GENERAL
This repair group covers basic engine management information .

See also the following :

• 03 Maintenance for engine air filter and fuel filter replacement
• 20 Fuel Storage and Supply for fuel pressure and delivery tests
• 26 Exhaust System for oxygen sensor and secondary air
injection information
• 28 Ignition for ignition system repairs
• OBD On-Board Diagnostics for information on OBD II system
and diagnostic trouble codes (DTCs)

Engine management systems

~ The Motronic (or DME) engine management system uses an
electronic engine control module (ECM) to control fuel injection and
ignition functions . Audi A6 models are equipped with versions of the
Motronic system.
24-2 Fuel Injection
General

Bosch Motronic M5.9.2 is used in 1998 - 1999 A6 models with 2.8

liter V6 engine. The main features of the M5 .9.2 system are :
• Cylinder sequential fuel injection (separate fuel mixture control fo r
each cylinder)
• Electronically mapped ignition system
•Adaptive heated oxygen sensor control , two sensors per catalytic
converter (4 in all)
• Camshaft sensors and variable exhaust camshaft timing
•Hot film mass air flow sensor with integral intake air temperature
sensing
• Idle air control
• Adaptive fuel metering
• Adaptive throttle position sensor
• Adaptive ignition knock control
•Check Engine light (malfunction indicator light or MIL) for
emissions re lated and catalytic converter damaging faults
• Secondary air injection
• Evaporative emissions control (EVAP) with fuel tank leak detection
• On-board diagnostics

Bosch Motronic ME 7.1 is used in 1999 and later V8 models and

2000 and later V6 models . The major differences between Bosch
ME 7.1 and Bosch M5 .9.2 are :
• Electronic throttle control (EPC)
•Individual ignition coils at each cyl inder (direct ignition)
• Turbocharge r control (if equipped)
• Integrated cruise control
• A/C compressor control
• Control module communication using CAN-bus

Bosch Motronic ME 7.1.1 is an upgrade over the older system .

Engine management systems and major features are summarized I

in Table a. ME 7.1 is shown schematically in Bosch Motronic 7.1

sensors and actuators (2.7 liter turbo V6 engine) I

Table a. Engine management system (Motronic) applicc: ions

a; c: u
a..
"C
en >o
...ro-
·- .~ w
0 CJ c: >
0 ... "C ~ c:
·- c: Q) "C CJ
Q)
c: Q)
E
...«I c: 0
e ·u;
·- 0
~ O'l
Q) :E O'l
c:
::cro .cen O'l
c:
c:
0
.~
c:
0 Q) -
... - 0
ti :::: .!::
O'l
c:
"C
0
~

0 Q; ·-
E-
Q)
.::&. ·-
-
«I c:
«I
·-
c:
·- E ·-
ro ro E
CJ·- Q)
- .c 0
e c:
~
Q),!::
w u 2> w~ .!: E ,a > CJ:;:: CJ) «I w- CJ
2.7 liter V6 bitu rbo APB 2000 - 2003 A6 , M Dtron ic ME 7.1 TLEV Yes Exhaust Yes Yes
allroad quattro
BEL 2003 - 2004 A6 , M Dtronic ME 7.1 LEV Yes Exhaust Yes Yes
allroad quattro
2.8 liter V6 AHA 1998 - 1999 A6 M Dtro nic M5.9 .2 TLEV Yes Exhaust Yes No
ATQ 2000 - 2002 A6 M Dtronic ME 7.1 LEV Yes Exhaust Yes Yes
3.0 liter V6 AVK 2002 - 2004 A6 M Dtronic ME 7.1 .1 ULEV Yes Intake Yes Yes
Exhaust
 Fuel Injection 24-3
General

Table a. Engine management system (Motronic) applications

6a..
Q)
c:
·a, Q)
Qi
"O

E
0 ()
·- c:
c: 0
g.(ij
I/)
c:
0 ;:_
·- 0
~ tJ'l
.>.

Q)
~
"O
:E
·-
O')
c:
Q) -
-ro
:0 .c: O')
C1l I/) c:
>-
ro-
"O ()
c: -~
0 c:
g
i-. · - .~
c:
0
i-. -
~
Q) -

t> :::: .;::

0

c:
"O
0
~ 0 i-.
·-Cl>
Ero -
C1l c:
C1l
·-
c:
·- E ·-
ro ro E () ·-
Q) .!:::::
Q) e c:
w u ~ ~ §! w (..) EE .2 > () ~ en ro -
w -
.c: 0
()
4.2 liter V8 ART, AWN , 1999 - 2004 A6 , S6 Motronic ME 7.1 LEV or Yes Yes Yes Yes
880 TLEV

4.2 liter VS BAS 2003 - 2004 Motronic ME 7.1.1 LEV Yes Yes Yes Yes
allroad quattro

4.2 liter VS biturbo BCY 2003 - 2004 RS6 Motronic ME 7.1.1 TLEV No Yes Yes Yes

NOTE -
• Audi identifies electrical components by a letter and/or a number in
the electrical schematics. See EWD Electrical Wiring Diagrams.
Th ese electrical identifiers are listed in parentheses as an aid to
electrical troubleshooting.
• Electronic throttle control (EPC) is also referred to as E-gas.

Bosch Motronic 7.1 sensors

3-
and actuators (2.7 liter turbo
V6 engine)
1. Engine control module (ECM)(J220)
4- ~ --~ 2. DLC (OBD 11) plug

Sensors
3. Mass airflow sensor (G70)
4. Engine speed sensor (G28)
5. Exhaust camshaft sensors (G40,

IL......
G163)
6. Oxygen sensors (G39, G108, G130,
7- G131)
7. Throttle valve control module (J338)
8-
~ Throttle angle sensors (G187, G188)
~ ---~ -21
9 -

10 -
~---------·
~ -----·--·-
\r ~ - 22
Throttle drive (G186)
8. Intake air temperature sensor (G42)
9. Engine coolant temperature (ECT)

12-r · ·-
11-====-~ _ ___,,. sensor (G2, G62)
2
10. Charge air pressure sensor (G31)

~
11. Knock sensors (G61 , G66)
'-.,o L ~ 12. Throttle position sensor (G79)

c;;;;,-o;;;
-- 24
~p Accelerator pedal position sender

1! . r,ll--~~5 (G185)
13. Exhaust temperature sensors (G235 ,

14-~~ ~~ ~26 G236)

· ~---~~ 14. Brake light switch (F)
1 5 - - ~-----
I '------8 ---27 Cruise control vacuum switch (F47)
16 28 15. Clutch vacuum switch (F36)
A60424001
16. Auxiliary signals
24-4 Fuel Injection
General

Bosch Motron ic 7 .1 sensors

and actuators (2. 7 liter turbo
VG engine) (continued)
Actuators
4- ~--- 17. Fuel pump (G6)
Fuel pump relay (J17)
18. Fuel injectors (N30 - N33, N83 - N84)
19. Ignition power output stage (N122,
N192)
20. Ignition coils (N, N128, N158, N163,
N164, N189)
21. Fuel tank evaporative control (EVAP)
canister purge regulator valve (N80)
22. Wastegate bypass regulator (N75)
23. Throttle valve control module (J338)
Throttle drive (G186)
24. Camshaft adjustment valves (N205,
N208)
2 -23 25. Turbocharger recirculating valve
(N249)

~
~
j!;~24
26. Oxygen sensor heaters (Z19, Z28,
Z29, Z30)
27. Electronic throttle (EPC) warning

rJL-25 light (K132)

28. Auxiliary signals
~~ ~26
· ----~~
1 - - - -8---:27
16 28
A60424001

Evaporative control system (EVAP)

The evaporative control system is designed to prevent fuel system
evaporative losses from venting into the atmosphere . The
Leak detection evaporative system allows control and monitoring of evaporative
pump (LOP)
losses by the on-board diagnostic (080 II) software incorporated in
the ECM.

~ The system includes :

• Carbon canister to store evaporated fuel.
• Plumbing to duct vapor from the fuel tank overflow reservoir to the
carbo n canister and from the canister to the intake manifold .
• Leak detection pump (LOP) (illustrated for 1998 2.8 liter A6) to
A60424003 monitor the integrity of the evaporative control system .

The fuel overflow reservoir and associated valves are in the rear of
the right rear fender, behind the wheel housing liner. The leak
detection pump is under the front of the same fender.
 Fuel Injection 24-5
General

On-board diagnostics
Most components and functions of the Motronic system are
monitored by on-board diagnostics (OBD 11) software in the engine
control module (ECM). If faults and malfunctions are detected , one
or more diagnostic trouble codes (DTCs) may be set.

~ In case of an emissions related fault or malfunction considered

catalyst-damaging , the Check Engine light (malfunction indicator
light or MIL) or EPC light is illuminated .

~ Access fault memory with VAG scan tool or equivalent plugged into
the DLC plug (inset) under left side dashboard. See OBD On-
Board Diagnostics for more information.

NOTE -
• After engine management system tests or repairs, the ECM may
recognize a malfunction and store a OTC. Therefore perform the
following after ending tests and repairs:
-Use VAG scan tool or equivalent to check OTC memory
-Erase OTC memory
-Reset or erase diagnostic data .
-Generate readiness code.
•After engine management system tests or repairs, the engine may
start, run for a short period and then cut out because the electronic
anti-theft immobilizer disables the ECM. In such cases:
-Use VAG scan tool or equivalent to check OTC memory
-Adapt ECM.

Warni ngs and Cautions

Read the following warnings and cautions before starting work on
the fuel injection system .

WARNING -
• Disconnect negative (-) battery cable and cover terminal with
insulated material when working on fuel related components.
• Gasoline is dangerous to your health. Wear suitable hand, skin
and eye protection when working on the fuel system. Do not
breathe fuel vapors. Work in a well-ventilated area.
• Do not smoke or create sparks around fuel. Be aware of pilot
lights in gas operated equipment (heating systems, water
heaters, etc.). Have an approved fire extinguisher handy.
• The fuel system is designed to maintain pressure in the system
after the engine is turned off Fuel is expelled under pressure
when fue l lines are disconnected. This is a fire hazard,
especially if the engine is warm. To prevent fuel from spraying,
wrap a clean shop rag around fuel line fitting before loosening
or disconnecting it.
• Exercise extreme caution when using spray-type cleaners on a
warm engine. Observe all manufacturer recommendations.
• Prior to working on fuel-related components, unscrew the fuel
filler cap to release pressure in the tank.
24-6 Fuel Injection
Engine Management Fuses and Relays

CAUTION-
• Cleanliness is essential when working on any part of the fuel
system. Thoroughly clean fuel line unions and hose fittings
before disconnecting them. Use only clean tools.
• Keep removed components clean. Seal or cover them with
plastic or paper, especially if repair cannot be completed
immedia tely Seal open fuel supply and return lines to prevent
contamination.
• When replacing parts, install only new, clean components.
Replace seals and 0-rings.
• Prior to disconnecting the battery, read the battery
disconnection cautions in 00 Warnings and Cautions.
• Before making any electrical tests with the ignition turned ON,
disable the ignition system. Be sure the battery is disconnected
when replacing components.
• To prevent damage to the ignition system or other electronic
components, including the engine control module (ECM),
always connect and disconnect wires and test equipment
with the ignition OFF
• Only use a digital multimeter for electrical tests.

ENGINE MANAGEMENT FUSES AND RELAYS

To gain access to fuse and relay panels, see 97 Fuses, Relays ,
Component Locations.

~ Dashboard fuse panel:

• Fuse 28: Fuel pump
1998 - 2000: 15A
2001 - 2004: 20A
•Fuse 29: Engine control module (ECM)
1998 - 2000: 30A
2001 - 2004 : 20A
• Fuse 32: Engine control module (ECM) 20A
• Fuse 34: Fuel injectors 15A

~ Under left dashboard:

• 13-fold relay and fuse panel :
1. Secondary air pump fuse 50A
2. Starter interlock relay (J207) , manual transmission
Park I neutral position (PNP) relay (J226) , multitronic (CVT)
transmission
• Micro central electric panel:
3. Fuel pump relay (J17)

NOTE-
• 1998 - 2000 models: Fuel pump relay also powers fuel injectors.
 Fuel Injection 24-7
Engine Control Module (ECM)

~ E-box , left rear engine compartment in plenum chamber :

• Fuse 5 : Engine control module (ECM) 15A
1a 4a
•Fuse 7: Secondary air pump 40A
• Relay 1 b: Coolant circulation pump relay (J 151 )
• Relay 2 : Secondary air pump relay (J299)
• Relay 3 : Engine control module (ECM) relay (J271 )

NOTE-
• 2004 3.0 liter V6 engine illustrated.

~ 8-fold relay and fuse panel , under left dashboard :

1. Engin e cooling fan relay (high speed )
2. Engin e cooling fan control module fuse SA
3. Engine cooling fan fuse 60A

ENGINE CONTROL MODULE (ECM)

ECM, accessing
- Open engine hood and remove plenum chambe r cover.

~ Remove electronics box (E-box) cover retaining bolts (arrows) . Lift

off cover.

~ Use sm all screwdriver to pry off ECM hold-down clip at sides

(arrows).
24-8 Fuel Injection
Peda l Sensors and Switches

PEDA L SENS ORS AND SWIT CHES

Accelerator pedal sens ors

~ Throttle position sensor (G79) and accele rator position
sensor
(G185) (arrow )

NOTE -
Motronic
• These compo nents are shared by models with Bosch
with electro nic throttle
ME 7. 1 and later (engine manag ement
control or EPC).

Cruise control switc hes

~ Pedal switches:
1. Clutch vacuum switch (F36)
2. Brake light switch (F)
Cruise control vacuum switch (F47)

Steerin g .
Cruise control stalk switch replace ment is covered in 48

1
2
A6042400 8
 Fuel Injection 24-9
2. 7 Liter Engine Management Components

2.7LITER ENGINE MANAGEMENT

COMPONENTS

Engine compartment (2.7 liter

5 8 9 11 14 turbo V6 engine)
~~
(/; ®-, 1. Oxygen sensor harness connector
~~1 \~ ' .·J
I
• Right bank oxygen sensor (G 130) and
heater (Z29) behind catalytic
1 2 3 4 6 7 10 converter
• 4-pin green
2. Oxygen sensor harness connector
•Left bank oxygen sensor (G131) and
heater (Z30) behind catalytic
converter
• 4-pin green
3. Oxygen sensor harness connecto r
•Right bank oxygen sensor (G39) and
heater (Z~ 9) in front of catalytic
converter.
• 4-pin black
4. Right knock sensor (G61) harness
connector
• 3-pin
5. Engine coolant temperature (ECT)
I
sensor (G62)
i ii • On coolant pipe behind right cylinder
bank
6. Wastegate bypass regulator val v e
25 24 (N75)
7. Fuel tank evaporative control (E VAP)
canister purge regulator valve (NBO)
8. Exhaust temperature sensor, right
23 21 20 (G235)
• Right rear of intake manifold
•Automatic transmission: Ganged with
left exhaust temperature sensor
(G236) at thi s location
9. Secondary air injection solenoid
valve (N112)
• Only on vehicle with automatic
transmission
10. Secondary air injection pump motor
(V101)
•Only on vehicle with automatic
transmission
11. Exhaust temperatu re sensor, left
(G236)
• Left rear of intake manifold
•Automatic transmission: Ganged with
right exhaust temperature sensor
(G235) at right rear of intake manifold
24-10 Fuel Injection
2. 7 Liter Engine Management Component

Engine compartment (2.7 liter

5 8 9 11 14 turbo V6 engine)
(continued)
12. Turbocharger recirculating valve
(N249)
1 2 3 4 13. Fuel pressure regulator
14. Left camshaft sensor (G163)
15. Secondary air injection pump relay
(J299)
• Only on vehicle with automatic
transmission
16. Engine control module (ECM) (J220)
17. Engine speed sensor harness
connector
• 3-pin grey
18. Left knock sensor (G66) harness
connector
• 3-pin
19. Oxygen sensor harness connector
• Left bank oxygen sensor (G 108) and
heater (Z28) in front of catalytic
converter
• 4-pin black
20. Left camshaft adjustment valve
(N208)
25 24 21. Throttle valve control module (J338)
•Throttle drive (G186)
•Throttle valve angle sensors (G187,
23 21 20 19 18 G188)
I A24-0326 22. Charge air pressure sensor (G31)
• In rubber elbow before throttle valve
control module
23. Right camshaft sensor (G40)
24. Left bank ignition coils power output
stage (N192)
25. Right bank ignition coils power
output stage (N122)
 Fuel Injection 24-11
2. 7 Liter Engine Management Components

26. Right camshaft adjustment valve

26 (N205)
27. Right bank oxygen sensor (G39) and
1r~fil1 heater (Z19)
( ='
• In front of catalytic converter
/
27 28 29 30 31
28. Knock sensor (G61)
29. Knock sensor (G66)
30. Engine speed sensor (G28)
• In transmission bellhousing , above
flywheel or torque plate
31. Left bank oxygen sensor (G108) and
heater (Z28)
• In front of catalytic converter
32. Left bank ignition coils (N163, N164,
N189)
33. Left bank fuel injectors (N33, N83,
N84)
34. Intake air temperature (IAT) sensor
(G42)
• Under front of intake manifold, near
throttle valve control module
35. Intake air temperature harness
connector
• 2-pin
36. Right bank fuel injectors (N30 - N32)
38 37 36 34 33 32 37. Right bank ignition coils (N, N128,
N158)
38. Mass airflow sensor (G70)

35 A24-0327

Engine management component details

(2.7 liter turbo V6 engine)
~ 2.7 liter turbo V6 with automatic transmission: Exhaust temperature
sensor modules ganged to right of intake manifold:
1. Right bank exhaust temperature sensor module (G235)
2. Left bank exhaust temperature sensor module (G236)
24- 12 Fuel Injection
2.8 Liter Engine Man agem ent Com pone s

~ Exhau st manifold:
1. Exhau st tempe rature senso r
2. Oxygen senso r before cataly tic conve rter

2.8LITE R ENG INE MAN AGE MEN T

COM PON ENT S

Eng ine com part men t (2.8 liter

8 9 10 VG engi ne)
1 2 3 4 5 6 7
1. Oxyg en senso r harne ss conne ctor
• Right bank oxygen sensor (G 130) and
heate r (Z29) behind catalytic
conve rter
• 4-pin green

2. Oxyg en senso r harne ss conne ctor

• Left bank oxyge n sensor (G 131) and
heate r (Z30) behind catalytic
conve rte r
• 4-pin green

3. Oxyg en senso r harne ss conne ctor

• Right bank oxygen sensor (G39) and
heate r (Z19) in front of catalytic
conve rter.
• 4-pir. black

4. Knoc k senso r (G61) harne ss

conn ector
5. Seco ndary air inject ion solen oid
valve (N112 )

6. Intake air tempe rature (IAT) senso r

(G42)

7. Oxyg en senso r harne ss c onne ctor

• Left bank oxygen sensor (G 108) and
heate r (Z28) in front of catalytic
conve rter
• 4-pin black

15 14 13 12 8. Engin e speed senso r harne ss

conne ctor
I A24-0 132 I • 3-pin grey
9. Left knock senso r (G66) harne ss
conne ctor
 Fuel Injection 24-13
2.8 Liter Engine Management Components

10. Electronics box (E-box)

•Engine control module (ECM) (J220).
16 17 18 19 20 21 See ECM, accessing in this repair
group .
• Secondary air injection pump relay
(J299). See Engine Management
Fuses and Relaysin this repair group .
11. Left camshaft adjustment valve
(N208)
12. Right camshaft sensor (G163)
13. Right bank oxygen sensor (G39) and
heater (Z19)
• In front of catalytic converter
14. Ground cable
•to Right engine mount
15. Mass airflow sensor (G70)
16. Fuel tank evaporative control (EVAP)
canister purge regulator valve (N80)
17. Engine coolant temperature (ECT)
sensor (G62)
•On coolant pipe behind right cylinder
bank
18. Throttle valve control module (J338)
•Throttle drive (G186)
• Throttle plate angle sensor (G 187)
•Throttle position sensor (G69)
•Closed throttle position switch (F60)
19. Intake manifold tuning valve
29 28 27 26 25 24 23 22 (change-over valve) (N156)
A24-0127 I 20. Fuel pressure regulator
21. Engine speed sensor (G28)
• In transmission bellhousing , above
flywheel or torque plate
22. Left camshaft sensor (G40)
23. Left bank oxygen sensor (G108) and
heater (Z28)
• In front of catalytic converter
24. Left knock sensor (G66)
25. Ignition coils and power output stage
26. Right knock sensor (G61)
27. Fuel injectors (N30 - N33, N83, N84)
28. Right camshaft adjustment valve
(N205)
29. Secondary air injection pump motor
(V101)
24- 14 Fuel Injection
3.0 Liter Engine Man agem ent Com pone n 's

3.0LITE R ENG INE MAN AGE MEN T

COM PON ENT S

Eng ine com part men t (3.0 liter

1 2 3 4 5 6 7 8 9 V6 engi ne)
1. Fuel tank evapo rative contr ol (EVAP )
canis ter purge regul ator valve (N80)
2. Mass airflo w senso r (G70)
• Includ es intake air temperature (IAT)
senso r (G42).

3. Right exhau st cams haft senso r

(G300 )
4. Right intake cams haft senso r (G40)
5. Brake boost er press ure senso r
(G294 )
•Auto matic transm ission vehicle
6. Left intake cams haft senso r (G163)
7. Left exhau st cams haft senso r (G301 )
8. Left bank ignitio n coils with powe r
outpu t stage (N292 , N323, N324)
9. Elect ronic s box (E-bo x)
• Engin e control module (ECM) (J220 ).
See ECM, acces sing in this repair
group .
• Secon dary air injection pump relay
--------~--- - (J299) . See Engin e Mana geme nt
Fuses and Relay s in this repair group .
•Seco ndary air injection pump fuse
(S130 )

16 15 14 13 12 11 10 10. Brake syste m vacuu m pump (V192 )

11. Left intake cams haft adjus tment
A24-0 445
valve (N208 ), exhau st cams haft
adjus tmen t valve (N319)
12. Left bank fuel inject ors (N33, N83,
N84)

13. Right bank fuel inject ors (N30 - N32)

14. Right intake cams haft adjus tment
valve (N205 ), exhau st cams haft
adjus tmen t valve (N318)
15. Right bank ignitio n coils with powe r
outpu t stage (N70, N127 , N291)
16. Seco ndary air inject ion pump (V101 )
 Fuel Injection 24-15
3. 0 Liter Engine Management Components

17. Right bank oxygen sensor (G39) and

17 18 19 20 21 22 23 24 25 26 27 28 29 30 heater (Z19)
• In front of catalytic converter
18. Harness connectors
• Right rear engine compartment
•See Electrical connectors (3.0 liter
V6 engine compartment) in this
/ ~II/'- J
repair group.
19. Right bank oxygen sensor (G130)
and heater (Z29)
• Behind catalytic converter
20. Engine coolant temperature (ECT)
sensor (G62)
•On coolant pipe behind right cylinder
bank
21. Throttle valve control module (J338)
•Throttle drive (G186)
•Throttle plate angle sensors (G187 ,
G188)
22. Secondary air injection solenoid
valve (N112)
- 23. Engine speed sensor (G28)
__ _c:l~~-/-1 1]\
- )
24. Harness connectors
• Left rear engine compartment ,
underneath coolant overflow tank
•See Electrical connectors (3.0 liter
V6 engine compartment) in this
37 36 35 34 33 32 31 repair group.

A24-0429 25. Accelerator pedal switches

•See Pedal Sensors and Switchesin
this repair group .
26. Fuel pump relay (J17) under
dashboard
• See Engine Management Fuses and
Relays in this repair group.
24-16 Fuel Injection
3. O Liter Engine Management Component

Engine compartment (3.0 liter

17 18 19 20 21 22 V6 engine) (continued)
27. Brake pedal switches
•See Pedal Sensors and Switchesin
this repair group .
28. Clutch pedal switch
•See Pedal Sensors and Switches in
this repair group .
29. Instrument cluster warning lights
•See On-board diagnostics in th is
repair group .
30. Left bank oxygen sensor (G131) and
heater (Z30)
• Behind catalytic converter
31. Left bank oxygen sensor (G108) and
heater (Z28)
• In front of catalytic converter
32. Fuel pressure regulator
33. Left knock sensor (G66)
• Underneath intake manifold
34. Intake manifold tuning valve
(change-over valve) (N156)
35. Right knock sensor (G61)
• Underneath intake manifold
36. Ground cable to right engine mount

37 36 35 34 33 31
A24-0429

Electrical connectors
(3.0 liter V6 engine compartment)
~ Right rear engine compartment:
1. 4-pin harness connector, green
Right bank oxygen sensor (G 130) and heater (Z29) behind
catalytic converter
2. 6-pin harness connector, black
Right bank oxygen sensor (G39) and heater (Z19) in front of
catalytic converter
3. 3-pin harness connector, blue
Knock sensor (G66)
4. 3-pin harness connector, black
Terminal 50
 Fuel Injection 24-17
3. 0 Liter Engine Management Components

~ Left rear engine compartment , underneath coolant overflow tank :

1. 6-pin harness connector, black
Left bank oxygen sensor (G108) and heater (Z28) in front of
catalyti c converter
2. 3-pin harness connector, grey
Engine speed sensor (G28)
3. 3-pin harness connector , blue
Knock sensor (G66)
4. 2-pin connector
Right camshaft adjustment

~ Rear of right cylinder head:

1. Exh aust camshaft sensor (G300) harness connecto r
2. Intake camshaft sensor (G40) harness connector

~ Rear of left cylinder head :

1. Intake camshaft sensor (G 163) harness connector
2. Exhaust camshaft sensor (G301) harness connector

~ Intake manifold tuning valve (change-over valve) (N156) connector

(arrow)
24- 18 Fuel Injection
Codes ART, AWN, 880 )
VB Engine Management Components (E gine

va ENGINE MANAGEMEN T COM PON ENT S

AWN, 880 )
{EN GIN E COD ES AR T,
Eng ine com part men t
12 13 (V8 eng ine, cod es ART, AWN,
BBD )
1. Fuel tank evap orativ e contr ol (EVAP)
14 15 16 canis ter purge regul ator valve (N80)
2. Righ t knoc k sens or (G61) harne ss
conn ector
• 3-pin

3. Oxyg en sens or harne ss conn ector

• Right bank oxyge n senso r (G 130) and
heate r (Z29) behin d catalytic
conve rter
• 4-pin green

4. Oxyg en sens or harne ss conn ector

• Right bank oxyge n senso r (G 131) and
heate r (Z30) behin d catalytic
conve rter
• 4-pin green
5. Mass airflo w sens or (G70)
• Includ es intake air temperature (IAT)
senso r (G42).

6. Oxyg en sens or harne ss conn ector

• Right bank oxygen sensor (G39) and
heate r (Z19) behind catalytic
conve rter.
• 4-pin

7. Cam shaft adjus tmen t valve (N205)

24 23 22 20 19 18 17 8. Fuel press ure regul ator

A24-0 268 9. Engin e coola nt temp eratu re (ECT)

sens or (G62)
• On coola nt pipe behind right cylind er
bank
 Fuel Injection 24-19
VB Engine Management Components (Engine Codes ART, AWN, 880)

10. Throttle valve control module (J338)

12 13 •Throttle drive (G186)
•Throttle plate angle sensors (G1 87 ,
G188)
7 8 9 10 11 14 15 16 11. Secondary air injection solenoid
valve (N112)
12. Oxygen sensor harness connector
•Left bank oxygen sensor (G108) and
heater (Z28) in front of catalytic
converter
• 4-pin
13. Engine speed sensor (G28) harness
connector
• 3-pin
14. Left camshaft sensor (G163)
15. Secondary air injection pump relay
(J299)
• E-box, left rear eng ine compartment in
air plenum . See Engine Management
Fuses and Relaysin this repair group .
16. Engine control module (ECM) (J220)
• E-box , left rear engin e compartment in
air plenum . See ECM , accessing in
this repair group .
17. Left bank ignition coils with power
output stages
18. Left knock sensor (G61) harness
connector
24 23 20 19 18 17 • 3-pin
A24-0268 19. Left camshaft adjustment valve
(N208)
20. Intake manifold tuning valve
21. Intake manifold tuning valve
22. Right camshaft sensor (G40)
23. Right bank ignition coils with power
output stages
24. Secondary air injection pump motor
(V101)
•Underneath engine , behind right
corner of front bumper

~ Intake manifold tuning valve (change-over valve ) actuation:

1. to Vacuum reservoir
2. Vac uu m unit, stage 3
3. Secon dary air injection solenoid (N112)
4. Ch eck-valve
5. Intake manifold tuning valve (N261 )
6. Vacuum unit, stage 2
7. Intake manifold tuning valve (N156)
24-20 Fuel Injection
VB Engine Management Components (E gine Code BAS, al/road quattro)

va ENGINE MANAGEMENT COMPONENTS

(ENGINE CODE BAS, ALLROAD QUATTRO)

Engine compartment (VB

engine, code BAS)
1. Fuel tank evaporative control (EVAP)
canister purge regulator valve (N80)
2. Mass airflow sensor (G70)
•Includes intake air temperature (IAT)
sensor (G42) .
3. Right rear engine compartment
harness connectors
• See Engine management
component details (V8 engine, code
BAS) in this repair group .
4. Right camshaft adjustment valve
(N205)
5. Right camshaft sensor (G40)
6. Engine coolant temperature (ECT)
sensor (G62)
7. Throttle valve control module (J338)
•Throttle drive (G186)
•Throttle plate angle sensors (G 187,
G188)
8. Oil pressure switch (F1)
9. Fuel pressure regulator
10. Left camshaft sensor (G163)
11. Left rear engine compartment
harness connectors
19 18 17 16 15 14 13 • See Engine management
component details (V8 engine, code
A24-0601
BAS) in this repair group .
12. Left camshaft adjustment valve
(N208)
13. Left bank ignition coils w ith power
output stages
14. Left knock sensor (G198, G199)
harness 3-pin connector
15. Secondary air injection solenoid
valve (N112)
16. Intake manifold tuning valve
(change-over valve) (N156)
17. Right knock sensor (G61, G66)
harness 3-pin connector
18. Right bank ignition coils with power
output stages
19. Secondary air injection pump motor
(V101)
 Fuel Injection 24-21
VB Engine Management Components (Engine Code BAS, al/road quattro)

Engine management component details

(V8 engine, code BAS)
<liiiiii{ Right rear engine compartment harness connectors :
1. 4-pin harness connector
Right bank oxygen sensor (G 130) and heater (Z29) behind
catalytic converter
2. 4-pin harness connector
Right bank oxygen sensor (G39) and heater (Z19) in front of
catalytic converter
3. Starter and alternator connector
4. 4-pin harness connector, brown
Left bank oxygen sensor (G131) and heater (Z30) behind
catalytic converter

<liiiiii{ Left rear engine compartment harness connectors , beh ind coolant
expansion tank:
1. 4-pin harness connector
Left bank oxygen sensor (G108) and heater (Z28) in front of
catalytic converter
2. 3-pin harness connecto r
Engine speed sensor (G28 )
3. 2-pin harness connector
Left camshaft adjustment
4. 4-pin harness connector
Left bank oxygen sensor (G131 ) and heate r (Z30) behind
catalytic converter

<liiiiii{ Rear of engine :

1. Left camshaft adjustment valve (N208)
2. Left camshaft sensor (G163)
3. Oil pressure switch (F1)
4. Throttle valve control module (J338)
5. Engine coolant temperature (ECT) sensor (G62)
6. Right camshaft sensor (G40)
7. Right camshaft adjustment valve (N205)

<liiiiii{ Front of engine :

1. Intake manifold tuning valve (change-over valve) vacuum unit
2. Knock sensor (G61)
3. Knock sensor (G66)
4. Intake manifold tuning valve (change-over valve) (N156)
5. Secondary air injection solenoid (N112)
6. Knock sensor (G198)
7. Knock sensor (G199)
24-22 Fuel Injection
VB Engine Management Components (E gine Code BCY, RS6)

~ Fuel tank evaporative emission control (EVAP) canister purge

regulator valve (N80) (arrow)

va ENGINE MANAGEMENT COMPONENTS

(ENGINE CODE BCV, RS6)
Engine compartment (VS
1 2 4 5 6 7 8 91011121314 15 16 engine, code BCV)
1. Right bank ignition coils with power
output stages (N70, N127, N291 ,
N292)
2. Right bank secondary air injection
mechanical combination valve
3. Right bank fuel injectors (N30 - N33)
4. Right camshaft adjustment valve
(N205)
5. Fuel pressure regulator
6. After-run coolant pump (V51)
connector
7. Turbocharger recirculating valve
(N249) connector
8. Knock sensor 1 (G61) connector
• 3-pin
9. Secondary air injection solenoid
(N112)
10. Intake air temperature (IAT) sensor
(G42)
11. Knock sensor 3 (G198) connector
• 3-pin
12. Engine coolant temperature (ECT)
23 22 21 20 sensor (G62)
13. Left camshaft sensor (G163)
14. Left bank fuel injectors (N83 - N86)
A24-0610
15. Left bank secondary air injection
mechanical combination valve
16. Left bank ignition coils with power
output stages (N323 - N326)
 Fuel Injection 24-23
VB Engine Management Components (Engine Code BCY, RS6)

17. Left camshaft adjustment valve

1 5 6 7 8 16 (N208)
18. Knock sensor 2 (G66) connector
• 3-pin
19. Left bank turoocnaryer recirculation
valve (mechanical)
20. Turbocharger recirculation va ive
(N249)
21. Throttle valve control module (J338)
•Throttle drive (G186)
•Throttle plate angle sensors (G187 ,
G188)
22. Right bank turbocharger
recirculation valve (mechanica l)
23. Right camshaft sensor (G40)

A24-0610
24-24 Fuel Injection
VB Engine Management Components (E , ine Code BCY, RS6)

Additional engine
1 2 3 4 5 6 7 8 9 10 11 2 13 14 15 16 17 compartment components
(VS engine, code BCV)
1. Secondary air injection pump motor
(V101)
2. Fuel tank evaporative control (EVAP)
canister purge regulator valve (N80)
3. Oxygen sensor harness connector
• Right bank oxygen sensor (G 130) and
heater (Z29) behind catalytic
converter
• 4-pin green
4. Oxygen sensor harness connector
•Left bank oxygen sensor (G131 ) and
heater (Z30) behind catalytic
converter
• 4-pin brown
5. Oxygen sensor harness connector
• Right bank oxygen sensor (G39) and
heater (Z19) in front of catalytic
converter.
• 4-pin black
6. Right bank oxygen sensor (G39) and
heater (Z19)
• In front of catalytic converter
24 23 22 21 20 19 18 7. Right bank oxygen sensor (G130)
and heater (Z29)
• Behind catalytic converter

A24-617 8. Wastegate bypass regulator valve

(N75)
9. After-run coolant pump (V51)
10. Left bank oxygen sensor (G108) and
heater (Z30)
• In front of catalytic converter
11. Left bank oxygen sensor (G131) and
heater (Z30)
• Behind catalytic converte r
12. Right exhaust temperature sensor
(G235)
•Brown
13. Left exhaust temperature sensor
(G236)
•Black
14. Electronics box (E-box)
•Secondary air injection pump relay
(J299)
• Coolant circulation pump relay (J 151 ).
See Engine Management Fuses and
Relays in this repair group .
 Fuel Injection 24-25
VB Engine Management Components (Engine Code BCY, RS6)

15. Engine control module (ECM) (J220)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 •See ECM, accessing in this repair
group .
16. Oxygen sensor harness connector
• Left bank oxygen sensor (G 108) and
heater (Z28) in front of catalytic
converter
• 4-pin
17. Engine speed sensor (G28)
connector
• 3-pin grey
18. Engine speed sensor (G28)
19. Knock sensor 3 (G198)
•Underneath intake manifold at cylinder
7 water jacket
20. Knock sensor 2 (G66)
• Underneath left exhaust manifold at
cylinder 6 water jacket
21. Left electrohydraulic engine mount
solenoid (N145)
22. Charge air pressure sensor (G31)
23. Knock sensor 1 (G61)
• Underneath intake manifold between
cylinders 2 and 3
24. Right electrohydraulic engine mount
24 23 22 21 20 19 18 solenoid (N144)

A24-617
24-26 Fuel Injection
Code BCY, RS6 )
VB Engine Managem ent Com pone nts (E gine

Eng ine man agem ent com pon ent deta ils
(VB engi ne, code BCV )
~ Fuel pump control module (J534 ) (1 )
• Right rear of veh icle
cove r next to rear
•In a cavity on a level with C-pilla r underneath
seat backrest (at right rear seat belt reel)

~ Engine speed sensor (G28) (1) and vehicle speed senso r (2)
 26-1

26 Exhaust System

GENERAL 26-1 V-8 engine exhaust system components

(allroad quattro , engine code BAS) .. . . .. . . . 26-7
Exhaust manifolds , catalytic converters
and oxygen sensors . . . . . . . . . . . . . . . . . . . . 26-1 V-8 engine exhaust system components
(RS6, engine code BCY) .. ... . .. . .. . . . . . . 26-8
On -board di agnostics .. . .. ....... ........ . 26-2
Warn ings and Cautions .. . .. .. . . . .. .. . .. .. 26-2 EXHAUST SYSTEM
COMPONENT REPLACEMENT . . .... .... . . .. 26-9
EXHAUST SYSTEM DIAGRAMS .... .. ..... . 26-3
Exhaust system , installation details . . .. ... . .. 26-9
2.8 lite r engine exhaust system components
(front ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-3 Oxygen sensor, replacing . . . . . . .. .. . . . .. . 26-1 o
2.7 liter or 2.8 lite r engine exhaust system components SECONDARY AIR INJECTION ... . .... . . . . . 26-1 O
(rear, fron t-wheel drive) . ..... . . ... . .. ... . 26-4 Secondary air injection system schematic .. . . 26-1 O
2.7 liter or 2.8 liter eng ine , VB engine (engine codes Secondary air injection fuse and relay .. . . ... 26-11
ART, AWD , 880) exhaust system components
Secondary air injection pump (V101) .. . . . . . . 26-11
(rea r, quattro) . . . ... . . . . .. . ..... . . .. ... 26-4
Combination valve . . . . . . . . . . . . . . . . . . . . . . 26-12
3.0 liter eng ine exhaust system components
(front-wheel drive) .. ...... ... . . . . . . ..... 26-5 Secondary air injection solenoid (N112) ..... 26-12
Vacuum reservoir ... . . . . .... ... . .. . .. . . . 26-13
3.0 lite r eng ine exhaust system components
(quattro) . ......... ... . . . . .... .. ... .. . 26-6

GENERAL
This repair group covers muffler, catalytic converter and oxygen
sensor replacement. Also included is a description of the secondary
air injection system .

See 24 Fuel Injection for engine management power supply fuse

and relay locations.

Exhaust manifolds, catalytic converters and

oxygen sensors
<liiiiii{ The 2 .7 liter turbocharged engine exhaust manifolds are insulated
double-walled elbows .This design leads to lower engine
compartment temperature and quicker exhaust system heat-up.

In 2 .7 liter, 3 .0 liter, VS allroad quattro and RS6 models, a

preliminary catalytic converter is installed in the exhaust manifold
just downstream of each turbocharger. This catalyst reaches
I operating temperature ("light-off") very quickly after a cold start. The
Turbocharger
main catalysts are further downstream , under the vehicle floo r.
26-2 Exhaust System
General

~ Oxygen sensors are threaded into the exhaust system before and
after the catalytic converters. In the interest of quicker warm-up , an
oxygen sensor with planar design is used . Due to the flat design of
the sensor and integration with the heater element, the sensor
reaches operating temperature approximately 10 seconds after
engine start-up.

element
A6042600
On-Board Diagnostics
Oxygen sensors and other components of the Motronic engine
management system are monitored by on-board diagnostics (080
II) software in the engine control module (ECM) . If engine
managements faults and malfunctions are detected , one or more
diagnostic trouble codes (DTCs) are set.

~ Access fault memory with Volkswagen scan tool or equivalent

plugged into the DLC plug (inset) under left side dashboard . See
OBD On-Board Diagnostics for more information .

Warnings and Cautions

WARNING-
• The exhaust system and catalytic converters operate at very
high temperatures. Allow components to cool before
servicing. Wear protective gloves to prevent burns. Do not
use flammable chemicals near a hot catalytic converter.
• Exhaust gases are colorless, odorless and very toxic. Run the
engine only in a well-ventilated area. Immediately repair any
leaks in the exhaust system or structural damage to the car
body that might allow exhaust gases to enter the passenger
compartment.
• Corroded exhaust system components crumble easily and
often have exposed sharp edges. To avoid injury, wear eye
protection and heavy gloves when working with exhaust parts.
• Heat shields protect the car occupants, undercoating, and
various other components from excessive heat. Damaged or
missing shields, particularly those above the catalytic
converter, increase interior temperatures and create a fire
hazard. Repair or replace as necessary

CAUT/O~
• Do not continue to operate the starter if the engine fails to start
promptly Extended cranking may allow excess fuel to enter
catalytic converter(s), creating a fire hazard and possibly
damaging the converter(s).
• Do not drag or bang the oxygen sensors.
• Do not bend the flexible pipe connection in the front exhaust
pipe more than 10°. Otherwise it can be damaged.
• When replacing exhaust parts, replace gaskets and fasteners.
 Exhaust System 26-3
Exhaust System Diagrams

EXHAUST SYSTEM DIAGRAMS

2.8 liter engine exhaust

2 3 system components
(front)
1. Spacer sleeve
2. Bolt
22 3. Washers
4. Bracket
5. Spact?r bushing
6. Rubber bushing
7. Nut, 25 Nm (18 ft-lb)
8. Spring
21
9. Bolt, 25 Nm (18 ft-lb)
10. to Center muffler
11. Left front pipe with catalytic
converter
12. Left bank oxygen sensor (G108) and
heater (Z28) in front of catalytic
converter
13. Oxygen sensor harness connector
• 4-pin black
14. Nut, 25 Nm (18 ft-lb)
15. Cap, 10 Nm (7 ft-lb)
16. Plug
17. Upper heat shield

7 18 19 18 7 18. Lower heat shield

A60426003 1 19. Left exhaust manifold
20. Gaskets
21. Right exhaust manifold
22. Right bank oxygen sensor (G39) and
heater (Z19) in front of catalytic
converter
23. Right front pipe with catalytic
converter
24. Right bank oxygen sensor (G130)
and heater (Z29) behind cataiytic
converter
25. Left bani< oxygen sensor (G131 )and
heater (Z30) behind catalytic
converter

NOTE -
• Audi identifies electrical components by a letter and/or a number in
the electrical schematics. See EWD Electrical Wiring Diagrams.
These electrical identifiers are listed in parentheses as an aid to
electrical troubleshooting.

-~- r ---

\
26-4 Exha ust System
Exhau st System Diagra ms

2.7 liter or 2.8 liter engine

7 exhau st system compo nents
(rear, front-w heel drive)
1. Clampin g nut, 40 Nm (30 ft-lb)
2. from Catalyti c converte r
3. Carriage bolt
4. Double clamp
5. Exhaus t hanger mountin g bolt,
25 Nm (18 ft-lb)
6. Exhaus thanger
7. Front muffler
8. Bracket
9. Exhaus thanger
10. Rear muffler
11. Double clamp
12. Cut pipe here
13. Resona tors

N26-015 1
1 11 5 6

2.7 liter or 2.8 liter engine

3 8 VB engin e (engin e codes ARr
AWD, BBD) exhau st system '
compo nents (rear, quattr o)
1. Clampin g nut, 40 Nm (30 ft-lb)
2. from Catalyti c converte r
1 2 3 4 5 6 3. Carriage bolt
4. Double clamp
5. Exhaus t hanger mountin g bolt,
25 Nm (18 ft-lb)
6 . Exhaus thanger
7. Front muffler
8. Double clamp

~
9. Cut pipe here
10. Right rear muffler
11 . Exhaus thanger

6 5
t
1 8
12. Bracket
13. Left rear muffler

N26-01 47 I
 Exhaust System 26-5
Exhaust System Diagrams

3.0 liter engine exhaust

i system components
! 14 (front-wheel drive)
15
-~
1. Exhaust hanger mounting bolt,
' I
16 23 Nm (17 ft-lb)

~. 2. Exhaust hanger
~ '
I I 3. Right front pipe with catalytic
i
converter

I
4. Nut, 27 Nm (20 ft-lb)
O I

I I
5. Right exhaust manifold
6. Gasket
7. Right bank oxygen sensor before
catalytic converter
• 55 Nm (40 ft-lb)
4 ----- 8. Left bank oxygen sensor before
3 ------~ catalytic converter
2 ------- • 55 Nm (40 ft-lb)
9. Left exhaust manifold
1 - -- ----
10. Gasket
11. Nut, 27 Nm (20 ft-lb)
12. Left bank oxygen sensor after
catalytic converter
• 55 Nm (40 ft-lb)
13. Left front pipe with catalytic
converter
I '

14. Double clamp

15. Nut, 40 Nm (30 ft-lb)
16. Right bank oxygen sensor after
catalytic converter
17. Exhaust hanger
18. Nut, 18 Nm (13 ft-lb)
19. Rear muffler
20. Double clamp
21 . Nut, 40 Nm (30 ft-lb)
22. Center muffler
23.Exhausthanger
24. Exhaust hanger mounting bolt,
23 Nm (17 ft-lb)
26-6 Exhaust System
Exhaust System Diagrams

3.0 liter engine exhaust

system components
·- ------15 (quattro)
'- - -16 1. Center muffler
~----'---- 17 2. Exhaust hanger mounti ng bolt,
23 Nm (17 ft-lb)
3. Exhaust hanger
4. Right front pipe with catalytic
converter
5. Nut, 27 Nm (20 ft-lb)
6. Right exhaust manifold
18
7. Gasket
8. Right bank oxygen sensor before
catalytic converter
5 ----~
• 55 Nm (40 ft-lb )
4 --------" 9. Left bank oxygen sensor before
catalytic converter
• 55 Nm (40 ft-lb)
10. Left exhaust manifold
11. Gasket
12. Nut, 27 Nm (20 ft-lb)
13. Left bank oxygen sensor behind
catalytic converter
- - - - 24 • 55 Nm (40 ft-lb)
14. Left front pipe with catalytic
converter
15. Double clamp
16. Nut, 40 Nm (30 ft-lb)
26 2 A26-0556
17. Right bank oxygen sensor beh ind
catalytic converter
18. Left rear muffler
19. Brace
20. Bolt
21.Exhausthanger
22. Exhaust hanger mounting bolt,
23 Nm (17 ft-lb)
23. Right rear muffler
24. Nut, 25 Nm (18 ft-lb)
25. Nut, 40 Nm (30 ft-lb)
26. Double clamp
 Exhaust System 26-7
Exhaust System Diagrams

V-8 engine exhaust system

components (allroad quattro,
, i engine code BAS)

~15 1. Center muffler

~..,;.------ 16 2. Exhaust hanger mounting bolt,

23 Nm (17 ft-lb)
3. Exhaust hanger
4. Right bank oxygen sensor behind
9 --~ catalytic converter
8 - - - - - -'t{,;a - - - -17 • 55 Nm (40 ft-l b)
7 5. Nut, 27 Nm (20 ft-lb)

6 ~7
18 6. Right exhaust manifold
7. Gasket
~- 19
5 ~~~~~~~ 8. Right bank oxygen sensor before
~- 20 catalytic converter
4 ---~
~ 21 • 55 Nm (40 ft-lb)
W~ 22 9. Nut, 27 Nm (20 ft-lb)
10. Left exhaust manifold
11. Gasket
I
I I 12. Left bank oxygen sensor before
catalytic converter
• 55 Nm (40 ft-lb)
13. Left front pipe with preliminary and
main catalytic converters
14. Left bank oxygen sensor behind
catalytic converter
• 55 Nm (40 ft-lb)
15. Double clamp
26 25 A26-0532
16. Nut, 40 Nm (30 ft-lb)
17. Right front pipe with preliminary and
main catalytic converters
18. Left rear muffler
19. Brace
20. Bolt
21. Exhaust hanger
22. Exhaust hanger mounting bolt,
23 Nm (17 ft-lb)
23. Right rear muffler
24. Nut, 25 Nm (18 ft-lb)
25. Nut, 40 Nm (30 ft-lb)
26. Double clamp
26-8 Exhaust System
Exhaust System Diagrams

V-8 engine exhaust system

components (RS6, engine
~~,~~-7---~~~- 14 code BCV)
,Q.__j.j..---!------15 1. Center muffler
-----16
2. Exhaust hanger mounting bolt,
25 Nm (18 ft-lb)

8 -----' 3. Exhausthanger

7-- 4. Nut, 50 Nm (37 ft-lb)

~~~
5. Right turbocharger
6. Gasket
7. Right bank oxygen sensor before
catalytic converter
• 55 Nm (40 ft-lb)
/ /
/ /
/ / 8. Nut, 50 Nm (37 ft-lb)
/ /
/ /
9. Left turbocharger
4 --__/ /
/
/
/

/
/
/
/
10. Gasket
/ /
/ / 11. Left bank oxygen sensor before
catalytic converter
• 55 Nm (40 ft-lb)
12. Left bank oxygen sensor behind
catalytic converter
• 55 Nm (40 ft-lb)
13. Left front pipe with preliminary and
main catalytic converters
14. Double clamp
15. Nut, 40 Nm (30 ft-lb)
16. Right bank oxygen sensor behind
252423 catalytic converter
A26-0649 • 55 Nm (40 ft-lb)
17. Rig_ht front pipe with preliminary and
main catalytic converters
18. Left rear muffler
19. Bolt, 25 Nm (18 ft-lb)
20.Exhausthanger
21. Exhaust hanger mounti ng bolt,
23 Nm (17 ft-lb)
22. Right rear muffler
23. Brace
24. Nut, 40 Nm (30 ft-lb)
25. Double clamp
 Exhaust Systern 26-9
Exhaust System Component Replacem ent

EXHAUST SYSTEM
COMPON ENT REPLACE MENT
The exhaust system is designed to be maintenance free , although
regular inspection is warranted due to the harsh operating
conditions. Under normal conditions , catalytic converters do not
require replacem ent unless they are damaged.

Exhaust system, installation details

The exhaust systems on most of the vehicles covered by this
manual are one-piece. One pipe starts at each exhaust manifold or
turbocharger and incorporates preliminary catalytic converter
(where equipped) , main catalytic converter, rnuftlers and tailpipe .

- Liberally apply penetrating oil to exhaust system fasteners and wait

several minutes before attempting removal.
VAS 6254
~ To replace damaged or rusted sections of the exhaust system , use
special tool VAS 6254 or equivalent pipe cutter.

A26-0790

~ Cut pipe at separation point (arrows) marked by depression around

circumference .

- Attach new pipe to old section using double clamp.

- Use new fasteners, clamps , mounts and gaskets when replacing

exhaust system components.

- Use high-tempera ture anti-seize compound on threaded fasteners

to make future replacement easier.

I N26-0174 I

~ Before tightening clamps and fasteners , push exhaust system

forward (in direction of vehicle motion , arrow) to preload exhaust
hangers.

Exhaust hanger preload (in direction of vehicle motion)

Distance a 5 - 11 mm (1Ji - % in)

Make sure exhaust system is not under stress and has sufficient
clearance from body.

I A26-0101
26-10 Exhaust System
Secondary Air Injection

~ Make sure double clamp bolt threads point down (arrow) . To

prevent bolt threads from becoming snagged and damaged by road
debris, make sure threads do not project below bottom edge of
clamp.

Tightening torque
Double clamp pinch fastener 40 Nm (30 ft-lb)

# A26-0241

Oxygen sensor, replacing

~ Use special tool VAG 3337 or equivalent to remove and install
oxygen sensor requires .

~
CAUTION-
• When installing oxygen sensor be sure to use high temperature
anti-seize compound that contains no silicone and is marked
"safe for oxygen sensors" (VAG part no. G 052 112 A3).

~ • Do not allow anti-seize compound to contaminate oxygen

sensor tip.

/~~/~ A60426004
- To locate correct oxygen sensor harness connector, see engine
compartment diagrams in 24 Fuel Injection .

Tightening torque
Oxygen sensor to exhaust system 55 Nm (40 ft-lb)
I

SECONDARY AIR INJECTION

6 7 The secondary air system pumps ambient air into the exhaust
stream after a cold engine start to reduce the warm-up time of the
catalytic converters and to reduce HC and CO emissions. The
engine control module (ECM) controls and monitors the secondary
air injection system .

Secondary air injection is used in normally aspirated engines, and in

turbocharged engines with automatic transmission .

Secondary air injection system schematic

c:=t:::::··········
1. from Air filter housing
3 _/ 2. Secondary air injection pump (V101 )
3. Secondary air injection pump relay (J299)
4. Engine control module (ECM) (J220)
5. Combination valve on right cylinder head
10
6. Secondary air injection solenoid (N112)
7. Check val ve
2
8. to Intake manifold
9. Combination valve on left cylinder head
10. Vacuum reservoir
I A26-052 1
 Exhaust System 26-11
Secondary Air Injection

Secondary air injection fuse and relay

~ Under left dashboard in 13-fold relay and fuse panel : Secondary air
pump fuse 50A (arrow).

For access information , see 97 Fuses, Relays , Component

Locations.

~ E-box , left rear engine compartment in plenum chamber:

1a 4a • Fuse 7: Secondary air pump 40A fuse
• Relay 2: Secondary air pump relay (J299)

A60424005

Secondary air injection pump (V101)

~ 2.7 liter V6 twin-turbo engine: At left rear of intake manifold (4).

~ 2.8 liter V6 , 3.0 liter V6, V8 engine(allroad quattro, engine code

BAS) : Underneath right front of engine , behind right end of front
bumper.
26-12 Exhaust System
Secondary Air Injection

~ VS twin-turbo engine (RS6, engine code BCV}. Right rear engine

compartment (arrow).

Combination valve
~ All engines: Rear of cylinder head (arrow) .

Secondary air injection solenoid (N112)

~ 2.7 liter V6 twin-turbo engine: At right rear of intake manifold (3).

~ 3.0 liter V6 engine: At engine compartment bulkhead behind

engine (arrow).
 Exhaust System 26-13
Secondary Air Injection

<Oiiii( V8 engine (allroad quattro, engine code BAS): Underneath front

engine cover, at front of intake manifold (arrow).

<Oiiii( V8 engine (RS6, engine code BCV): Underneath front engine

cover, at right front of intake manifold (arrow) .

Vacuum reservoir
All engines : Under left front wheel housing liner.
 _ _ _ _ _ 1 1- ---- ~----
__
 27-1

27 Battery, Alternator, Starter

GENERAL .. .......... . . ..... .. . ..... ... . 27-1 STARTER ........ . . . ... . ........ . .... . . 27-10
Cruise control . . . . . . . . .. ... .. . . . . ... .. . .. 27-2 Starter troubleshooting . . . . . . . . . . . . . . . . . . . 27-10
Battery reconnection notes .. ... .. . .. . . ... .. 27-2 Starter, removing and installing (V6 engine) ... 27-10
Troubleshooting . ......... ... . . . . . ... .. .. 27-3 Starter, removing and installing (V8 engine) . .. 27-12
Warnings and Cautions .. .. .. .. . .. ... ... .. 27-4
ALTERNATOR ........ . ......... . . .. .... 27-13
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-5 Charging system quick check . ..... . ....... 27-13
Electrolyte level , checking .. ... . . . .... . . .. . . 27-6 Alternator, removing and installing .. . .. . .... 27-14
Battery residual voltage , checking .... . .. .. . . 27-6
TABLES
Static current draw, checking ... . . . . . . . ... . . 27-6
Open circuit voltage test .... ... .... ...... .. 27-7 a. Battery, starter and alternator
troubleshooting . . . . . . . . ............ . .. . . ... . . 27-3
Electrolyte specific gravity, testing .. . ... ... .. 27-7
b. Open circuit voltage and battery charge .. . . ... .. .. 27-7
Load voltage , testing ... . . .... ..... ... . . ... 27-8
c. Specific gravity of battery
Battery charging ...... .... . . . ...... . .. . .. 27-9 electrolyte at 27°C (80°F) ... .. . ... . . . . ... . ... . . 27-8
Battery, disconnecting and connecting .. . . .... 27-9 d. Battery load current and minimum voltage . . . ... . .. 27-8
Battery, removing and installing ..... .. .. .. . 27-10 e. Charging system quick check results .. . .. . . . . ... 27-13

GENERAL
This rep air group covers battery, alternator and starter service and
repairs .

The alternator and starter are wired directly to the battery. To prevent
accidental shorts that might blow a fuse or damage wires and
electrical components , disconnect the negative (-) battery lead
before working on the electrical system .

Various versions of alternators, starters, and batteries have been

used in Audi A6 models. Replace components according to the
original equipment specification. When in doubt, consult an
authorized Audi parts department.

Also see the following :

• 03 Maintenance for engine accessory belt replacement
• 9 Electrical System-General for bus information and electrical
diagnostics
• EWD Electrical Wiring Diagrams for battery, charging system
and starter schematics

NOTE -
• The alternator is identified as generator by the vehicle
manufacturer.
27-2 Battery, Alternator, Sta :er
General

Cruise control
Cruise control functions are controlled by the engine control mod ule
(ECM). The only serviceable cruise control components are the
steering wheel , clutch and brake pedal switches and related wiring.
See the following repair groups :
• 30 Clutch for clutch pedal position switch
• 46 Brakes-Mechanical for brake light switch
• 96 Interior Lights, Switches, Anti-theftfor steering column stalk
switches

Battery reconnection notes

In addition to battery I power supply warnings and cautions in th is
repair group and in 00 Warnings and Cautions, observe the
following whenever the battery is disconnected or accidentally
discharged.
• Reset climate control.
• Reset clock.
• Reset radio presets.
•Disconnect and reconnect Audi Telematics (telephone) back-up
battery.
• Reinitialize window regulator motors.

Climate control, resetting

For climate control to operate in automatic mode, set to 75°F (23°C).

-"iiii( Press AUTO button to select automatic operation. Indicator light

(arrow) lights up.

Press - or+ buttons on each side to set temperature to 75°F (23°C).

A6048700 1a

Clock, resetting

- See owner's manual.

Radio presets, resetting

Prior to disconnecting battery, note down radio presets. To reset ,

see owner's manual.

Telematics back-up battery, reconnecting

- On vehicle equipped with Audi Telematics by OnStar®, switch OFF
emergency (back-up) battery for the Telematic control module prior
to disconnecting vehicle battery.

- After reconnecting vehicle battery, switch emergency (back-up)

battery ON.
 I

Battery, Alternator, Starter 27-3

General

Window regulator motors, reinitializing

If the battery is disconnected , the window control module loses its

memory of window current position and disables one-touch 11
automatic up I down function . To restore one-touch operation: I

Switch igniti on ON .

Use window switches to raise windows to top .

Operate each window switch in CLOSE direction for 1 second to

reinitialize one-touch operation .

- Test each window by briefly pressing switch in OPEN di rection .

Make sure window opens fully.

Troubleshooting
Tests for individual electrical system components are described
under component headings in this repai r group. Table a gives some
general troubleshooting ideas .

Table a. Battery, starter and alternator troubleshooting

Symptom Probable cause Corrective action

Engi ne does not crank . Fault in immobilizer system . Try another ignition key. If problem pers ists , contact your
authorized dealer.

Faulty automatic tra nsmission range switch. Check, and if necessary, replace automatic transmission
ra nge switch .

Engin e cranks slowly or Battery cables loose, dirty or corroded . See 03 Maintenance for battery service .
not at al l, solenoid clicks
w hen starter is operated . f--B_a_t_
te_r_
y _d_is_c_h_a_rg_e_d_._ _ _ _ __ __ _ _ --t_C_h_a_rg_e_ b_a_tt_e_ry_ a_n_
d _te_s_t_. _R_e_p_la_c_e_i_f_n_e_c_
e_s s_a_r_y_.- - - - - - j
Battery to body gro und cable loose, dirty or Inspect ground cable. Clean , tighten or replace if
corroded . necessary.

Poor connection at starter motor terminal 30 . Check connections , test for voltage at starter. Test for
voltage at clutch switch or automatic transmission range
switch. See 97 Fuses, Relays, Component Locations.

Starter motor or solenoid faulty. Test starter.

Batte ry does not stay Short ci rcuit drai ni ng battery. Test for excessive current drain with everything electrical
cha rg ed more than a few off.
days.
Short dri ving tri ps an d high electrical drain on Evaluate driving style. Where possible , reduce electrical
chargi ng system. consumption when making short trips .

Engine accesso ry belt loose, worn , damaged . See 03 Maintenance for belt service.
Batte ry faulty. Test battery and replace if necessary.

Battery cables loose, dirty or corroded . See 03 Maintenance for battery service .

Alternator faulty. Test alternator and voltage regulator.

I
27-4 Battery, Alternator, Star·er
General

Warnings and Cautions

WARNING -
• Wear goggles, rubber gloves, and a rubbe r apron when
working around the battery and battery acid (e lectrolyte) .
Battery acid contains sulfuric acid and can cause skin irritation
and burning.
• If battery acid is spilled on your skin or clothing, flush the area at
once with large quantities of water. If electrolyte gets into your
eyes, bathe them with large quantities of clean water for several
minutes and call a physician.
• Allow a frozen battery to thaw before attempting to recharge it.
• Gases given off by the battery during charging are explosive. Do
not smoke. Keep open flames away from the battery top, and
prevent electrical sparks by turning off the battery charger before
connecting or disconnecting it.
• If the battery begins gassing (boiling) violently when charging,
reduce the charging rate immediately
• Charge the battery in a well ventilated area.
• When removing the battery, disconnect negative (-) terminal
first.
• Before beginning repairs on the electrical system:
-Switch electrical consumers OFF
-Switch ignition OFF and remove ignition key

CAUTIO~
• Do not disconnect the battery cables while the engine is
running. The alternator will be damaged.
• Do not operate the alternator with its output terminal (B+ or 30)
disconnected and the other terminals connected. Do not short,
bridge, or ground any terminals of the charging system.
• Disconnect the negative (-) battery cable when working at or
near the alternator. Battery voltage is always present at the rear
of the alternator, even with ignition key OFF
• Disconnect the negative (-) battery cable first and reconnect it
last. Cover the battery post with an insulating material whenever
the cable is removed.
• Disconnect the battery cables during battery charging. This
prevents damage to the alternator and other solid-sta te
components.
• Loosen battery cell caps before charging the battery but leave
them on the battery to prevent battery acid splatter.
• Do not reverse battery terminals. Even a momentary wrong I
connection can damage the alternator or electrical components.
• Replace the battery if the case is cracked or leaking. Leaking
electrolyte can damage the car. If electrolyte is spilled, clean the
area with a solution of baking soda and water.
• Batteries are damaged by quick charging. Use quick charging as
a last alternative when slow charging is not possible.
• Do not quick charge a totally discharged battery
•Do not allow the battery charging rate to exceed 16.5 volts.
• Prior to disconnecting the battery, read the battery
disconnection precautions in 00 Warnings and Cautions .
 Battery, Alternator, Starter 27-5
Battery

CAUTIO~
• Do not store precision tools in same room where batteries are
being charged. Tools may corrode due to chemical reactions.
• Only use a digital multimeter when testing automotive electrical
components.
• Disconnecting the battery may erase the radio code and radio
presets. Note radio code and stored stations and restore them
after reconnecting the battery
• On-board computer and clock stored settings may be lost when
the battery is disconnected.
• Do not depend on the color of insulation to tell battery positive
and negative cables apart. Label cables before removing.
• If a quick charger is used to charge the battery, disconnect the
battery from vehicle electrical system and remove. This
prevents damage to paint work and upholstery

BATTERY
The battery is in the plenum chamber, behind the engine.

~ Open engine hood , release battery cover latches (arrows) and flip
cover up to gain access to battery.

~ Battery components:
1. Filler cap
2. Positive (B+) terminal
3 . Electrolyte level indicator
4. Negative plate (grey)
5. Separator (insu lator)
6. Positive plate (dark brown)
7. Negative (-)terminal

The six-cell , 12-volt lead-acid battery is rated in ampere I hours (Ah)

and cold cranking amps (CCA). The Ah rating is determined by the
average amount of current the battery can deliver over time without
A604 2700 1
dropping below a specified voltage . The CCA rating is determined
by the battery's ability to deliver starting current at 0°F (-18 °C).

If the battery discharges when vehicle is not driven , there may be a

constant drain or current draw causing it to discharge when ignition
is OFF. Depending on the amount of draw and battery condition , a
full discharge can happen overnight or it may take a few weeks .
Althou gh a small static drain on the battery is normal (example :
clock or radio memory) , a large drain such as a relay sticking on or
 27-6 Battery, Alternator, Sta1t er
Battery

a faulty switch causes the battery to discharge quickly. Perform a

static current draw test first when experiencing battery discharge.
See Static current draw, checking in this repair group.

If current draw on the battery is not excessive but it still discharges ,

test the battery charge using open circuit or load voltage test. See
Open circuit voltage test and Load voltage, testing in this repair
group. Batteries with removable filler caps can also be tested by
checking electrolyte specific gravity. See Electrolyte specific
gravity, testing in this repair group. Inexpensive specific gravity
testers are available at most auto supply stores .

Some vehicles are equipped with batteries that have a central gas
venting system with anti-flash protection. The anti-flash protection
consists of a small round fiberglass mat. Its purpose is to vent gases
that form in the battery through a vent opening in the battery cover.
Anti-flash protection is also installed to prevent ignition of flammable
gases in the battery.

Electrolyte level, checking

~ Visually check battery electrolyte level on batteries with
II ~ recognizable MAX and MIN markings (arrow).
I )
L=<Cd> ~1 \ \

)-01 -
(
J-0\ I
If there are no markings on battery housing , or if electrolyte level
cannot be read , remove battery filler caps to view electrolyte level .
Check that level is at same height as visible plastic peg .
11

l i==I ~ max ~
min
1= = 1
r
t - Top off each battery cell as necessary with distilled water using a
battery filling bottle. Use a hydrometer to remove excess electrolyte.

CAUTION-
• Use genuine Audi battery filler caps fitted with 0-ring seals.
J

~ -v--1 N02-0492
I NOTE-
• Use of distilled water to fill battery cells prevents contamination of
battery electrolyte and decreases the likelihood of self-discharge.

Battery residual voltage, checking

- Make sure vehicle is not started or driven for at least 2 hours before
taking measurements.

- Make sure no loads are applied to battery for at least 2 hours before
taking measurements.

- Make sure battery is not charged for at least 2 hours before taking
measurements.

- With ignition switched OFF, use digital multimeter to measure

voltage between battery terminals.
• If multimeter displays 12.5 volts or more, battery is OK.
• If voltage is below 12.5 volts , continue with tests.

I
Static current draw, checking
- Make sure ign ition and all electrical accessories are switched OFF.

- Disconnect negative (-)cable from battery.

 I

Battery, Alternator, Starter 27-7

Battery

~ Connect a digital ammeter between battery negative post and

(+) ~ negative battery cable and measure current draw.

Static current draw parameters

Batte ry
Normal 0 - 100 mA

Too high > 500 mA

- If current draw is 500 mA (0.5 amp) or highe r, remove one fuse at a

time until th e current drops to a normal range . See EW D Electrical
Wiring Diagrams to help locate wiring or component faults .

002406 1 Open circuit voltage test

- Load battery with 15 amps fo r one minute: Switch headlights ON
with engine OFF

- Turn headlights OFF and disconnect battery ground cable .

- Connect acc urate digital voltmeter to batte ry posts and check

battery voltage.

- See Table b for ope n-circuit voltage levels and state of charge .

Table b. Open circuit voltage and battery charge

Open circuit voltage State of charge
12.6 volts or more Fully charged
12.4 volts 75% cha rged
12.2 volts 50% cha rged
12.0 volts 25% cha rged
11 .7 volts or less Fully discharged

The battery may be in satisfactory condition if open -circ uit voltage is

at least 12.5 volts.

- If open-circuit vo ltage is at 12.5 volts or above , but battery still lacks

power for startin g, perform a load voltage test to determine battery
service condition . See Load voltage, testing in this repair group.

- If open-circuit vo ltage is below 12.5 volts , recharge battery. After

charging , if batte ry still fails open circuit voltage test, replace it .

Electrolyte specific gravity, testing

I•
Checking the specific gravity of each battery cells can pro vide
I•
1.
accurate information about the battery condition .

. Test electrolyte specific gravity with a battery hydrometer. Th e

hydrometer is a glass or plastic cylinder with a freely moving float
inside . When electrolyte is drawn into the cylinde r, the level to which
the float sinks indicates the specific gravity of the el ectrolyte . The
more dense the concentration of sulfuric acid in the electrolyte , the
less the float sinks, resulting in a higher reading and ind icating a
higher state of charge .

Note that electrolyte tempe rature affects hydrometer reading . Check

electrolyte temperature with a thermometer. Add 0 .004 to
hydrometer reading for every 6°C (10°F) that electrolyte is above

I
 27-8 Battery, Alternator, Star er
Battery

27°C (80°F). Subtract 0.004 from reading for every 6°C (10°F) that
electrolyte is below 27°C (80°F) .Make sure that battery electrolyte
temperature is at least 10°C (50°F).

- Load battery with 15 amps for one minute: Switch headlights ON

with engine OFF.

- Turn headlights OFF. Remove battery filler caps.

~ Immerse hydrometer in a cell and extract sufficient electrolyte so

that indicator floats free in electrolyte. Read specific gravity and
compare to specifications in Table c.

Table c. Specific gravity of battery electrolyte at 27°C (80°F)

Specific gravity Charge condition
1.265 Fully charged
1.225 75% charged
1.190 50% charged
1.155 25% charged
1.120 Fully discharged

- If the average specific gravity of the six cells is 1.225 or higher, the
battery is in satisfactory condition .

- If the average specific gravity is 1 .225 or higher, but the battery lacks
power for starting , determine the battery's service condition with a
load voltage test. See Load voltage, testing in this repair group.

- If electrolyte density is below 1 .225 , charge battery. After

recharging , if specific gravity varies by more than 0.005 between
any two cells , replace battery.

- Install filler caps with 0-rings and wipe up spilled electrolyte.

Load voltage, testing

A load voltage battery test is made by connecting a specific resistive
load to the battery terminals and then measuring battery voltage .

- Make sure battery is fully charged and at room temperature.

- Disconnect negative (-) battery cable.

- Connect battery load tester and apply specified load (Tabled ,

column 3) for 15 seconds and read off battery voltage (Tabled ,
column 4) . If voltage is below specification , or minimum voltage does
not stay at a steady reading , replace battery.

Table d. Battery load current and minimum voltage

Battery Cold cranking Load cu rrent Minimum
capacity (Ah) amps (CCA) (amps) vo ltage
36 Ah 340 100 10.0
40 Ah-49 Ah 220 200 9.2
50 Ah-60 Ah 265-280 200 9.4
61 Ah-80 Ah 300-380 300 9.0
81 Ah -110 Ah 380-500 300 9.5

I
 Battery, Alternator, Starter 27-9
Battery

Battery, char~1ing

Recharge a discharged battery using a battery charger. Read and

follow the instructions provided by the battery charger's
manufacturer.

Use slow-charging rate (10% of battery capacity) to prevent battery

damage caused by overheating .

CAUT/O~
•Prolonged battery charging evaporates the electrolyte to a
level that can damage the battery
• Loosen battery cell caps before charging battery but leave them
on battery to prevent battery acid splatter.

Battery, disconnecting and connecting

Make sure the vehicle electrical system is protected by
disconnecting the battery negative (-)terminal prior to working on
any electrical system components.

CAUTIO~
• Do not loosen or remove ground strap from body Disconnect
terminal from battery only

-4"iiii( Open engine hood , release battery cover latches (arrows) and flip
cover up to gain access to battery.

-4"iiii( Unbolt and disconnect battery negative(-) cable (arrow). Position

cable to side where it cannot come in contact with battery negative
(-) terminal.

- When reconnectin~l negative(-) battery terminal , make sure positive

(+)terminal is connected first .

Tightening torque
9 Nm (80 in-lb)
Battery cable to battery (M6) I
- After connecting battery terminal:
•Switch ignition ON, then OFF.
•Check for diagnostic trouble codes (DTCs) using VAG scan tool or
equivalent.
• Reset electrical consumers. See Battery reconnection notes in
this repair group.
• Check function of all electrical consumers.
27-10 Battery, Alternator, Stater
Starter
Battery, removing and installing
~ Open engine hood and pull off rubber molding at engine
compartment rear bulkhead . Pull plenum chamber cover forward
and remove .

~ Working at battery:
•Disconnect negative(-) cable (A).
•Disconnect positive (+) cable (B) .
• Remove battery hold-down bracket bolt (C) .
• Remove hold-down bracket and lift battery out.

CAUTIO~
• Disconnect negative (-) cable first and reconnect it last.

Installation is reverse of removal. Secure battery firmly, but do not

overtighten hold-1down bracket bolt.

Tightening torque
Battery cable to battery (M6) 9 Nm (80 in-l b)

Battery hold-down to plenum chamber (MS) 15 Nm (11 ft-l b)

- Make sure battery venting hoses (if present) are routed correctly to
side.

- After connecting battery termi nals:

•Switch ignition ON , then OFF.
•Check for diagnostic trouble codes (DTCs) using VAG scan tool or
equivalent.
• Reset electrical consume rs . See Battery reconnection notes in
this repair group.
• Check function of all electrical consumers.

STARTER

Starter troubleshooting
A factory -installed anti-theft immobilizer is used on Audi A6 models.
This system prevents operation of the starter if a specially coded
ignition key is not used. See 96 Interior Lights, Switches , Anti-
theft.
 Battery, Alternator, Starter 27-11
Starter

~ On manu al transmission cars , the clutch pedal position switch

(F194) operates via the starter interlock relay (J207) (arrow) in the
13-fold rel ay panel to prevent the starter from operating unless the
clutch pedal is pushed fully to the floor. See the following for
additional details:
• 30 Clutch for clutch pedal position switch location
• 97 Fuses, Relays, Component Locations for 13-fold relay panel
access information

On autom atic transmission cars , the transmission multifunction

range switch (F125) signals the immobilizer to prevent the engine
from starti ng in gear positions other than PARK or NEUTRAL.

~ In models with multitronic (CVT) transmission , the transmission

multifunction range switch (F125) signals the park I neutral position
(PNP) rel ay (J226) (arrow) in the 13-fold relay panel when the
transmissi on is in PARK or NEUTRAL. The PNP relay then signals
the electronic immobilizer to allow the starter to operate. See 97
Fuses, Relays , Component Locations for 13-fold relay panel
access information .

On back of starter, the large wire at terminal 30 is direct battery

voltage. Th e smaller wire at terminal 50 operates the starter
solenoid via ignition switch .

- If starter turns engine slowly when ignition is in START position :

• Check battery state of charge . See Load voltage , testing in this
rep air gro up.
• Inspect starter wires , terminals and ground connections for good
contact. In particular, make sure ground connections between
battery, body and engine are completely clean and tight.
• If no faults are found , starter may be faulty.

- If starter fai ls to operate :

• Check electronic anti-theft immobilizer. Try another ignition key. If
no faults can be found , have the immobilizer system checked using
VAG scan tool or equivalent.
• Check clutch pedal operated starter interlock switch or
transmi ssion range switch (automatic transmission).

Ch eck for battery voltage at terminal 50 of starter motor with key in

START position .
• If vol tag e is not present, check wiring between ignition switch and
starter termi nal. Check immobilizer system and other inputs that
disrupt input to starter. See EWD Electrical Wiring Diagrams .

If voltage is present and no other visible wiring faults can be found ,

problem is most likely in starter motor.

Starter, removing and installing (V6 engine)

Disconnect battery ground cable . See Battery, disconnecting and
connecting in this repair group.

2.7 liter turbo engine : Remove alternator. See Alternator,

removing and installing in this repair group.
27-12 Battery, Alternator, St er
Starter
Raise car and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed fo r the
purpose. A floor jack is not adequate support.

~ Working at back of starter motor under right cylinde r bank:

•Disconnect ground cable (1) and starter and solenoid wires (2 , 3).
•Working at transmission side of bellhousing , remove starte r
mounting bolts (arrows) .
• Lift out starter.

- Installation is reverse of removal.

Tightening torques

Starter to engine 65 Nm (48 ft-lb)

Starter cable to terminal B+ on starter (MB) 16 Nm (12 ft-lb)

- After connecting battery terminals , reset electrical consu mers. See

Battery reconnection notes in this repair group.

Starter, removing and installing (VB engine)

- Disconnect battery ground cable . See Battery, disconnecting and
connecting in this repa ir group.

Raise car and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

- Remove lower engine cover (splash shield). See 03 Maintenance.

~ Working at left engine mount:

• Detach engine mount electrical connector (1)
•Detach cable retainer (2) from engine mount.

A 13-0367 I

~ Detach ground cable (arrow) at starter housing .

 Battery, Alternator, Starter 27-13
Alternator

~ Working at rear of starter motor :

• Remove starter bracket mounting bolt (arrow).
• Detach starter and solenoid wires .

~ Remove starter mounting bolts (arrows).

Lower starter while turning clockwise .

Installation is reverse of removal.

Tightening torques

Cable retainer to engine mount 22 Nm (16 ft-lb)

Starter to engine 65 Nm (48 ft-lb)
Starter bracket to engine 10 Nm (7 ft-lb)
Starter cable to terminal B+ on starter (M8) 16 Nm (12 ft-lb)
A13-0366 1-
- After connecting battery terminals, reset electrical consumers . See
Battery reconnection notes in this repair group.

ALTERNATOR
Charging system quick check
- Use a digital multimeter to measure voltage across the battery
terminals with key OFF and then again with engine running .
Compare results to Table e .

Table e. Charging system quick check results

Battery
Condition voltage Probable cause
Key OFF, 12.6 Battery and charging system normal
engine not <12.4 Battery discharged
running
Battery faulty
Charging system faulty
Engine 13.5 -· 14.5 Charging system normal
running <13.2 Battery discharged , requires chargi ng
Charging system faulty
> 14.8 Charging system faulty
27-14 Battery, Alternator, St ter
Alternator

Alternator, removing and installing

- Disconnect battery ground cable. See Battery, disconnecting and
connecting in this repair group.

- Raise car and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

- Remove lower engine cover (splash shield) . See 03 Maintenance.

<fiiiiiii( Remove air cleaner duct mounting screws (arrows) at lock carrier.
Remove air duct (1 ).

Place lock carrier in service position . See 50 Body-Front.

<fiiiiiii( 2.7 liter turbocharged engine : Loosen right intercooler hose clamps
(1) and remove hose (2) .

<fiiiiiii( Automatic transmission :

•Loosen ATF lines by loosening bolt (1 ).
•Loosen AC lines by loosening bolt (2) .
•Remove line (5) by removing bolts (3) and hose clamp (4).
 Battery, Alternator, Starter 27-15
Alternator

~ Manual transmission: Remove A/C refrigerant lines mounting

bracket (1) above torque arm .

~ Cut wire-ties (2) and unlatch tabs.

- Unhook starter and alternator wires from bracket (1 ).

- Remove engine accessory belt. See 03 Maintenance. If belt is to be

reused , mark direction of rotation prior to removal.

I A27-0023 I

~ Working under right front of engine, loosen clamp (arrow) and

remove cooling air duct from alternator.

~ Working at rear of alternator, detach connectors from alternator

posts 30 I B+ and D+ (1 , 2).

- I

ti •
27-16 Battery, Alternator, Stater
Alternator
"'iii{ Loosen and remove alternator mounting fasteners:
• Counterhold nut (2) to remove top bolt (1 ).
•Loosen and remove lower bolt (3).

- Remove alternator from below, taking care to move A/C refrigerant

lines and other hoses and wires aside very carefully.

CAUTIO~
• Do not bend or kink NC refrigeran t lines.

- Installation is reverse of removal.

Tightening torques
Alternator to engine block:
•Top bolt (M10) 45 Nm (33 ft lb)
• Lower bolt (MS) 22 Nm (16 ft-lb)

Connector to alternator posts:

• 30 I B+ 16 Nm (12 ft lb)
• D+ 4 Nm (35 in-lb)

- If reusing accessory belt, install in direction of rotation marked

previously.

"'iii{ V6 belt routing .

A 13-00 18

"'iii{ VS belt routing (not all road quattro).

- Check belt ribs to make sure they fit pulleys correctly.

A 13-0230
 28-1

28 Ignition System

GEN ERAL .................... . ......... 28-1 IGNITION SYSTEM COMPONENTS .......... 28-4
Ignition management ....... . ............ . 28-1 Spark plugs 28-4
Ignition firing order . .................... . . 28-2 Ignition coils . ................... . ... .... 28-4
Disabling ignition system .. .. .. ..... .. .... . 28-2 Spark plug wires .. .. ......... . . ....... .. . 28-5
On-board diagnostics . .................... 28-3 Camshaft sensors .... . .... ..... ......... 28-6
Warnings and Cautions .... . . .... ... . . .... 28-4 Knock sensors 28-6

GENERAL
This repair group provides ignition system information .

See also :
• 03 Maintenance for spark plug replacement
• 24 Fuel Injection for Motronic system applications
• 96 Interior Lights, Switches, Anti-theft for ignition switch
replacement
• EWD Electrical Wiring Diagrams

Ignition management
Audi A6 ig nition is controlled by the Motronic engine management
system , whi ch also controls fuel injection and emission control
functions .

Ignition advance <iiii{ Ign ition timing is electronically mapped and not adjustable. A three-
dimensional map :similar to the illustrati on is stored in the Motronic
engine control module (E CM ).

In applying the map, the ECM computes igniti on timing based on

inputs from the following sensors, in order of importance :
• Crankshaft position sensor for timing reference point.
•Mass airflow sensor for engine load .
• Camshaft sensors for re lative camshaft positions .
-------
--- • Knock sensors to modify and correct ignition timing based on

~----
changing operating conditions.
load--
001 1539
28-2 Ignition System
General

Ignition firing order

V6 engine: Cylinder 1 is at the right front of the engine, followed by
cylinders 2 and 3. Cylinders 4 , 5 and 6 are on the left side of the
engine , from front to back.

VB engine: Cylinder 1 is at the right front of the engine , followed by

cylinders 2, 3 and 4. Cylinders 5, 6, 7 and 8 are on the left side of the
engine , from front to back.

Ignition firing order

V6 engine 1-4-3-6-2-5

VS engine 1-5-4-8-6-3-7-2

Disabling ignition system

The ignition system operates in a lethal voltage range and also
contains sensitive electronic components . To guard against system
damage, and for personal and general safety, carry out ignition
system service and repair work carefully.

- If the engine must be cranked without starting :

• Disable fuel system to prevent excess fuel from flooding cylinders.
• Disable ignition system to prevent discharge of dangerously high
voltage.

~ Remove fuel pump fuse (fuse 28 , arrow) in dashboard fuse panel.

- Remove engine upper cover(s) . See 03 Maintenance.

~ 2.8 liter engine: Disconnect ignition coil connector.

 Ignition System 28-3
General

- 2.7 liter, 3.0 liter, V8 engines : Pull off (arrows) each individual
ignition coil co nnector.

On-board diagnostics
Most components and functions of the Motronic system are
monitored by on-board diagnostics (OBD II ) software in the engine
control module (ECM). If faults and malfunctions are detected , one
or more diagnostic trouble codes (DTCs) may be set.

~ In case of an emissions related fault or a malfunction considered

catalyst-damaging , the Check Engine light (malfunction indicator
light or MIL) or EPC light is illuminated.

~ Access fault memory with VAG scan tool or equivalent plugged into
the DLC plug (inset) under left side dashboard . See 080 On-
Board Diagnostics for more information .

NOTE -
• After engine management system tests or repairs, the ECM may
recognize a malfunction and store a OTC. The refore perform the
following after ending tests and repairs:
-Use VAG scan tool or equivalent to check OTC memory
-Erase OTC memory
-Reset or erase diagnostic data.
-Generate readiness code.
•After engine management system tests or repairs, the engine may
start, run for a short period and then cut out because the electronic
anti-theft immobilizer disables the ECM. In such cases:
-Use VAG scan tool or equivalent to check OTC memory
-Adapt ECM.

~-----r---
28-4 Ignition System
Ignition System Components

Warnings and Cautio ns

WARNIN G-
• Do not touch or disconnec t any cables from the coils while the
engine is running or being cranked by the starter.
• The ignition system produces high voltages that can be fatal. Avoid
contact with exposed terminals. Use extreme caution when
working on a car with the ignition switched on or the engine running.
• Before operating the starter without starting the engine (for
example when making a compress ion test) disable the ignition.
See Disabling ignition system in this repair group.

CAUTIO~
• Prior to disconnecting the battery, read the battery
disconnection precautio ns given at the front of this manual.
• Use a high impedance digital multimete r for voltage and
resistance tests.
• Use an LEO test light in place of an incandescent-type test
light.
• Do not attempt to disable the ignition by removing the coils from
the spark plugs.
• Connect and disconnec t the ECM, Motronic system wiring or
test equipmen t leads only when the ignition is OFF
• Switch multimete r functions or measurem ent ranges only with
the test probes disconnected.
• Do not disconnec t the battery while the engine is running.

IGNITIO N SYSTE M COMPO NENTS

Engine managem ent compone nt location illustrations are in 24 Fuel
Injection . Compone nts specifically associated with ignition are
covered below.

Spark plugs
See 03 Maintenance for spark plug applications and replaceme nt
procedure.

Ignition coils
~ 2.8 liter engine: Ignition coils and power stage are ganged at front,
of engine, under upper engine plastic cover. There is no distributor
distributor cap or ignition rotor.
 Ignition System 28-5
Ignition System Components

~ 2.7 liter, 3.0 liter, V8 engines: Each ignition coil is mounted above
the corresponding spark plug . Ignition coil electrical connectors
(arrows) are ganged for each cylinder bank.

2.7 liter engine, code APB: Power stages are separate

components on air filter housing .

2.7 liter engine, code BEL, 3.0 liter engine, V8 engines: Power
stages integrated with ignition coils.

There is no distributor, distributor cap or ignition rotor.

~ 2.7 liter, 3.0 liter, V8 engines: To remove ignition coils , use Audi
special tool T40039 , pull all ignition coils out of spark plug shaft.

- Installation is reverse of removal.

• Insert all ignition coils loosely into spark plug shaft.
• Align ignition coils to the connectors and then connect all of the
connectors onto ignition coils .
•Press ignition coils uniformly onto the spark plugs by hand (do not
use an impact tool) .

Spark plug wires

~ 2.8 liter engine: Plug wires are routed from central coil pack to each
spark plu g.

2.7 liter, 3. 0 liter, V8 engines: Spark plug wire for each cylinder is
integrated wi th corresponding ignition coi l.
28-6 Ignition System
Ignition System Components

Camshaft sensors
<iii( Camshaft sensors (arrows) on each camshaft detect camshaft
position. This input is used by the ECM to determine when to fire
each spark plug.

2.7 liter turbocharged V6 engine illustrated . Other engines are

similar.

198 54

<iii( 3.0 liter engine: Two camshaft sensors (1, 2) per bank are used.

Knock sensors
<iii( Two or three knock sensors monitor engine knock. The ECM uses
Knock signal from knock sensors to optimize ignition timing.

Knock sensors are located under the intake manifold. 2.7 liter
turbocharged V6 engine is illustrated. Other engines are similar.

/
-, r ..1
/ J

198 51
 30-1

30 Clutch

GENERAL . ... . . . .... . ..... .. .. .. . ....... 30-1 Clutch slave cylinder, removing and installing .. 30-8
Self-adjusting clutch pressure plate .......... 30-1 Clutch system , bleeding . . .. ...... . .. . ... . 30-1 o

CLUTCH PEDAL .......................... 30-1 CLUTCH ASSEMBLY ........... ... .. . . . .. 30-11

Clutch pedal assembly .... . .. ....... ...... 30-2 Clutch components (5-speed) ..... .. . .... . 30-11
Clutch pedal position switch (F194) .... ...... 30-3 Clutch release mechanism (5-speed) .. .... . 30-12
Clutch pedal position switch (F194), Clutch components (6-speed) .. .. ......... 30-13
removing and installing .................. 30-3 Clutch release mechanism (6-speed) . .. .. .. 30-14
Clutch pressure plate, checking ............ 30-15
CLUTCH HYDRAULIC SYSTEM ... ......... . 30-4
Clutch , centering ... ............ ........ 30-15
Clutch hydraulic components . . ........... . . 30-4
Clutch pressure plate (SAC) , resetting ..... . . 30-16
Master cylinder, removing and installing ... . ... 30-5

GENERAL
This repair group covers clutch hydraulic and mechanical repairs .

Service to the clutch assembly requires removal of the transmission

from the vehicle. Special tools and equipment are required to
remove the transmission , service the clutch , and bleed the clutch
hydraulic system. See 34 Manual transmission for transmission
removal procedure.

Self-adjusting clutch pressure plate

A6 models equipped with 2.7 liter V6 bi-turbo engine feature a Self-
Adjusting Clutch (SAC) pressure plate. The SAC clutch pressure
plate automatically compensates for clutch disc wear to provide
consistent clutch pedal feel. See Clutch pressure plate (SAC) ,
resetting in this repair group.

CLUTCH PEDAL
The illustration on the following page shows clutch pedal assembly
components for vehicles equipped with 5-speed and 6-speed
manual transmissions . When servicing , replace self-locking nuts,
circlips and gaskets

NOTE -
• Audi identifies electrical components by a letter and/or a number in
the electrical schematics. See EWD Electrical Wiring Diagrams.
Where appropriate, these electrical identifiers are listed in
parentheses as an aid to electrical troubleshooting.
30-2 Clutch
Clutch Pedal

Clutch pedal assembly

1. Mounting bracket
2. Pivot pin
• For clutch and brake pedals
• Install with groove (arrow) toward
clutch pedal
---
&--4 3. Locking clip
4. Bolt, 25 Nm (18.5 ft-lb)

5 5. Brake pedal
6. Clutch pedal
'-.
'-.
'-. '-. 7. Pin
'-.
'-.
'-. > •Clip to clutch pedal
8. Locking clip

>
"
'-.
'-.
9. Clutch master cylinder
'-
1O.Bolt, 20 Nm (15 ft-lb)
'-.
'-.
:::. 11.Spring mount
• Insert in mounting bracket with over-
center spring
12.0ver-center spring
13.Bolt, 5 Nm (4 ft-lb)
~ ___
• For clutch and brake pedal pivot pin

~ ~~ 14.Seal
15.Torx bolt, 25 Nm (18.5 ft-lb)

6 - - - - -- - -----;-

N30-0196
 Clutch 30-3
Clutch Pedal

Clutch pedal position

switch (F194)
1. Mounting bracket
2. Cable bracket
3. Locking clip
4. Pin
•Clip onto clutch pedal
5. Clutch pedal
6. Clip
7. Bracket for harness connector
8. Clutch pedal position switch (F194)
• See Clutch pedal position switch ,
adjusting in this repair group
9. Clip
10.Screw and washer, 8 Nm (6 ft-lb)
11.Securing plate

A30-0035

Clutch pedal position switch (F194), adjusting

The clutch pedal position switch (F194) prevents the engine from
starting unless the clutch pedal is depressed .

~ Working above the clutch pedal , loosen 2 bolts (arrows).

- Have assistant depress clutch pedal to stop.

- Place feeler gauge (A) with selected dimension a (3.2 ± 0 .2 mm)

between operating surface of clutch pedal and switch plunger.

- Swing switch (B) toward feeler gauge (A) and tighten two mounting
bolts (arrows).

Tightening torque
Clutch pedal position switch mounting
bracket to pedal assembly bracket 8 Nm (6 ft-lb)
30-4 Clutch
Clutch Hydra ulic System

CLUTCH HYDRAULIC SYSTEM

Clutch hydraulic components

1 2 4 5
1. Brake fluid reservoir
2. Supply hose
3. Hose/pipe assembly
4. Mounting bracket
5. Clutch pedal
6. Bolt, 20 Nm (15 ft-lb)
7. Pin
8. Clutch master cylinder
• Do not operate after clutch pedal has
19 been removed
9. Seal
1O.Retaining clip
11.Transmission
12.Clutch slave cylinder
• Do not operate after clutch ped al has
been removed
•Brake fluid must not be allowed to get
onto the transmission
18 -____:_-=---:_~
• Lightly grease before installing
3- - - - • When installing push in until the
securing bolt can be fitted .
13.Bleeder valve/slave cylinder
•Tighten to 4.5 Nm (3 .3 ft-lb)
~------ 13 • A broken bleeder valve can be
unscrewed with a 3 mm socket
- - - - - 14 14.Dust cap
A30-0032 15.Retaining clip
16.Bracket
• Secured to transmission
17.Bolt, 20 Nm (15 ft-lb)
18.Nut
19.Seal
 Clutch 30-5
Clutch Hydraulic System

Master cylinder, removing and installing

Remove plenum chamber cover.

Switch ignition OFF and disconnect battery ground (-) strap.

NOTE -
• Make sure no brake fluid spills into the plenum chamber or on
transmission.
• When working in footwell, protect carpet from brake fluid using
rags.

~ Clamp supply hose (A) from brake fluid reservoir using special pinch
tool 3094. Pull hose off master cylinder and plug hose.

Remove supply hose grommet from bulkhead.

Lever out retaining clip (C) using a screwdriver and pull pipe (B) out
slightly.

~ If equipped , remove bolt (1) and swing brake fluid container (2) to
the right .

- Remove Torx bolts (3 and 4) .

- Working under dash board , remove driver's storage compartment.

~ Detach clutch pedal from master cylinder. To do this , unclip pin using
a screwdriver (1) pull out pin (2) . Carefully press clutch pedal off.

NOTE-
• Make sure clutch pedal does not press switch (1) out of the
retaining clip. This damages the thread of the switch and the switch
will have to be replaced.
• Switch must not be installed more than once.
30-6 Clutch
Clutch Hydraulic System

~ Remove bolts (2) for clutch master cylinder and for mounting bracket
(3).

- Pull complete pedal assembly slightly to rear and remove clutch

master cylinder (4) .

~ To install , insert clutch master cylinder and tighten bolts (2). Make
sure seal (1) with washer contacts mounting bracket at rea r.

Tightening torque

Master cylinder to mounting bracket 20 Nm (15 ft-lb)

I

- Press connecting pipe (3) into recess (B) at mounting bracket.

~ Slide complete pedal assembly forward , insert bolt (3) and tighten
by hand . At the same time , have an assistant guide pipe from
plenum chamber into clutch master cylinder.
 Clutch 30-7
Clutch Hydraulic System

~ Tighten mounting bolts for brake booster (3 and 4).

Tightening torque

Brake master cylinder to brake booster I 25 Nm (18.5 ft-lb)

- Tighten mounting bolt for brake fluid container (1)

~ Press in retaining clip (C) as far as it will go.

\ - Push pipe (8) into clutch master cylinder until it engages audibly.

Insert supply hose rubber grommet into place on bulkhead.

Push in supply hose (A) from brake fluid reservoir as far as it will go.

- Remove special tool 3094.

~ Tighten pedal assembly bolt (arrow) to secure pedal assembly to

dashboard carrier.

Tightening torque

Pedal assembly to dashboard carrier 25 Nm (18 .5 ft-lb)

- Connect clutch master cylinder to clutch pedal. Engage bolt lock in

clutch pedal.

- Bleed clutch system after installing clutch master cylinder. See

Clutch system, bleeding in this repair group.
30-8 Clutch
Clutch Hydraulic System

~ Check adjustment of vent valve (1) above clutch pedal. Vent valve
must contact clutch pedal (3) completel y and must operate at full
travel.

- Gap measurem ent a between retaining clip and mounting bracket

may be a max . of 0.5 mm .

- To adjust, hold clamp and turn vent valve (1 ).

- Install driver's storage compartm ent.

Clutch slave cylinder, removing and installing

~ To aid access, unbolt left drive axle (A) from transmiss ion and move
clear to one side.

- Remove heat shield (8) from transmiss ion .

- If necessary, unscrew bolts (arrows) and remove left transmission

support (C) together with transmiss ion mounting .

~ Remove bolt (arrow) and take out slave cylinder from the rear.

NOTE-
• Do not depress clutch pedal after removing slave cylinder.
• Do not allow brake fluid to come into contact with transmiss ion . If
necessary, clean transmiss ion housing.
 Clutch 30-9
Clutch Hydraulic System

~ To disconnect pipe, first pry out retaining clip (A) with a screwdriver
until it disengages audibly. The pipe can then be pulled out.

••1
A

~ Before mounting the slave cylinder into the transmission housing ,

coat area a of collar with lithium grease.

Lightly coat tip of push rod using copper grease.

NOTE -
• To aid installation, engage 6th gear (6-speed transmission) or 4th
gear (5-speed transmission) before fitting slave cylinder.
• Pre-tension clutch slave cylinder far enough for the securing bolt to
be easily inserted.

A30-0037

~ Insert clutch slave cylinder into mounting hole in transmission

housing , keeping it in line with direction of operation of push rod ,
then tighten bolt (a rrow).

NOTE -
• If the clutch slave cylinder is inserted off-line there is a danger that
the push rod will be guided past the clutch release lever.
•Always replace securing bolt.

~ To connect pipe to slave cylinder, press in retaining clip (A ) as far as

it will go. Push pipe into slave cylinder until it engages audibly.

Reinstall drive axle and heat shield

Reinstall transmissi on support and transmission mounting (if

removed) .

Bleed clutch system . See Clutch system, bleeding in this repa ir

group.
30-10 Clutch
Clutch Hydraulic System

Tightening torques
Clutch slave cylinder to transmission 20 Nm (15 ft- lb)

Heat shield for drive axle 25 Nm (18.5 ft- lb)

Drive axle to drive flange:

•MB 40 Nm (30 ft- lb)
• M10 70 Nm (52 ft- lb)

Transmission support to transmission 40 Nm (30 ft-lb)

Transmission mounting to subframe 23 Nm (17 ft-lb)

Clutch system, bleeding

"iiii( Clutch system bleeding require brake filler/bleeder unit (VAG1869 or
V.A.G 1869 equivalent).

NOTE-
• Open bleeder valve before switching on brake filler/bleeder unit.
• Make sure no brake fluid leaks onto transmission .
• Bleed clutch system after working on hydraulic clutch mechanism.
• Top off brake fluid reservoir to MAX before bleeding clutch system.

Pull clutch pedal back to rest position .

- Connect brake filler/bleeder unit (VAG 1869 or equivalent) but do not

switch on yet.
W00-0457

"iiii( Connect bleeder hose (A) to clutch slave cylinder (arrow) and open
bleeder valve .

- Connect bleeder hose to pressure hose of collector bottle.

- Switch on brake filler/bleeder unit and bleed approx . 100 cc (3 oz) of

brake fluid (do not exceed 2.5 bar positive pressure).

- Close bleeder valve.

Tightening torque

Bleeder valve to clutch slave cylinder I 4.5 Nm (3.3 ft-lb )

- Depress clutch pedal several times after completion of bleeding

process.

- Bleed system again if necessary.

 Clutch 30-11
Clutch Assembly

CLUTCH ASSEMBLY

NOTE -
• Clutch replacement requires transmission removal. See 34
Manual Transmission.
• Replace clutch and pressure plate with damaged or loose rivets.
•Match clutch plate and pressure plate to engine application.
• Clean input shaft splines and hub splines. Remove corrosion and
apply a very thin coating of grease (G 000 100 or equivalent) to the
splines. Make sure hub moves freely on shaft. Remove excess
grease.
• Pressure plate has anti-corrosion coating. Clean contact surface
before installation.
• If clutch was burnt out, thoroughly clean bellhousing, flywheel and
parts of the engine facing transmission.

Clutch components (5-speed)

1 2 3 4 5
1. Flywheel

l • Make sure centering pins are tightly

seated
• Contact surface for clutch lining must
be tree of scoring , oil and grease
2. Bolt, 60 Nm (44 ft-lb)+ 180° turn
• Always replace
3. Clutch disc
• Install spring pack (coil springs) toward
pressure plate. Clutch lining must make
full contact with flywheel. Marking
"Getriebeseite" (if provided) goes
toward pressure plate.
• Lightly grease splines
4. Pressure plate
• Check ends of diaphragm spring
• Check spring connection and rivets
5. Bolt, 25 Nm (18 ft-lb)
• Loosen and tighten in stages and in
diagonal sequence
A 6 B
6. Needle roller bearing

A30-0027

NOTE -
• Mark (A) on flywheel must coincide with mark (B ) on pressure
plate.
30-12 Clutch
Clutch Assembly

Clutch release mechanism

15 14 13 12 (5-speed)

~
ef:!/J
1. Transmission
2. Ball stud
•Tighten to 25 Nm (18.5 ft-lb)
•Lubricate with MoS2 grease
< 3. Intermediate piece

/
/.
4. Dished washer
/-
/
/ •Smaller diameter (convex side) to
guide sleeve
5. 0-ring
• Always replace
6. Input shaft oil seal
• Pull out of guide sleeve with oil seal
extractor lever VW 681
• Drive to stop with fitting sleeve VW 192
7. Guide sleeve
• Before removing and installing , cover
input shaft splines with a shrink-fit hose
to protect oil seal.
8. Retaining spring
• Secure to clutch release lever
9. Clutch release lever

1 2 3 4 5 6 7 8 9 10 11 • Before installing , coat contact surface

of clutch slave cylinder plunger with a
thin layer of copper grease .

A30-0060 10.Self-locking bolt, 35 Nm (26 ft-lb)

• Always replace
11.Release bearing
• Do not wash-out bearing , only wipe
• Replace noisy bearing
• Allow retaining tabs on release bearing
to engage in release lever
12.Plunger
•Grease end of plunger with copper
grease .
13.Bracket
•Secured to transmission along with
slave cylinder
14.Bolt, 20 Nm (15 ft-lb)
• Always replace
15.Clutch slave cylinder
• Do not operate clutch pedal after
removing
• Pretension slave cylinder so mounting
bolt can be inserted easily . See Clutch
slave cylinder (5-speed) , removing
and installing.
 Clutch 30-13
Clutch Assembly

Clutch components (6-speed)

1 2 3 4 5

r~ ~~
1. Flywheel
• Dual mass flywheel only for 2.7 liter V6
bi-turbo engine
I • Make sure centering pins are tightly
i seated
•Contact surface for clutch lining must
be free of grooves , oil and grease
2. Bolt
•Vehicle without dual-mass flywheel :
tighten to 60 Nm (44 ft-lb)+ 90°
•Vehicle with dual-mass flywheel :
tighten to 60 Nm (44 ft-lb)+ 180°
• Always replace
3. Clutch plate
• Install with spring pack (coil springs) or
the word "Getriebeseite" towards
pressure plate and transmission
• Do not grease
4. SAC pressure plate
• See Pressure plate, checking in this
repair group.
•See Adjusting ring in SAC clutch
pressure plate, resettingin this repair
6 group .
• See Clutch with SAC pressure plate,
removing and installing in this repair
group.
A30-0038 5. Bolt, 22 Nm (16 ft-lb)
• Tighten gradually in diagonal sequence
and in several stages
6. Needle roller bearing
30-14 Clutch
Clutch Assembly

Clutch release mechanism

10 13 (6-speed)
1. Transmission
2. Intermediate piece
• Always replace
3. Shaft seal
• Install depth (factory): 3.5 mm (0.14 in)
• Install depth (repairs) : 4.5 mm (0 .18 in)
4. Guide sleeve
5. Bolt, 15 Nm (11 ft-lb)
6. Clutch release lever
• Engage lever in lugs of intermediate
piece
• Coat contact surface of clutch slave
cylinder push rod with a thin layer of
copper grease
7. Leaf spring
8. Bolt, 25 Nm (18.5 ft-lb)
• Always replace
9. Release bearing
• Do not wash out, wipe clean only
• Replace noisy bearings
• Retainer lugs on release bearing must
engage in release lever
1 2 3 4 6 7 8 9 1a.Clutch slave cylinder
•See Clutch slave cylinder (6-speed),
A30-0036 installing in this repair group .
11.Bolt, 20 Nm (15 ft-lb)
• Always replace
12.Bracket for hose/pipe assembly
• Engage in clutch slave cylinder
13.Push rod
•Coat tip of push rod with copper grease
 Clutch 30-15
Clutch Assembly

Clutch pressure plate, checking

~ Check spring connection between pressure plate and cover for
cracks and make sure rivets are tight.

Replace clutch with damaged springs or loose rivets (arrows).

~ Check ends of the diaphragm spring (arrows ).

- Wear of diaphragm spring: up to 112 thickness of spring finger.

V30-0458

Clutch, centering

NOTE -
• Models with SAC pressure plate: If necessary, reset SAC pressure
plate. See Clutch pressure plate (SAC) , resetting in this repa ir
group.

~ Use clutch tool 3176 to center clutch disc . Use flywheel lock 3067 to
3176 remove and install pressure plate.

Position clutch disc spring pack (co il springs) or marking

"Getriebeseite" toward pressure plate and transmission .

Do not in sert mounting bolts until clutch lining and contact surface of
pressure plate make full contact with flywheel.

- Loosen an d tighten bolts in small stages and in diagonal sequence.

3067
Tightening torque
Clutch pressure plate to flywheel 25 Nm (18 ft-lb)
Clutch pressure plate (SAC) to flywheel 22 Nm (16 ft-lb)
30-16 Clutch
Clutch Assembly

Clutch pressure plate (SAC), resetting

NOTE -
• When fitting a new clutch disc together with a used SAC pressure
plate, the adjuster ring in the pressure plate has to be reset by
turning it back as far as it will go. If this is not done, the SAC
pressure plate will operate with reduced clamping force, which will
cause clutch slip and excessive wear (especially of the clutch
disc) .
• If clutch disc is not being replaced, it is not necessary to reset the
adjuster ring.
• New SAC pressure plates are pre set, and do not have to be reset.

<liiiii{ Insert 3 securing bolts (A) into pressure plate mounting holes, 120°
from each other (1 /3 turn) , as shown in illustration .
A30-0042
- Screw 3 nuts (B) (MS) on bolts (A ) and tighten nuts slightly.

<liiiii{ Place SAC pressure plate on press so that only 3 bolt heads
(arrows) make contact with press plate.

Position special tool 3062 in center of pressure plate.

NOTE-
• Do not use force when performing the following steps, otherwise
the forks on the adjuster ring can break off.

<liiiii{ Apply two screwdrivers to forks on adjuster ring . Compress pressure

plate until it is just possible to move adjuster ring.

- Using two screwdrivers, turn back adjuster ring evenly in direction of

arrows until it reaches stop.

3062 Hold adjuster ring against stop and release press so that adjuster
ri ng is held in this position .

A30 -004 1
 32-1

32 Torque Converter

GENERAL . ........... .. ........ . . .. ..... 32-1 TORQUE CONVERTER SERVICE ............ 32-2
Torque converter description . . . . . . . . . . . . . . . 32-1 Torque converter, removing and installing ..... 32-2
Torque converter identification . . . ........... 32-2 Torque converter, draining .... . ............ 32-3
Torque converter oil seal , replacing ....... . .. 32-3

GENERAL
This repair group covers description and service notes for automatic
transmissio n torque converter. Torque converter service requires
removal of the transmission from the vehicle using special tools and
equipment. Automatic transmission removal is not covered in this
manual.

For additional information , see:

• 37 Automatic Transmission

Torque converter description

<liiiii{ The torqu e con verter is a fluid coupling device connecting the
engine and the transmission . It is driven by a steel drive plate
attached to the engine crankshaft. In addition to connecting the
engine and transmission, the torque converter drives the automatic
transmissi on fluid (ATF) pump within the transmission . The pump
delivers ATF under pressure.

Torque converter sections are welded together and then balanced;

no internal service is possible.

NO TE -
• Torque con verter with lock-up clutch illustrated. Not all models
include this feature.

Torque converter identification

~ Different versions of the torque converter are installed depending on
engine type . The torque converter is marked with a 3-digit
application code on the side facing the engine. For application
information , check with an authorized Audi dealer parts department .
32-2 Torque Converter
Torque Converter Service

TORQUE CONVERTER SERVICE

Torque converter, removing and installing

- With transmission separated from engine and out of vehicle , remove
converter by firmly grasping and carefully pulling straight out.

CAUTION-
• Be prepared to catch leaking ATF fluid.

~ Examine hub (arrow) of torque converter for excessive wea r.

Replace if damaged or faulty.

Replace oil seal. See Torque converter oil seal, replacing in this
repair group.

Push torque converter hub through seal onto transmission shaft as

far as first stop.

- Press torque converter into transmission bell housing while rotating

it until recess in torque converter hub engages in ATF pump gear
shaft and torque converter is felt to slip into place.

~ When torque converter is correctly installed , the distance between

the faces of the threaded holes on the torque converter and the
contact face of the transmission bell housing is about 23 mm (0.9 in).

If the torque converter is not fully installed , this distance is about

11 mm (0.43 in).

CAUTION-
• If the torque converter is not correctly installed, the ATF pump
shaft will be destroyed when the transmission is connected to
the engine.

Torque converter, draining

- If torque converter is contaminated by foreign particles, drain torque
converte r completely. Use VW special tool 1358, 1782 or equivalent.

~ Siphon ATF from torque converter. VAG 1358 A shown with adapter
VAG 1358 A/1 . Follow manufacturers instructions for operation .

NOTE-
• Be sure to allow sufficient time for fluid to drain from all internal
passages of torque converter.

To refill torque converter, see automatic transmission fluid filling

instructions in 37 Automatic Transmission .

VAG 1358
 Torque Converter 32-3
Torque Converter Service

Torque converter oil seal, replacing

Torque converter oil seal is located in the transmission housing front
cover at the transmission input shaft.

- With transmission separated from engine and out of vehicle ,

carefully pull out torque converter.

~ ~ Front drive models: Insert removal tool VW 681 or equivalent

~
directly behind sealing lip of seal. Make sure contact ring directly
behind seal is not damaged .

- Pry oil seal out of transmission housing. Use care to avoid gouging
A32-0002 I housing wi th tip of removal tool. Seal is destroyed during removal .

- Install contact ring . Replace contact ring if damaged

- Li ghtly lubricate outer circumference of seal and sealing lips with

ATF.

NOTE -
• Open side of seal points towards transmission .

~ Use drift 3295 to install seal as far as stop on drift.

Install torq ue converter. See Torque converter, removing and

installing in this repair group.

~ All wheel dri ve models: Remove circlip in front of seal. Insert

removal tool VW 681 or equivalent directly behind sealing lip of seal.
Make sure wave washer directly behind seal is not damaged .

- Pry oil seal out of transmission housing. Use care to avoid gouging
housing with tip of removal tool. Seal is destroyed during removal .

~
Install wave washer. Replace washer if damaged.

~
Lightly lubricate outer circumference of seal and sealing lips with
ATF.

NOTE -
A32-0002 I • Open side of seal points towards transmission .

....;;;( Use drift 3455 to install seal as far as stop on drift.

Insert circlip. Make sure circlip is seated in bottom of groove.

Install torque converter. See Torque converter, removing and

installing in this repair group.
 34-1

34 Manual Transmission

GENERAL ...... . ......... .... ....... ... . 34-1 Gear selector mechanism (5-speed) , adjusting . 34-7
Gear shift adjustment (5-speed) , checking 34-9
TRANSMISSION OIL. ....... ..... . ... ..... . 34-2
Gear selector mechanism (6-speed),
Manual transmission oil. .. .. . ... ....... .. . . 34-2
rem oving and installing .......... .... . . . . 34-9
5-speed manual transmission oil level ... . .... 34-2
Gear selector mechanism (6-speed), adjusting 34-12
6-speed manual transmission oil level . . ...... 34-3 Gear shift adjustment (6-speed), checking . .. 34-14
GEAR SELECTOR SERVICE . ...... . ........ 34-4 TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . 34-15
Gear selector mechanism Transmission (5-speed) ,
assembly (5-speed) . .. ........ . ........ 34-5 re moving and installing 34-15
Gear selector mechanism (5-speed), Tran smission (6-speed),
removing and installing . . ................ 34-6 re moving and installing 34-22

GENERAL
This repair group covers repair information for cable-operated gear
shift mechanisms and removal and installation of the 5-speed or
6-speed manual transmission. Transaxle or transmission teardown ,
disassembly, or internal repairs are not covered .

For additional information , see the following :

• 03 Maintenance for engine and transmission identification.
• 30 Clutch for hydraulic and mechanical clutch repairs
• 40 Front Suspension for drive axles
• 96 Interior Lights, Switches, Anti-theft for back up light switch

A6 models were equipped with one of two different quattro (all-wheel

drive) manual transmissions.

Transmission Type
5-speed man ual 01A
6-speed manual 01E

Transmissions are identified by type , code , serial number,

manufacturer identification code and build date. Transmission
identification plates containing some or all of this information are
affixed to the transmission housing. See 03 Maintenance for more
information .

CAUTIO~
• To avoid damaging plastic interior trim, use a plastic prying tool
or a screwdriver with the tip wrapped with masking tape.
34-2 Manual Transmission
Transmission and Final Drive Oil

TRANSMISSION AND FINAL DRIVE OIL

Manual transmission oil

Manual transmission gear box and final drive share a common oil
supply. Checking oil level of transmission also checks oil level of final
drive (differential) .

~ To remove manual transmission filler plug , use either a 17 mm Allen

17mm wrench or a triple-square socket driver, special tool 3357. A
Allen MN2567 combination tool with both 16 mm anti-tamper triple-square (XZN )
and 17 mm Allen ends is available as MN2567 .
I I
Current specifications for manual transmission oil are shown in
Table a. If oil container is not marked with appropriate specification,
assume that the oil is not suitable .

Table a. Manual transmission oil specifications

Transmission types 01 A, 01 E Synthetic oil SAE 75W90
VAG part no. G 005 000
or G 052 145 S2
A60403027

CAUTION-
• Part numbers for transmission lubricants are for reference only
Be sure to check with an authorized Audi parts department for
the latest recommendations.

Approximate refill capacities in Table bare listed by transmiss ion

type .

Table b. Manual transmission oil capacities (approximate)

Transmission type Oil capacity in liters (US qt)
01 A (5-speed AWD ) 2.7 (2.8)
01 E (6-speed AWD)
• Transmission code EDU 2.3 (2.4)
• Transmission code EEY or EHS 3.6 (3 .8)
(al lroad quattro)

5-speed manual transmission oil level

Make sure vehicle is level during this operation. If front of vehicle is
higher than rear, such as when driven up on ramps , oil inside
transmission pools toward rear, and level cannot be accurately
determined.

Checking level

Raise vehicle and support safely.

WARNING-
• Make sure the car is stable and well supported at all times . Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.
 Manual Transmission 34-3
Transmission and Final Drive Oil

~ Oil filler plug (arrow) is on left of transmission below speedometer

sender; it may be concealed by heat shield for drive axle. Depending
on transmission version fitted , use either special tool 3357 or 17 mm
Allen wrench to loosen and remove oil filler plug .

- Oil level is correct when transmission is filled up to lower edge of

filler hole.

Filling

If oil is low:
• Place oil drain pan underneath transmission filler plug
•Top up transmission oil with SAE 75 W 90 (synthetic oil) . Make
sure oil is filled up to lower edge of filler hole.
•Allow excess oil to drip out.

- Screw in oil filler plug .

Tightening torque
Oil filler plug to transmission housing I 25 Nm (18 ft-lb)

6-speed manual transmission oil level

When checking 6-speed manual transmission oil leve l, use a piece
of stiff wire (such as a coat-hanger) bent at right angle, as a dipstick.

Make sure vehicle is level during this operation . If front of vehicle is

higher tha n rear, such as when driven up on ramps , oil inside
transmission pools toward rear, and level cannot be accurately
determi ned.

Checkin g level

Raise veh icle and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

~ Oil fille r plug (8) is on left, ahead of drive axle flange . Use either
special tool 3357 or 17 mm Allen wrench to loosen and remove oil
filler plug .

A34-0078 I
34-4 Manual Tran smission
Gear Selector Service

~ Check transmission oil level using stiff wire hook inserted into fill

~ etool
hole.

L;ir 6-speed manua l transmission oil level guidelines

Vehicle without transm ission oil 7 ± 1 mm (% in)
cooler below fill hole opening

1 ± 1 mm
(transmission
117 ± 1 mm
(transmission without
oil cooler)
Vehicle with transmission oil
cooler
1 ± 1 mm (1/2s in)
below fill hole open ing
with oil

cooler) 'f;;;:i§:f{:f:'.;::f ~ Filling

11 .·- -·- ~·~ ~ ~ ~~:/'~
/,/ - If oil is low, top up transmission oil with SAE 75 W 90 (synthetic oil) .
~~~?E~~~~ A60403021

CAUTIO N-
•Adhere strictly to the oil level guidelines. The transmission is
very sensitive to overfilling.

- Screw in oil filler plug.

Tightening torque
Oil filler plug to transmission housing 40 Nm (30 ft-lb)

GEAR SELEC TOR SERVIC E

NOTE-
• To remove the complete shift linkage, remove the exhaust system.
See 26 Exhaust System .
• To disassemble the shift linkage in the installation position, the shift
mechanism housing must be lowered.
• Lubricate sliding surfaces with polycarba mide grease.
 Manual Transm ission 34-5
Gear Selector Service

_...,
Gear selector mechanis m
I
(5-speed)
_._______ 9 1. Shift knob

1- - -\J 2. Shift boot

3. Circlip
4. Bushing
5. Compression spring
6. Ball stop
7. Compression spring
8. Bushing
3------
9. Shift lever
4 -----~
10. Spacer tube
5 -----~
11. Nut, 8 Nm (ft-lb)
6 - - - - - --
12. Nut, 8 Nm (ft-lb)
13. Cover
14. Nut, 10 Nm (7 ft-lb)
15. Connecting piece
16. Nut, 23 Nm (17 ft-lb)
17. Connecting piece
18. Circlip
19. Buffer
20. Ball housing (upper)
21. Ball housing (lower)
. . . ______ _ __ 31 22. Bolt, 10 Nm (7 ft-lb)
N34-0607 II 23. Bolt, 23 Nm (17 ft-lb)
24. Washer
25. Shift mechanism housing
26. Nut, 10 Nm (7 ft-lb)
27. Nut, 10 Nm (7 ft-lb)
28. Shift fork
29. Bolt
30. Tensioning ring
31. Boot
32. Shift rod
33.Clamp
34. Bolt, 23 Nm (17 ft-lb)
35. Bolt, 23 Nm (17 ft-lb)
36. Bolt
37. Washer
38. Washer
39. Pivot rod
34-6 Manual Transmission
Gear Selector Service

Selector mechanism (5-speed),

removing and installing
- Unscrew gear shift knob from shift rod .

NOTE-
• Cover on gear shift is removed together with cover fo r center
console.

~ Use a plastic prying too l to lift up cover for center console slightly
(A) .

- Pull cover slightly toward rear (8) and lift off complete cover.

I
I A34-0118 I
I

~ Remove noise insulating cover for gear shift housing (arrows).

~ Unscrew nuts securing gear sh ift housing (arrows).

- Separate exhaust system behind catalytic converter. If necessary

remove front exhaust system .

- Remove driveshaft.
 Man ual Transmission 34-7
Gear Selector Service

~ Remove selector rod (A) .

- Unscrew Allen bolt on push rod (8 ).

- Remove front heat shield above exhaust system .

- Swing gear shift housing with selector rod and push rod down and
remove.

Installing

- Install in reverse order.

- Push selector rod on so that the securing bolt fits in the recess in the
selector shaft.

~ Then secure selector rod (A) with bolt.

- Secure push rod to transmission (8 ) with bolt.

- Adju st gear selector mechanism . See Gear selector mechanism

(5-speed ), adjusting in this repair group.

- Install driveshaft and adjust. See 39 Differential and Final Drive.

Tighten ing torques

Gear shift housing to body 10 Nm (7 ft-lb)
Selector rod to transmission 20 Nm (15 ft-lb)

Push rod to transmissi on 40 Nm (30 ft-lb)

Gear selector mechanism (5-speed), adjusting

- Requirements:
•Components of selector mechanism and linkage must be in good
conditio n.
•Selector mechanism must move freely.
•Transmission , clutch and clutch mechanism must be in good
condition .
• Transmission in neutral.

- Unscrew gear shift knob from gear shift.

NOTE -
• Cover on gear shift is removed together with cover for center
console.

I
~ Lift up cover for center console slightly (A).

- Pull cover slightly toward the rear (8 ) and then lift off complete cover.

A34-0118 I
I
34-8 Manual Transmission
Gear Selector Service

~ Remove noise insu lating cover for gear shift housing (arrows).

~ Measure distance between body and rear push rod (in selector
mechanism) . Distance a should equal 41 mm .

If this is not the case , adjust dimension a as follows :

•Loosen push rod bolt (arrow) . Rear push rod (in selector
mechanism) should move freely in both directions on slide .
•Set to distance a by moving rear push rod (in selector mechanism).
• Tighten push rod bolt.

Tightening torque
Push rod adjusting bolt 25 Nm (18 ft-lb)
I

~ Loosen bolt for shift rod (arrow) . Shift rod/shift mechanism must
move freely.

~l a !~
~ Align shift lever as follows :
. I • Shift lever vertical in direction of travel.
• Shift lever slightly inclined toward rear (a) .

NOTE-
• Shift lever is shown from the right side.

Hold shift lever in this position .

- Tighten bolt for shift rod.

Tightening torque
A34-0280

Shift rod adjusting bolt 25 Nm (18 ft-lb)

I
 Manual Transmission 34-9
Gear Selector Service

NOTE -
• Make sure position of shift lever does not change when bolt is
tightened.

Gear shift adjustment (5-speed), checking

Make sure gear shift lever rests in the 3rd/4th gear gate when
transmission is in neutral.

- Operate clutch .

- Check that all gears can be engaged .

- Check operation of reverse gear lock:

• The gear shift should return by itself from the 5th/reverse gate into
the 3rd/4th gate.
• It must not be possible to shift directly into reverse gear from 5th
gear.
• It must only be possible to shift into reverse gear when shift lever
starts in the neutral gate between 3rd/4th gears.

NOTE -
• If only 5th gear and reverse gear cannot be engaged, check the 5th
and reverse gear locking unit and replace if necessary

- Attach covers and gear shift knob.

Selector mechanism (6-speed),

removing and installing
Unscrew shift knob from lever.

NOTE -
• Shift cover is removed together with cover for center console.

~ Use a plasti c prying tool to slightly lift cover for center console

I
upward (A).

Pull cover slightly back (8) and remove complete cover.

A34-0 11 8 I
I

~ Remove noise insulation for selector mechanism housing (arrows) .

34-10 Manual Transmission
Gear Selector Service
<iiiiiiii( Remove nuts securing selector mechanism housing (arrows) .

<iiiiiiii( Remove heat shield mounting nuts (arrows) for left inner drive axle
joint.

- Detach left inner drive axle (1 ). Lift axle towards the front and tie up.

- Remove rear section of exhaust system (rearward of exhaust pipe

clamps) .

- Remove heat shield above driveshaft.

<iiiiiiii( Remove heat shield for driveshaft from differential (arrows) .

- Remove driveshaft.

<iiiiiiii( Unscrew bolts (1 and 2) on left and right.

 Manual Transmission 34-11
Gear Selector Service

~ Lower rear of subframe (distance a) a maximum of 50 mm (2 in ).

~ Do not pull ball head (A) of connecting rod (2) off shift rod (1 ). The
ball head is destroyed when pulled off.

- Nut (B) and bolt (C) must be removed to remove shift rod .

~ Unbolt connecting rod (2) on right side of transmission .

- Remove bolt from push rod (1 ).

NOTE -
• Reuse any washers installed between the pushrod and the
transmission (arrow) .

~ Unscrew nut (1) and pull selector rod lever (2) off transmission
selector shaft.

- Swing gear shift housing with selector rod and push rod down and
remove .
34-12 Manual Transmission
Gear Selector Service

- Installation is carried out in reverse order. Note the fo llowing :

• Bolt on driveshaft.
•Adjust driveshaft.
•Adjust gear selector mechanism.
• Align exhaust system free of stress.

Tightening torques
Bolt (1) 75 Nm (55 ft-lb)

Combination bolt (2) 110 Nm (81 ft-lb)

+ 90° turn

Gear shift housing to body 10 Nm (7 ft-lb)

Selector rod to transmission 25 Nm (19 ft-lb)

Connecting rod to transmission 25 Nm (19 ft-lb)

Push rod to transmission 40 Nm (30 ft-lb)

Drive axle to drive flange :

•MS 40 Nm (30 ft-lb )
• M10 70 Nm (52 ft-lb)

Heat shield for drive axle 25 Nm (19 ft-lb)

Clamp for exhaust pipe 40 Nm (30 ft-lb )

Gear selector mechanis m (6-speed), adjusting

- Adjustment requirements:
•Selector mechanism , operating and relay elements must be in
good condition .
• Selector mechanism must move freely.
•Transmissio n , clutch and clutch mechanism must be in good
condition .
• Transmission in neutral.

- Unscrew gear shift knob from gear shift.

NOTE-
• Shift cover is removed together with the cover for center console.

~ Use a plastic prying tool to slightly lift cove r for cen ter console
upward (A).

- Pull cover slightly back (8) and lift off complete cove r.

I
A34-0118
I
I
 Manual Transmission 34-13
Gear Selector Service

~ Remove noise insulation for selector mechanism housing (arrows ).

~ Measure distance between body and rear push rod (in selector
mechanism) . Distance a should equal 43 mm . If not, continue with
procedure .

~ Loosen bolt (arrow) for pivot rod .

• Rear pivot rod (in shift control mechanism) must move freely back
and forth on sliding piece .

- Adjust measurement a by moving pivot rod rear (in shift control

mechanism) .

- Tighten bolt for pivot rod .

Tightening torque
Pivot rod adjustment bolt 25 Nm (18 ft-lb)

~ Loosen bolt for selector rod (arrow). Connection between selector

I rod and selector mechanism should move freely.

N34-061 3 I=
___./
34-14 Manual Transmission
Gear Selector Service

Adjust gear shift as follows:

~ Gear shift vertical , maximum inclination of 3° to right (a).

NOTE -
• Illustration shows gear shift from behind (looking towards front of
vehicle)

A34-0 109 I

I ~ Gear shift inclined slightly backwards (approx. 7°).

~~
I NOTE-
• Illustration shows gear shift from the right.

Hold gear shift in this position.

- Tighten selector rod bolt.

Tightening torque
Selector rod adjustment bolt 25 Nm (18 ft- lb)

A34-0110 I
NOTE-
• Gear shift must remain in the same position while bolt is being
tightened.

Gear shift adjustment (6-speed), checking

- Gear shift lever must rest in the 3rd I 4th gear gate when
transmission is in neutral.

- Check operation of 1st and 2nd gear stop.

Engage 2nd gear and push gear shift to the left against the stop.

Reduce pressure on gear shift until it moves back to pressure point.

•Spring-back measured at gear shift handle : 3-5 mm.

- Check that all gears can be engaged .

- Check operation of reverse gear lock.

• It should only be possible to engage reverse gear after pressing
the gear shift down to overcome the reverse gear lock.
• It must be possible to move the gear shift, without pushing and
without force , forwards from the reverse gear lock to the 3rd/4th
gear plane.

If the gear shift setting is incorrect, continue with procedu re .

 Manual Transmission 34-15
Transmission Service

~ Loosen bolt for selector rod (arrow).

I
NOTE-
• The angle of forward I backward inclination of the gear shift must
not be changed while the following adjustments are being made.

N34-06 13 1-
____./

~ Move gear shift to the left or to the right until distance x is 8.5 mm
(0 .33 in) .

- Hold gear shift in this position.

- Tighten selector rod bolt.

- Check gear shift setting again .

Fit covers and gear shift knob.

Tightening torque
Selector rod to selector fork 25 Nm (18 ft-lb)
A34-0 144 I
TRANSMISSION SERVICE

Transmission (5-speed),
removing and installing
- Special tools:
•Transm ission jack V.A .G 1383 A
• Transmission support 3282
•Adjustment plate 3282/10
•Assembling appliance 3139
• Wrench set for oxygen sensors 3337
•Grease G 000 100

- Switch ignition OFF and disconnect battery ground (-) strap.

~ Remove intake hose (A) .

- Unbolt coolant system expansion tank (B) and lay to one side .

- Remove oxygen sensors on left and right exhaust pipes with special
tool 3337 and move clear to the side.

- Unscrew engine/transmission securing bolts accessible from above.

34-16 Manual Transmission
Transmission Service
~ Remove lower engine cover (arrows). See 03 Maintenance for
more information.

~ Unbolt lower engine cover bracket (arrow).

~ Remove bolts (1 and 2) for heat shields above right axle shaft.

- Remove heat shield above left axle shaft.

~ Unbolt front exhaust pipes with catalytic converters from left and
right exhaust manifolds (3 nuts on each side) (arrows).

- Remove clamping sleeves of exhaust system and remove catalytic

converters together with exhaust pipe downward .

A34-0129 I
 Manual Transmission 34-17
Transmission Service

~ Remove engine speed sender (G28) on left of transmission (arrow)

and move clear to side.

- Remove drive axles from drive flanges and tie up as high as

possible ; do not damage protective coating.

~ Pull connector off wheel speed sender (A).

- Pull off back-up light connector (8). Disconnect all other electrical
connections and ground wires from transmission and from the
engine I transmission securing bolts.

~ Unbolt starter from engine/transmission and secure as necessary.

NOTE -
• Starter cables do not have to be disconnected.

~ Detach selector rod arrow (A).

- Unscrew Allen bolt out of push rod (8) .

34-1 8 Manual Transmission
Transmission Service
(arrow s).
- Unbolt heat shield for drives haft from differential cover

~ Unbolt drivesha1ft (1) from transm ission and rest it on

heat sh ield (2).

(arrow ).
- Secure driveshaft to fuel pipe bracket (3) with wire

~ Unscrew bottom engine I (A

transm ission securing bolts, except fo r
and B).
bolts indicated by arrows

~ Set up transmission support 3282 for remov ing manual transmiss ion
plate 3282/ 10 and attach to
01A (all wheel drive) with adjust ment
transmission jack VAG 1383 A.

NOT E-
the directi on of
• Attach ments (A) are shown ; arrow (BJ points in
travel.
n.
•Adjus tment platt? 328211O only fits in one positio

V34-258 3
 Manual Transmission 34-19
Transmission Service

Run transmission jack VAG 1383 A with transmission support 3282

in under the transmission and take up the weight of the
transmission .

NOTE -
• If the transmission lift 3282 is not available, the transmission can
be removed and installed using transmission lift 1383A and
universal mounts VAG 135912 .

....;( Align adjustment plate parallel to transm ission and lock safety
support (arrow) on transmission .

....;( Unbolt right and left transmission supports complete with bonded
rubber mountings from transmission and subframe (1 and 2) .

....;( Remove remaining engine I transmission securing bolts (A and 8).

- Press transmission off dowel sleeves and lower carefully with

transmission jack VAG 1383 A just far enough for access to clutch
slave cylinder.

NOTE -
• When lowering transmission ensure hydraulic pipe and hose to
slave cylinder are not damaged.
34-20 Manual Transmission
Transmission Service

~ Remove clutch slave cylinder (arrow) and secure with wire. Do not
disconnect fluid lines.

NOTE-
• Do not depress clutch pedal after detaching slave cylinder.

Lower transmission completely.

NOTE-
• Remove carefully, watching for hoses, electrical wires or
mechanical parts that might become snagged.

Installing
Installation is reverse of removal. Remember to:
•Clean input shaft splines and (if reusing clutch disc) hub splines.
Remove corrosion and apply only a very thin coating of grease
G 000 100 to splines. Do not grease guide sleeve .
• Check clutch release bearing for wear. Replace if necessary.
•Coat slave cylinder push rod tip with thin layer of copper grease.
•Check whether dowel sleeves for aligning engine I transmission
are fitted in cylinder block. Install if necessary.
•Use tap to clean threaded holes for mounting clutch slave cylinder
to transmission and shift coupling to shift rod.
• Replace self-locking nuts.

~ Lift transmission until clutch slave cylinder and fluid line bracket can
be installed (arrow) .

Fit intermediate plate between transmission and engine on engine

dowel sleeves.

Ensure that intermediate plate is correctly positioned on engine .

Install lower engine I transmission securing bolts and bolts for

starter. Install starter.

- Before installing , use a tap to clean threads in transmission drive

axle flange to remove traces of thread locking compound .

Replace gaskets on axle shafts and on front of driveshaft.

Bolt on drive axles and drive axle heat shields.

Bolt on driveshaft heat shields and driveshaft.

- Align exhaust system so it is free of stress.

Insert oxygen sensors and tighten .

If equipped, install the engine speed sensor (G28) .

- Check adjustment of shift and pivot rod and adjust if necessary.

- Check oil level in transmission.

- After connecting battery, enter anti-theft code for radio.

 Manual Transmission 34-21
Transmission Service

- Close electric windows in front doors all the way to their top positions
using electric switches . Then operate all electric window switches
again for at least one second in the "close " direction to activate
automatic one-touch function .

- Set clock to correct time.

Tig htening torq ues

~ Transmiss ion to engine (6-cylinder)

Item No. Bolt Qty. Torque

M 12 x 67 3 65 Nm (48 ft-lb)
2 M 12x 90 65 Nm (48 ft-lb)
3 M 12 x 80 65 Nm (48 ft-lb)
4 M 10 x 45 3 45 Nm (33 ft-lb)
5 (lower) M 10 x 135 45 Nm (33 ft-lb)
5 (upper) M 12 x 130 65 Nm (48 ft-lb)
A = cente ri ng sleeves

~ Transmissi on I engine mounts

Item No. Bolt Qty. Torque

M 10 x 35 3 40 Nm (30 ft-lb)

2 M 8x 20 2 20 Nm (15 ft-lb)

Tighteni ng to rques
Axle shaft heat shield to transmission 23 Nm (17 ft-lb)

Bracket fo r noise insulation to body 10 Nm (7 ft-lb)

Catalytic converter to mounts 25 Nm (19 ft-lb)

Clamp fo r exhaust pipe 40 Nm (30 ft-lb)

Clutch sl ave cylinder to transmission 20 Nm (15 ft-lb)

Drive axle to transmission flange :

•MS 40 Nm (30 ft-lb)
• M10 70 Nm (52 ft-lb)

Oriveshaft heat shield to differential cover 25 Nm (1 9 ft-lb)

Driveshaft to transmission 55 Nm (41 ft-lb)

Engine speed sender (G28) to block 10 Nm (7 ft-lb )

Pushrod to transmission 40 Nm (30 ft-lb)

Selector rod to transmission 23 Nm (17 ft-lb)

34-22 Manual Transmission
Transmission Service

Transmission (6-speed),
removing and installing
- With ignition switched OFF and disconnect battery ground (-) strap.

~ Loosen bolts (arrows) and remove engine cover panels

(A , B, and C) . See 03 Maintenance for more information.

~ Detach air intake duct. To do this , pull off retainer catch (1 ), loosen
clamps (2) and unscrew bolts (3).

- Remove cooling system expansion reservoir and lay to one side.

~ Unplug oxygen sensor connector on left (2) and move wire clear.

~ Unplug oxygen sensor connector on right (1) and move wire clear.
 Manual Transmission 34-23
Transmission Service

~ Unscrew two bolts securing heat shield (2) on exhaust pipe (right
and left) .

Unscrew nuts (3) on exhaust pipe (right and left).

Unscrew engine I transmission mounting bolts accessible from

above.

~ Remove lower engine cover (arrows) . See 03 Maintenance for

more information .

~ Unbolt lower engine cover bracket (arrow).

- Unbolt heat shields from transmission above left and right drive
axles.

- Unbolt left and right drive axles from transmission , lift clear and tie
aside.

NOTE -
• Take care not to damage protective coating on drive axles.

Loosen exhaust system clamps and push clamps towards rear.

- - - - = = = = = = - - - - - - - - - -1'.13zt=Q-·s u -

~ Remove heat shield for driveshaft from cover for differential

(arrows) .
34-24 Manual Transmission
Transmission Service
~ Unbolt driveshaft (1) from transmission and rest it on heat shie ld (2).

- Secure driveshaft to fuel pipe bracket (3) with wire (arrow).

a
I A34-0128 I
I Ill\

~ Remove bolts (arrows) and remove transverse mount (A).

~ Unscrew and remove bolts (1 and 2) on right and left an d remove

support (A).

~ Lower rear of subframe (distance a) a maximum of 50 mm (2 in) .

 Manual Transmission 34-25
Transmission Service

~ Unscrew bolts (1 and 2) and remove side transmiss ion mounts.

~ Loosen clamp (3) , lift heat shield (2) slightly and unscrew remaining
nuts (5).

- Lift heat sh ield (2) and pull out front exhaust pipe together with
catalytic converter (4) .

- Note that oxygen sensor (1) and wire have to be guided through
opening in heat shield (2) .

NOTE-
• Avoid excessive bending of the flexible pipe connection at front
exhaust pipe. The angle between the catalytic converter and the
front exhaust pipe must not exceed 10°. Otherwise the flexible
connection will be damaged.

~ Lift transmission to access two lower bolts securing engine to

transmission.
• A - Axle stand
• 8 - VAG 1 383A

A34-016 1

~ Unscrew two bolts securing transmission to engine (arrows) .

NOTE -
• The two M 1O x 60 Allen bolts must be replaced by new M 1O x 55
bolts (part no. N 104 684 01) so that bolts (arrows) can be
tightened to the correct torque after installing the transmission .

- Lower transmission again slowly.

~
A34-0173 I
34-26 Manual Transmission
Transmission Service

~ Remove engine speed sender (G28) from left hand side of

transmission (arrow) and place to one side .

- Pull connector off speedometer sender.

- Pull back-up switch connector off.

- Unbolt starter and push it forward as far as it will go.

NOTE -
• Do not disconnect starter cables.

~ Unbolt connecting rod (2) for selector rod on right side of

transmission.

- Remove Allen bolt from push rod (1 ).

NOTE -
• Reuse any washers installed between the pushrod and
transmission (arrow).

A34-0282 I

~ Unscrew nut (1) and pull selector rod lever (2 ) off transm issi on
selector shaft.

- Remove all connecting bolts for engine I transmission from below,

except for one bolt for securing .

3282/12 ~ Set up transmission support 3282 with adjustment plate 3282/ 12 for
removal of manual transmission 01 E (all-wheel drive) and place on
transmission jack VAG 1383 A.

NOTE-
• The positions for the attachments are shown (A) .
•Adjustment plate 3282112 can only be fitted in one position.
 Manual Transmission 34-27
Transmission Service

~ Support transmission with VAG 1383 and adapter 3282.

NOTE -
• If adapter 3282 is not available, the transmission can be removed
and installed using transmission jack VAG 1383 A.

Remove the last remaining engine I transmission securing bolt.

Press transmission off dowel sleeves and lower carefully just far
enough for access to the clutch slave cylinder.

NOTE -
• When lowering transmission ensure hydraulic line to slave cylinder
is not damaged.

~ Remove bolt (arrow) and take out slave cylinder from rear. Do not
detach hydraulic line.

NOTE -
• Do not depress clutch pedal after removing slave cylinder.

Lower transmission completely.

NOTE -
• Remove carefully, watching for hoses, electrical wires or
mechanical parts that might become snagged.

Installation is reverse of removal. Remember to :

• Replace all seals and gaskets .
• Replace al l self-locking nuts.
• Check whether dowel sleeves for aligning transmission with
engine are in engine flange . Insert if necessary.
•Clean input shaft splines and (if reusing clutch disc) hub splines.
Remove corrosion and apply only a very thin coating of grease G
000 100 to splines. Do not grease guide sleeve.

Check clutch release bearing for wear and replace if necessary.

~ Coat slave cylinder collar a with lithium grease before mounting to

transmission housing.

Coat clutch slave cylinder push rod tip with thin layer of copper
grease.

- On vehicle with V6 biturbo engine, fit intermediate plate on dowel

sleeves of engine flange .

A30-0037
34-28 Manual Transmission
Transmission Service

~ Replace two M1 Ox 60 Allen bolts with new M10 x 55 bolts

(part no. N 104 684 01) so that bolts (arrows) can be tightened
to correct torque.

- Before installing transmission , tie electrical wiring off to one side so

that it cannot be trapped between engine and transmission .

~
A34-0173 I
~ Lift transmission until clutch slave cylinder and hydraul ic line bracket
can be installed (arrow) .

- Align exhaust system so it is free of stress.

- Before installing , use a tap to clean threads in transm ission drive

axle flange to remove traces of thread locking compoun d.

- Replace gaskets on drive axles and on front of driveshaft.

- Bolt on drive axle heat shields and drive axles.

- Bolt on driveshaft heat shields and driveshaft.

- Check adjustment of selector rod and push rod ; re adjust if

necessary.

- Check oil level in transmission .

- Connect battery and enter anti-theft code for radio.

- Close windows fully using electric window switches. Hold win dow
switches in the "close " position for at least one second to reactivate
one-touch function .

- Set clock to correct time.

~ Vehicle with 6-cyl. biturbo engine

Item No. Bolt Qty. Torque

1 M 12 x 90 2 65 Nm (48 ft- lb)

2 M 12 x 100 1 65 Nm (48 ft-l b)

3 M 10 x 60 1 45 Nm (33 ft- lb)

4 M 10 x 60* 2 45 Nm (33 ft-lb)
5 M 10 x 150 1 65 Nm (48 ft-lb)

6 M 12 x 130 1 65 Nm (48 ft-lb)

7 M 12 x 80 2 65 Nm (48 ft-lb)
* Replace two M 10 x 60 bolts with new M 10 x 55 bolts
(part no. 104 684 01) to achieve correct torque specification .
A = dowel sleeves for aligning
 Manual Transmission 34-29
Transmission Service

Tightening torques

Bracket for noise insulation to subframe 10 Nm (7 ft-lb)

Catalytic converter to mounting lugs 25 Nm (1 g ft-lb)
Clamp for exhaust pipe 40 Nm (30 ft-lb)
Clutch slave cylinder to transmission 20 Nm (15 ft-lb)
(always replace)

Connecting rod to transmission 23 Nm (17 ft-lb)

Drive axle to drive flange:
•MS 40 40 Nm (30 ft-lb)
• M10 70 70 Nm (52 ft-lb)
Driveshaft to transmission (always replace) 55 Nm (40 ft-lb)
Engine speed sender (G28) to block 10 Nm (7 ft-lb)
Front exhaust pipe to turbocharger 30 Nm (22 ft-lb)

Heat shield to differential cover 25 Nm (1 g ft-lb)

Heat shield to transmission 25 Nm (1 g ft-lb)

Heat shield to turbocharger I exhaust pipe 10 Nm (7 ft-lb)

Push rod to transmission 40 Nm (30 ft-lb )

Selector rod to transmission 23 Nm (17 ft-lb)

Transmission suppo rt to transmission 40 Nm (30 ft-lb)

~ Subframe to body

Tightening torque
Support (A) to body (1) 75 Nm (55 ft-lb)

Subframe to body (2) (always replace) 115 Nm (85 ft-lb)

+ go 0 turn
Transmission mount to subframe (3) 25 Nm (1 g ft-lb)

~ For 6-cylinder biturbo engine only.

Tightening torque
Cross piece to subframe (always replace) 40 Nm (30 ft-lb)
(fit bolt from bottom upwards) +goo

.. ·v

~
I
 37-1

37 Automatic Transmission

GENERAL . . ...... ... ... . .... . . .. .. . .. .. . 37-1 Tiptronic switch (F189) ,

Back-up light switch functi on . .. .. ... ........ 37-2 removing and installing .. . ..... . ........ 37-10
Shift mechanism, removing and installing .... 37-11
TRANSMISSION OIL. ..... . ... ............. 37-2
Selector lever cable , removing and installing .. 37-14
Automatic transmissi on fluid (ATF) ........ . . . 37-2 Selector lever cable , checking and adjusting .. 37-17
ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-3 Ignition interlock, checking ............ ... . 37-18
CVT ATF level. . . . . . . . . . . . . . . . . . . . . . . . . . . 37-5 Ignition interlock cable , removing and installing 37-18
SHIFT MECHANISM AND COMPONENTS ..... 37-7 TRANSMISSION OIL PAN
Shift mechanism assembly ...... ... . ...... 37-7 AND COMPONENTS . . .. ... . ... .. .. ... .. . 37-20
Shift mechanism, checking . .... . ... .. . . . .. 37-8 Transmission oil pan , removing and installing . 37-20
Selector lever handle, removing and installing .. 37-9 ATF screen, removing and installing .. . ..... 37-20
Shift mechanism cover, Vehicle speed sensor (G22) ,
removing and installing .... . . .... . . ..... 37-10 removing and installing . .... ... . ..... . . . 37-21
Tiptronic switch (F 189), checking ... ....... . 37-10 Transmission rpm sensor (G 182),
removing and installing . . . ... . . ........ . 37-21

GENERAL
This repair group covers external components and adjustments
to A6 automatic transmissions . Special tools and equipment are
required to re move the automatic transmission . Removal of the
automatic transmission is outside the scope of th is manual.

A6 models were equipped with one of three different automatic

transmissio n versions , depending on engine type and front-wheel-
drive (FWD) or all-wheel-drive (AWD) requirements.

Table a. Automatic transmission codes

Description Type
5-speed automatic with Tiptroni c® AWD 01L
5-speed automatic with Tiptronic® 01V
FWD or AWD
Multitronic® or continuously variable transmission (CVT) 01 J
FWD

Transmission s are identified by type , code , serial number,

manufacturer identification code and build date. Transmission
identification plates containing some or all of this information are
affixed to the transmission housing.

For additional information on identifying engine and transmission ,

see 03 Maintenance.

- I -

'
~J,j.
37-2 Automatic Transmissio1~
Transmission Oil

Back-up light switch function

When automatic transmission is placed in reverse , multifu nction
transmission range switch (F125) switches back-u p lights ON.

When CVT transmission is placed in reverse , transmission control

module (J217) indicates gear position to park I neutral position
(PNP) relay (J226) . PNP relay then switches back-up lights ON.

For more information on back-up lights, see 96 Interior Lights,

Switches, Anti-theft.

TRANSMISSION OIL

Automatic transmission fluid (ATF)

Current specifications for ATF are shown in Table b. If fluid container
is not marked with appropriate specification , assum e that the oil is
not suitable.

Table b. ATF specifications

Transmission types 01 L, 01 V VAG ATF
part no . G 052 162 A2
Transmission type 01 J CVT ATF
(Multitronic®, continuously part no. G 052 180 A2
variable transmission or CVT)

CAUT/O~
• ATF used in CVT transmission is different from fluid used in the
conventional automatic transmission. Only use ATF specifically
intended for CVT transmission.

Approximate transmission refill capacities in Table care li sted by

transmission type. Automatic transmission application information is
in Table a in this repair group.

Table c. ATF capacities (approximate)

Oil capacity in liters (US qt)

Transmission type New fill Change
01L 9.8 (10.4) 3.5 - 4.0 (3. 7 - 4.2)
01V 9.0 (9 .5) 3.5 - 4.0 (3.7 - 4.2)
01J (CVT) 7.5 (7.9)
 Automatic Transmission 37-3
Transmission Oil

ATFlevel
Make sure vehicle is level during this ope ration . If front of vehicle is
higher than rea r, such as when driven up on ramps , oil inside
transmission pools toward rear, and level cannot be accurately
determined.

Checking level

ATF level varies according to temperature as volume increases with

a rise in temperature. Therefore, to check ATF level accurately,
measure fluid temperature. ATF temperature may be measured
using transmission control module on-board diagnostics connected
to VAS 5051 or equivalent scan tool.

- Before startin g an ATF level check , observe the following :

• Electrical consumers OFF.
• A/C system OFF.
•Transmission not in emergency running ("limp home") mode .
• ATF temperature not above approximately 30°C (86°F).
• Vehicle level.

~ Connect scan tool (VAG 1551 or equivalent) to data link connector

(DLC, inset) , located under driver's knee bar, to left of steering
column .

- Start engine with transmission in PARK and read ATF temperature

on scan tool .

Raise vehicle and support safely.

WARNING -
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Place oil drip pan underneath transmission .

~ Working underneath vehicle , remove transmission fill plug .

WARNING -
• Hot transmission oil can scald. Wear protective gloves and
goggles.

- ATF level is correct when a little ATF runs out at a temperature

between 30°C (86°F) and 45°C (113°F).
• For tropical climates , allow ATF to drip out until temperature rises
to approx . 50°C (122°F) .
•If no ATF runs out when temperature reaches 40°C (1 04°F), add
ATF.
37-4 Automatic Transmissio
Transmission Oil

Filling
VAG 1924
~ Use fluid pump with shut-off valve such as VAG 1924 or equivalent
to fill transmission .

~ Insert filling hook of VAG 1924 into opening of ATF guard cap in filler.

~ Add ATF until ATF flows from plug opening .

- Replace filler plug . Use new gasket.

Tightening torque
ATF level
ATF filler plug to ATF sump (use new gasket) j 80 Nm (59 ft-lb)
I

ATF sump
PB0403015
 Automatic Transmission 37-5
Transmission Oil

CVT ATF level

CAUTIO~
• ATF used in 01J CVT (Multitronic®J transmission is different
from fluid used in the conventional automatic transmission.
Only use ATF specifically intended for CVT transmission,

Make sure vehicle is level during this operation . If front of vehicle is

higher than rear, such as when driven up on ramps , oil inside
transmission pools toward rear, and level cannot be accurately
determined .

Checking level

ATF level varies according to temperature as volume increases with

a rise in temperature. Therefore, to check ATF level accurately,
measure flu id temperature. ATF temperature may be measured
using transmission control module on-board diagnostics connected
to VAS 5051 or equivalent scan tool .

- Before starting an ATF level check , observe the following :

• Electrical consumers OFF.
• A/C system OFF.
•Transmission not in emergency running ("limp home") mode.
• ATF temperature not above approximately 30°C (86°F).
•Vehicle level.

~ Connect scan tool (VAG 1551 or equivalent) to data link connector

(DLC, inset) , located under driver's knee bar, to left of steering
column.

- Start engine with transmission in PARK and read ATF temperature

on scan tool.

- With engine idling , depress brake pedal and shift through selector
lever positions (P, R, N, D). Leave selector in each position approx .
2 seconds.

Raise vehicle and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

~ Working underneath vehicle , loosen transmission splash shield

mounting fasteners (3 , 4) . Remove splash shield .

- Place oil drip pan underneath transmission .

37-6 Automatic Transmissio
Transmission Oil

~ Remove transmission filler plug (8 ).

WARNING-
• Hot transmission oil can scald. Wear protective gloves and
goggles.

- ATF level is correct when a little ATF runs out at a te mperature

between 35°C (95°F) and 45°C (113°F) .
• For tropical climates , allow ATF to drip out until temperature ri ses
to approx. 50°C (122°F) .
• If no ATF runs out when temperature reaches 40°C (104°F), add
ATF.

Filling
~ Use fluid pump with shut-off valve such as VAS 5162 or equivalent
to fill transmission .

- Add ATF until ATF flows from plug opening .

- Replace filler plug . Use new gasket.

Tightening torque
ATF filler plug to ATF sump (CVT) I 20 Nm (15 ft-lb)
 Automatic Transmission 37-7
Shift Mechanism and Components

SHIFT MECHANISM AND COMPONENTS

Shift mechanism assembly

1. Gear selector handle
•See Gear selector handle, removing
and install ing in this repair group
2. Sleeve
• Engages into grip for selector handle
3. Cover
•With transmission range display,
7 display for shift lock and Tiptronic
4. Cover
8 5. Trim piece
6. Symbol panel
• Circuit board with integrated
Tiptronic switch (F189)
7. Slide cover
8. Guide
9. Mounting bushing
10. Locking clip
•Install with angled ends pointing
toward inside of mounting bracket.
11. Pull rod

~ 26 12. Spring
I
13. Selector lever
! ~ 27
@ 14. Stop buffer
32 29 I A37-0253 I
15. Detent
16. Cable lever
17. Spring clip with roller
18. Spring clip with roller
19. Frame
• Clip onto mounting bracket
• Ribbed side must point up
20. Nut, 10 Nm (7 ft lb)
21. Mounting bracket
22. Fulcrum pin
23. Locking pawl
24. Shift lock solenoid switch (N110)
25. Fulcrum pin
26. Cover
•With seal for mounting bracket
27. Nut, 1O Nm (7 ft lb)
28. Securing clip
• Install with angled end forward
37-8 Automatic Transmissio
Shift Mechanism and Components

Shift mechanism assembly

4~
(continued)
29. Locking plate

5~
• Install with angled end toward inside of
3 mounting bracket

6~
30. Selector lever cable
• Do not bend or kink . Lightly lubricate
cable eye and ball socket before
installing.
15 • Replace selector cable if rubber
sleeves are damaged.
• Make sure rubber sleeves on
transmission side are not twisted .
31. Bolt, 23 Nm (17 ft lb)
32. Support bracket
33. Cable tie
34. Ignition I starter switch
35. Ignition interlock cable
• Do not kink
36. Locking lever
• For ignition key removal lock
37. Securing spring
38. Mounting bracket

32 31 30 29

NOTE-
• Lubricate bearings and sliding parts with lubricant
(part no. G 052 142 A2 or equivalent) .

Shift mechanism, checking

- Without stepping on brake , place selector lever in P and switch
ignition ON:
• The shift lever is locked and cannot be moved from P (the shift lock
solenoid switch locks the selector lever).

- With brake pedal depressed :

• The shift lock solenoid releases the selector lever. Selecting a
driving range must be possible without binding or snagging with the
button in the handle depressed.

- Move selector lever slowly from P to R, N, D, 4, 3, 2 and check

whether the driving range positions in instrument cluster display
match the console shift lever display.

- Without stepping on brake, place shift lever in N with ignition ON :

• The shift lever is locked and cannot be moved from N with button
in lever pressed (the shift lock solenoid switch locks the shift lever) .
 Automatic Transmission 37-9
Shift Mechanism and Components

- With brake pedal depressed :

• The shift lock solenoid releases the shift lever. Selecting a driving
range must be possible without binding or snagging with the button
in the handle depressed .

- With selector lever in D, ignition and lig ht switched ON .

• Move selector lever out of driving range D into Tiptronic gate.
•Illumination of D symbol on the cover of the shift mechanism must
dim and the + and - symbols must light up.

Start engine and let id le . Engage parking brake and depress brake
pedal:
• Sift lever position indicator in instrument cluster must change
during shifting into Tiptronic-gate from PRND432 to 54321 .

NOTE-
• It must not be possible to operate the starter motor in driving
ranges 2 , 3, 4 , D and R.
•For right hand drive (RHO) vehicles, the starter should only be able
to be operated with selector lever in P and N with locking button in
selector lever handle released.
•During vehicle speeds above 5 kph (3 mph) and shifting into N, the
shift lock solenoid must not engage and lock the selector lever. The
selector lever can be shifted into a driving range.
• When driving slower than 2 kph (1.2 mph) (the car is almost
stopped) and shifting into N, the shift lock solenoid must only
engage after about 1 second. The selector lever can only be
shifted out of N when the brake pedal is depressed.

Selector lever handle, removing and installing

~ Move selector lever to position 3 .

Push sleeve (1) down to stop.

Pull button (2) out of selector leve r handle (3) to stop and pull handle
upward to remove (dimension a= 3 mm) .

- To replace handle , move selector lever to position 3 .

- Carefully pull button (2) out of handle (3) to stop.

- With knob extended , attach handle in driving direction on selector

lever to stop.

- Turn handle (3) until knob (2) is pointing to driver. This causes
handle to engage into groove of selector lever.

Make sure handle engages into circular groove of selector lever.

Push in knob in handle.

Pull up sleeve (1) until it engages in handle .

37-10 Automatic Transmissio
Shift Mechanism and Components

Shift mechanism cover,

removing and installing
- Remove center console. See 70 Interior Trim .

- Remove selector lever handle. See Selector lever handle,

removing and installing in this repair group.

~ Release 4 retaining clips (arrows) and lift of cover (1) with guide .

- Unplug connector at side of guide .

- Installation is reverse of removal.

Tiptronic switch (F189), checking

The Tiptronic switch is integrated in the printed circuit of the sym bol
insert located in the cover of the shift mechanism . See Tiptronic
switch (F189), 1removing and installing in this repair group.

It consists of thriee Hall sensors (A, B and C) that are triggered by a

magnet on the slide cover.
• A - Sensor for downshift
• B - Sensor for Tiptronic recognition
• C - Sensor for upshift

A37-0325

~ In case of malfunction first check whether the magnet on slide cover

(C) is properly mounted . If necessary replace slide cover.

- Check wiring at Tiptronic switch .

- Check steering wheel buttons and their wiring connections.

Tiptronic switch (F189),

removing and installing
- Remove center console and extension . See 70 Interior Trim .

- Remove handle for selector lever. See Selector lever handle,

removing and installing in this repair group.

~ Carefully disengage 4 clips (arrows) and remove cover upward.

NOTE-
• If clips are damaged or broken, replace the applicable
components.
 Automatic Transmission 37-11
Shift Mechanism and Components

~ Lift out printed circuit board with small screwdriver ove r 3 clips
(arrows) .

Remove printed circuit board with integrated Tiptron ic switch .

NOTE-
• If the printed circuit board is glued into the cover, replace the
complete cover with printed circuit board.

- To install swi tc h, in sert printed circuit board with integrated T iptronic

switch into cover of shift mechanism .

Carefully snap printed circuit board into cover.

NOTE -
• The 3 clips (arrows) must engage visibly above the printed circuit
board.

Place cover on guide of sliding cover and snap cl ips in place.

Install handle for selector lever.

Install center console and extension .

Shift mechanism, removing and installing

NOTE -
• Shift mecha nism procedure shown is for FWD models. AWO
models are similar.

Place sh ift selector lever in PARK.

Remove selector lever handle. See Selector lever handle,

removing and installing in this repair group.

Remove shift mechanism cover. See Shift mechanism cover,

removing and installing in this repair group.

Disconnect electrical harness connecto r for shift lock solenoid .

~ Unhook locking cable (arrows) .

Raise veh icle and safely support

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.
37-12 Automatic Transmissio
Shift Mechanism and Components

~ Loosen mounting parts (3 and 4) and remove rear part of lower

engine cover.

~ Remove bolts (1 to 4) at both floor crossmembers (if applicable).

~ Disconnect exhaust system at double clamps (arrows) .

NOTE-
• Flex joint in front exhaust pipe must not be bent more than 10°,
otherwise it may be damaged.

- Remove heat shield for exhaust system beneath shift mechanism.

- AWD models : Disconnect driveshaft from transmission and support

from body using stiff wire .
0

~....;;_;;;,;~
I A26-0552 11
\\\\\
 Automatic Transmission 37-13
Shift Mechanism and Components

~ Remove lower cover from shift mechan ism (arrows) .

(
- Remove selector lever cable boot from cover and slide back.

A37-05 12 I

~ Remove securing plate (1) for selector lever cable on shift

mechanism down ward .

Remove locking clamp (3) from pin .

Remove selector lever cable (2) from pin .

NOTE-
• Do not bend or kink selector lever cable.

1 A37-051 3 I
~ Working from above: Remove nuts (arrows) securing mechanism .

- With an assistant supporting shift mechanism from below, press

retaining clips (1 and 2) inward and shift mechanism downward at
the same time.

- Pull out selector lever cable at the same time , so that it does not
bend . Re move shift mechanism .

- Installation is reverse of removal. Remember to :

•Install selector lever cable. See Selector lever cable , removing
and installing in this repair group.
•Install interlock cable. See Ignition interlock cable, removing
and installing in this repair group.
• Install exhaust system so that it is free from stress.

Tightening torques
Shift mechanism to body (replace nuts) 10 Nm (7 ft-lb)
Bottom cover to shift mechanism 10 Nm (7 ft-lb)
Floor crossmember to body
•MB 22 Nm (16 ft-lb)
• M10 45 Nm (33 ft-lb)
37-14 Automatic Transmissio
Shift Mechanism and Components

Selector lever cable, removing and installing

- Shift selector lever to P.

- Raise vehicle and safely support .

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

- Disconnect front exhaust system with catalytic converters from rear

exhaust system and hang up with wire.

<liiiiiii( Remove heat shield (A) above driveshaft.

- Remove heat shield (B) for driveshaft from differential cover

(arrows) .

- Disconnect driveshaft at transmission and support or hang up with

wire.

- Remove rubber sleeve of selector lever cable and push it back.

<liiiiiii( Remove lower cover from mounting bracket (arrows) .

<liiiiiii( Press together ends of spring clip (B) and remove .

- Pull out lock plate (A) for selector lever cable at mounting bracket
downward .

- Remove selector lever cable from selector lever.

reI
- - - - - - - - - - - - - 1 N37-0479
------- '---
 Automatic Transmission 37-15
Shift Mechanism and Components

~ Remove bolts (1, 3 and 4) and remove heat shield (A ) for selector
lever cable.

~ Pry off sel ector lever cable with special tool 80-200 (or equivalent)
from lever and selector shaft (arrow)

~ Remove bracket (B) from transmission .

- Remove bracket (B) from selector lever cable by removing nuts (5).

- Pull out sel ector lever cable from mounti ng bracket without kinking
cable.

- To install , move selector lever, lever and selector shaft in position P

(parking lock must engage) .

NOTE -
• Slightly lubricate eye and socket before installing.
• Do not bend or kink selector lever cable.

- Guide selector lever cable into mounting bracket.

- Attach selector lever cable to selector lever.

~ Press ends of spring clamp (B) together and secure selector lever
cable.

Install lock plate (A) for selector lever cable at mounting bracket.

NOTE-
• Angled ends of lock plate must point toward end of selector lever
cable.

re
I N37-0479 I
------- '-----
37-16 Automatic Transmissi n
Shift Mechanism and Components

~ Attach selector lever cable hand-tight to bracket (8) .

- Attach bracket (8) hand-tight to transmission .

- Attach selector lever cable to lever and selector shaft.

- Straighten selector lever cable in bracket (8) .

~ Tighten bracket to transmission (1) and selector lever cable to

bracket (2) with proper torque . Counterhold at hex head (3).

~ Install heat shield (A).

2 3 A 4 A37-0350

~ Tighten mounting bracket to body.

- Check adjustment of selector lever cable. See Selector lever cable,

checking and adjusting in this repair group.

- Reconnect driveshaft to transmission flange.

- Reconnect front and rear exhaust systems.

 Automatic Transmission 37-17
Shift Mechanism and Components

Tightening torques
Bracket to transmission 23 Nm (17 ft-lb)
Heat shield to transmission (M6) 9 Nm (80 in-lb)
Heat shield to transmi ssion (M8) 23 Nm (17 ft-lb)
Mounting bracket to body 10 Nm (7ft lb)
Selector lever cable to bracket 12 Nm (9 ft-lb)
Selector lever mechanism to body 8 Nm (71 in -lb)

Selector lever cable, checking and adjusting

- Shift selector lever to P.

Raise vehi cle and safely support.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove heat shield at selector lever cable .

~ Pry off selector lever cable using lever 80-200 (or equivalent) from
lever and selector shaft (arrow).

Move selector lever from P to 2.

• Shift mechanism and selector lever cable must move easily. If
necessary replace selector lever cable or repair shift mechanism .

- Shift selector lever to P.

•When moving shift lever and selector shaft to P, parking lock must
engage. Both front wheels must not turn in one direction .
• It must be possible to attach selector lever cable to lever /selector
shaft, otherwise adjust selector lever cable.

Adjusting
Selector lever cable must be separated from lever/selector shaft.

- Shift selector lever to P.

•When lever/selector shaft are moved to P, the parking lock must be
engag ed and the front wheels must not turn in one direction .

-4'iiii( Loosen nuts (arrow) for bracket on transmission.

NOTE -
• For illustration purpose the heat shield is not shown.

- Attach selector lever cable on lever/selector shaft.

 Automatic Transmission 37-17
Shift Mechanism and Components

Tightening torques

Bracket to transmission 23 Nm (17 ft-lb)

Heat shield to transmission (M6) 9 Nm (80 in-lb)

Heat shield to transmission (MS) 23 Nm (17 ft-lb)

Mounting bracket to body 10 Nm (7ft lb)

Selector lever cable to bracket 12 Nm (9 ft-lb)

Selector lever mechanism to body 8 Nm (7 1 in -lb)

Selector lever cable, checking and adjusting

- Shift selector lever to P.

Raise vehicle and safely support.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove heat shield at selector lever cable .

~ Pry off selector lever cable using lever 80-200 (or equivalent) from
lever and selector shaft (arrow) .

- Move selector lever from P to 2.

• Shift mechanism and selector lever cable must move easily. If
necessary replace selector lever cable or repair shift mechanism .

- Shift selector lever to P.

• When moving shift lever and selector shaft to P, parking lock must
engage. Both front wheels must not turn in one direction.
• It must be possible to attach selector lever cable to lever /selector
shaft, otherwise adjust selector lever cable.

Adjusting
Selector lever cable must be separated from lever/selector shaft.

- Shift selector lever to P.

•When lever/selector shaft are moved to P, the parking lock must be
engaged and the front wheels must not turn in one direction .

-<Oiiii{ Loosen nuts (arrow) for bracket on transmission .

NOTE -
• For illustration purpose the heat shield is not shown .

- Attach selector lever cable on lever/selector shaft.

37-18 Automatic Transmis ion
Shift Mechanism and Components

~ Straighten selector lever cable at bracket (8).

- Install heat shield (A) .

- Tighten bolts (2 and 3) at bracket.

- Check shift mechanism . See Shift mechanism , checking in this

repair group.

Tightening torques

Bracket to transmission 23 Nm (17 ft-lb)

Heat shield to transmission (M6) 9 Nm (80 in-lb)
A37-0350 Heat shield to transmission (MB) 23 Nm (17 ft-lb)
Selector lever cable to bracket 12 Nm (9 ft-lb)
Selector lever mechanism to body 8 Nm (71 in-lb)

Ignition interlock, checking

The ignition interlock prevents or allows the key and shift
mechanism to move depending on their respective positions. Follow
the steps below to check the ignition interlock.

- Turn ignition key ON then depress brake pedal and hold :

• Shifting from P must be possible without "snagging" when button
on shift lever is depressed .
• Removing the ignition key must not be possible in any driving
position except in P.

- Move shift lever to P.

•It must be possible to turn Ignition key OFF without binding .

- Remove ignition key.

•It must not be possible to move shift lever from P.

Ignition interlock cable,

removing and installing
Removing

- Shift selector lever to 2.

- Obtain radio anti-theft code.

- Disconnect battery ground connection.

- Remove handle fo r selector lever. See SeJector lever hand\e,

removing and installing in this repair group.

' - Remove front center console. See 70 Interior Trim.

- Remove steering wheel. See 48 Steering .

- Turn ignition key ON.

- Shift selector lever to P.

 Automatic Transmission 37-19
Shift Mechanism and Components

Lift clip for retainer (1) and pull out interlock cable from
ignition/starter switch .

Remove cover with gate (selector lever actuation).

Unclip interlock cable from securing spring at mounting bracket

while slightly lifting securing spring.

Free cable from cable tie (2) and remove.

Installing

::·~ ~r<::::)<:'
Route interlock cable without kinks.

- Turn ignition key ON .

11
1 1
1
I - Insert cable in ignition/starter switch .
J, I .

' / - Check locking device (1) for proper engagement.

Jt .-,- .~ ..
- Attach lock cable with cable tie (2) to airbag sensor.

- Turn ignition key OFF.

- Shift selector lever to P.

- Clip in cable in securing spring of mounting bracket .

- Insert cable bracket (3) in shift mechanism and cable eye in lever for
cable.

N37-0428 I

Adjusting
, ~ If
.... __.:~ ~ ~

- Shift selector lever to P.

- , . )-' OA .,t::(::::)
.<::t - Loosen bolt (6).

I I.
- Clamp (3) must be movable by hand in direction of arrow (5 ) .
'r I
~~~~~~----',l~)/ Move steering column to lowest position .

Insert gauge 3352 A (4) between lever for interlock cable and cable
eye.

Pull cabl e in direction of arrow (5) and tighten bolt (6 ) .

Tightening torque
Interlock cable clamp bolt 10 Nm (7 ft lb)
I
Remove adjustment gauge .

- Check ignition key lock after every adjustment of interlock cable . See
Ignition key lock, checking in this repair group.
N37-0428 I
- Install steering wheel.

- Install front center console.

37-20 Automatic Transmis ion
Transmission Oil Pan and Component

- Install handle for selector lever.

- Reconnect battery ground cable.

- For vehicles with theft-protected radio, reactivate code .

TRANSMISSION OIL PAN AND COMPONENTS

Transmission oil pan, removing and installing

- Drain automatic transmission fluid (ATF). See 03 Maintenance.

- Loosen bolts for transmission oil pan in diagonal sequence.

Remove oil pan.

NOTE -
• Clean magnet in oil pan (4 magnets). Check that magnets have
complete contact with oil pan.

Installation is in reverse order of removal. Note the following :

• Replace seals.
• Tighten bolts for oil pan in several steps.
• Refill transmission with ATF.

Tightening torques
Drain plug to oil pan 12 Nm (9 ft-lb)
Oil pan to transmission (tighten diagonally) 10 Nm (7 ft-lb )

ATF screen, removing and installing

- Remove transmission oil pan . See Transmission oil pan,
removing and installing in this repair group.

00
0 0
~
-

-
Remove 2 bolts for ATF screen (arrow) .

Remove ATF screen from valve body.

Apply thin coat of petroleum jelly to intake side of screen gasket.

- Install ATF screen .

- Install oil pan.

- Refill transmission with ATF.

Tightening torques
ATF screen to valve body 5 Nm (44 in-lb)
Drain plug to oil pan 12 Nm (9 ft-lb)
Oil pan to transmission (tighten diagonally) 10 Nm (7 ft-lb)
 Automatic Transmission 37-21
Transmission Oil Pan and Components

Vehicle speed sensor (G22),

removing and installing
~ Working at transmission , remove connector for vehicle speed
sensor (G22).

- Press down clamp for sensor, turn and remove it.

- Installation is reverse of removal . Note the following:

•Replace both 0-rings for sensor (arrow).
• Apply thin coat of petroleum jelly to 0-rings.
•Insert sensor and snap clamp in place.

Transmission rpm sensor (G182),

removing and installing

NOTE -
• Do not reuse a sensor that was dropped (the permanent magnet
breaks).

- Remove valve body.

~ Disconnect connector (A) on back-side of valve body.

- Remove rpm sensor (G182) (8 ) at valve body.

~ Install rpm sensor (1) using spacers (2) (length 8.7 mm).

- Reattach electrical connector.

- Install valve body.

NOTE -
• The sensor side with the connector terminals points toward the
valve body

- Refill transmission with ATF.

Tightening torques
ATF drain plug to oil pan 12 Nm (9 ft -lb)
ATF screen to valve body 5 Nm (44 in -l b)
Oil pan to transmission (tighten diagonally) 10 Nm (7 ft-lb)

Transmission rpm sensor to valve body 5 Nm (44 in-lb)

Valve body to transmission
(tighten from inside-out) 8 Nm (71 in-lb)
 39-1

39 Final Drive, Driveshaft

GENERAL ............ . ......... . .. . . . ... 39-1 Driveshaft, removing and installing . ... ... .... 39-4
Driveshaft, adjusting .. ... . ... .. .. .... .. ... 39-6
FINAL DRIVE . ....... . . ... . .. ... . . ... .. .. 39-1
Radial run-out, measuring .. . ... . ..... .... .. 39-9
Final drive oil . ... .. .. . .. . ...... . . .... .. .. 39-1
Front final drive oil level .. . . .... . . .. . .. . . . . 39-2 TABLES
Rear final drive oil level .. .. .. ... . . . .. .. .... 39-3 a. Fin al drive oil specifications . .. ... . . . . ..... .. ... 39-2
b. Fin al drive oil capacities (approximate) ........... 39-2
DRIVESHAFT . .. .. . . . . . . .... . . . . . . . .. ..... 39-4
Driveshaft assembly .... . ................. 39-4

GENERAL
This repair group covers front and rear final drive oil service, and
driveshaft removal and adjustment.

CAUTIO~
• Do not bend driveshaft universal joint beyond 25°. Joint may be
damaged.
• Store and move driveshaft fully extended.
• Driveshaft cannot be repaired, only adjusted.
• If remo ving one side of driveshaft, support from body with wire.
•Match mark parts before removal. Install parts in previously
marked position to maintain driveshaft balance. Imbalance can
result in damage to bearings, vibration and noise.
• Before replacing driveshaft because of noise I vibrations, check
adjustment. See Driveshaft, adjusting in this repair group.
• When disconnecting driveshaft from rear final drive, do not
reinstall balance washer between shim and bolt head.

FINAL DRIVE

Final drive oil

In manu al transmission models, the front , center and rear final
drives (differentials) are filled with the same oil as the transmission
gearbox . In automatic models, the final drive housing (s) are filled
with a different oil than ATF.

Current specifications for final drive oil are shown in Table a. If oil
container is not marked with appropriate specification , assume that
the oil is not suitable .
39-2 Final Drive, Driveshaf1
Final Drive

Table a. Final drive oil specifications

Manual transmission models Synthetic oil SAE 75W-90
Audi part no . G 005 000
Automatic transmission Synthetic oil SAE 75W-90
models Audi part no . G 052 145 S2

Approximate refill capacities for final drive units are listed in

Table b.

Table b. Final drive oil capacities (approximate)

Oil capacity in liters (US qt)
Transmission type Final drive location~ ype) New fill Change
Manual Front wheel drive Filled with transmission
Quattro (AWD):
• Front final drive Filled with transmission
• Center final drive Filled with transmission
• Rear final drive, 01 R 01 H 1.5 (1.6)
Automatic 01 L Quattro (AWD) :
• Front final drive 1.3 (1.4)
• Center final drive 0.88 (0.93)
• Rear final drive, 01 R 1.5 (1 .6)
Auto matic 01 V Front wheel drive 0.8 (0 .85)
Quattro (AWD):
• Front and center final jrive 0.8 (0.85) 0.75 (0.8)
• Rear final drive, 01 R 1.9 (2.01)
Multitronic (CVT) 01J Front wheel drive 1.3 (1.4)

Front final drive oil level

Make sure vehicle is level during this operation . If front of vehicle is
higher than rear, such as when driven up on ramps , oil inside final
drive housing pools toward rear, and level cannot be accu rately
determined .

Checking level

- Perform short test drive to increase gear oil temperature to approx .

60°C (140°F) .

- Switch engine OFF and allow gear oil to settle for 5 minutes.

- Raise vehicle and support safely.

WARNING -
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

~ Unscrew oil filler plug (arrow) .

II
 Final Drive, Driveshaft 39-3
Final Drive

"'iiiiii( Check final drive oil level using stiff wire hook inserted into fill hole.

Final drive oil level

Measure with bent wire 8.5 mm (1/3 in)
below fill hole opening

l
8.5 mm

Filling

If oil level is low, top up final drive with SAE 75W-90 (synthetic oil) .

CAUTION-
• Adhere strictly to the oil level guidelines. The final drive is very
sensitive to overfilling.

If gear oil level is at lower edge of oil filler hole , extract 0.2 liters
(7 oz) to correct oil level.

- Screw in new oil filler plug .

Tightening torque
Oil filler plug to fro nt final drive housing 20 Nm (15 ft-lb)
(use new bolt)
I
Rear final drive oil level
Make sure vehicle is level during this operation . If front of vehicle is
higher th an rear, such as when driven up on ramps , oil inside final
drive hou si ng pools toward rear, and level cannot be accurately
determin ed.

Checking level

Raise vehicle and support safely.

WARNING -
• Make sure the car is stable and well supported at all times. Use
a pro fessional automotive lift or jack stands designed for the
p urp ose. A floor jack is not adequate support.

"'iiiiii( Use 17 mm Allen wrench to loosen oil fill plug to check rear final
drive oil.

Remove fill plug. Oil level is correct when final drive is filled up to
lower ed ge of filler hole.
39-4 Final Drive, Driveshaft
Driveshaft

Filling
- To top up oil:
• Place oil drain pan underneath final drive fill plug
•Manual transmission : Top up final drive with SAE 75W-90
(synthetic oil) , part no. G 005 000 .
•Automatic transmission: Top up final drive with SAE 75W-90
(synthetic oil) , part no. G 052 145 S2 .
•Make sure oil is filled up to lower edge of filler hole . Final drive oil
capacity is in Table b.
• Allow excess oil to drip out.

- Screw in oil fill plug .

Tightening torque
Oil fill plug to rear final drive housing I 35 Nm (26 ft-lb)

DRIVES HAFT

Driveshaft assembly
1. Rear fi nal drive
2. Drive shaft
3. Gasket
• Always replace
4. Backing plate
5. Bolt, 55 Nm (41 ft-lb)
• Always replace
6. Adjustment shim
7. Nut, 25 Nm (18 ft-lb)
8. Stud bolt, 10 Nm (7 ft-lb)
9. Transm ission

9 3 4 5 8 7 6 5 4 3

N39-05 11

Driveshaft, removing and installing

NOTE-
• Observe driveshaft cautions at the beginning of this repair group.

- Remove crossmember below exhaust system (if installed) .

- Remove rear part of exhaust system behind clamping sleeve(s) .

~ Remove heat shields for driveshaft from body (arrows).

 Final Drive, Driveshaft 39-5
Driveshaft

~ Remove heat shield for driveshaft from differential cover (arrows) .

~ Check for factory marking on driveshaft and at flange/driveshaft at

rear final drive. If not found , mark location of driveshaft flange (A) to
rear final drive (8) .

Remove three upper mounting bolts from each drive shaft constant
velocity joint.

CAUTIO~
• Do not remove driveshaft before installing VAG 3139 alignment
fixture .

~ Attach special tool VAG 3139 alignment fixture with 3139/3 spacers
and tighten plastic nuts.

Remove remaining three mounting bolts at front and rear constant

velocity joints.

~ Remove nuts (arrows) for intermediate bearing and remove

driveshaft with alignment fixture.

A/3213 NOTE-
• Only store and move driveshaft in fully extended (horizontal)
position.

I
39-6 Final Drive, Driveshaft
Driveshaft

~ Installation is reverse of removal. Note the following:

• For proper balance, drive shaft flanges (A) and rear final drive (8 )
must be installed so that factory marks (or marks made previously)
are aligned.
• If new drive shaft is installed and factory marks on rear final drive
flange are no longer visible , check and mark radial run-out at
flange and align marks on drive shaft to new mark on flange . See
Radial run-out, measuring in this repair group.
•Replace gaskets on drive flanges (remove protective film and
attach gasket to drive flanges).
• After disconnecting driveshaft from rear final drive, do not re install
additional balance washer (thick washer) between shim and bolt
A39-0263
(if equipped).
• Clean thread bores in flanges before installing driveshaft.
• Always replace drive shaft bolts.

- Adjust drive shaft. See Driveshaft, adjusting in this repair group.

- Install exhaust system so it is free of stress.

Tightening torques
Driveshaft to manual transmission 55 Nm (41 ft-lb)
Driveshaft to rear final drive 55 Nm (4 1 ft-l b)
Front crossmember to body 25 Nm (18 ft-lb)
Heat shield to differential 25 Nm (18 ft-l b)
Intermediate bearing to body 25 Nm (18 ft-lb)
Nuts for clamping sleeve 40 Nm (30 ft-lb)

Driveshaft, adjusting
Driveshaft adjustments must be made precisely. A poorly adjusted
drive shaft is usually the cause of vibrations and humm ing noises.

Remove crossmember below exhaust system (if installed).

Remove rear part of exhaust system behind clamping sleeve(s).

~ Remove heat shields for driveshaft from body (arrows) .

 Final Drive, Driveshaft 39-7
Driveshaft

~ Attach special tool VAG 3213 alignment fixture with 3139/3 spacers
and tighten plastic nuts.

~ Remove nuts (arrows) for intermediate bearing .

NOTE-
• Do not remove stud bolt.

~ Align intermediate bearing of drive shaft so that distance a (left side)

is equal to distance a (right side).

- Measure distance a to determine adjustment shims according to

table below.

Available adjustment shims

Distance a (mm) Shim thickness (mm)
0 ... 3.0 -

3.1 ... 5.0 2

5.1 ... 7.0 4
7.1 ... 9.0 6
9.1 ... 11.0 8
11 .1 ... 13.0 10
39-8 Final Drive, Driveshaft
Driveshaft

<tiiiiii{ Install adjustment shims as follows:

• Loosen plastic nuts of alignment fixture (A) far enough so that
bracket for intermediate bearing (1) has some clearance
(measurement a) to stud (2).

<tiiiiii{ Insert appropriate adjustment shim (1) and swing bracket for
intermediate bearing (2) to other side .

- Place second adjustment shim (4) onto stud (3).

- Now tighten both plastic nuts of alignment fixture (A) again .

3 -
~\!_ 4

~S{
A39-03 13

-·-·-·
~ u
B C A

1
<tiiiiii{ To center driveshaft, slide drive shaft with alignment fixture towa rd

-
rear to stop and mark location of intermediate bearing (A) .

Slide drive shaft with alignment fixture toward front to stop and mark
location of intermediate bearing (B) .

Center drive shaft so that intermediate bearing (C) is centered

between markings (A and B).

- Tighten intermediate bearing in centered position .

Remove mounting fixture .

A39-0314 Remainder of installation is reverse of removal.

Install exhaust system free of stress.

Tightening torque
Front crossmember to body 25 Nm (18 ft-lb)
Intermediate bearing to body 25 Nm (18 ft-lb)
Nuts for clamping sleeve 40 Nm (30 ft-lb)
 Final Drive , Driveshaft 39-9
Driveshaft

Radial run-out, measuring

NOTE-
• Measure radial run -out if rear final drive flange is removed. Make
new marks and remove old marks.
• Mark location of largest radial run-out if new driveshaft is installed
and marks on final drive flange are no longer visible.
•Align new mark with mark on driveshaft.

~ Attach special tool VAG VW387 dial gauge holder with dial indicator
to connection between crossmember and final drive .

- Set dial indicator onto ground diameter of drive shaft flange (arrow)
and set to 0 with 1 mm preload .

- Turn differential gear via both rear wheels (left and right flanges) at
the same time in one direction until drive flange/driveshaft flange
has made on complete revolution .

Mark largest radial run -out on outer edge of flange (equivalent to

largest distance from turning axis) .

Remove old mark on flange .

Installing driveshaft. Match mark on driveshaft to mark on flange .

See Driveshaft, removing and installing in this repair group.
 40-1

40 Front Suspension

GENERAL ...... .. .. . ..... .. ............. 40-1 FRONT STABILIZER BAR ........ .. . . ..... 40-13
Curb weight position ..... .. .......... . . . .. 40-1 Front stabilizer bar, removing and installing . .. 40-13
allroad quattro "jack mode" ...... ........ ... 40-2 Front stabilizer bar links ...... . ... . .... . .. 40-14
Warnings and Cautions .... .. . . ..... ... . ... 40-2
FRONT DRIVE AXLES . . . . . . . . . . . . . . . . . . . . 40-15
FRONT STRUT ASSEMBLY .. . .... .. ... .. .. 40-3 Front drive axle , removing and installing .. . ... 40-15
Front suspension strut, removing and installing . 40-3 CV joint boot, replacing ... . .. . . . .. ... . . ... 40-16
Front strut assembly components ...... .. .. .. 40-5 Front drive axle assembly with inner CV joint . 40-18
Front strut assembly details .......... ... ... 40-6 Front drive axle assembly with inner
triple roller joint (AAR 2900) . ........ ... . 40-19
FRONT SUSPENSION ARMS . . . . . . . . . . . . . . . 40-8
Front drive axle assembly with inner
Front suspension components ... . . .. . . .. .. . 40-8 triple roller joint (AAR 3300i) ... .... . . . ... 40-20
Front suspension components , allroad quattro 40-11
Front suspension control arms .......... . .. 40-13

GENERAL
This section covers repairs to the front suspension and related
components. Also see :
• 42 Rear Suspension for rear suspension servicing and repair
information
• 44 Wheels, Tires, Wheel Alignment for wheel alignment
specifications

Special tools , equipment and procedures are required for most front
suspension repair and component replacement. On suspension
components with bonded rubber bushings, tighten fasteners with
vehicle at curb weight position . See Curb weight position in this
repair group.

Wheel alignment is almost always disturbed when suspension

components are removed or replaced . Plan on a wheel alignment
after suspension repairs .

Curb weight position

Bonded rubber bushings can only be flexed to a limited extent. Place
suspension under load (curb weight position) before tightening
suspension arms with bonded rubber bushings.

~ In this illustration jack stands and wheel ramps are used to place
vehicle at curb weight position . Then tighten suspension arms with
bonded rubber bushings to torque specification .
40-2 Front Suspension
General

allroad quattro "jack mode"

Prior to jacking or lifting allroad quattro vehicle , set ride height
control to "jack mode" to protect suspension shock absorbers and
struts.

WARNING-
• Make sure that no one is lying under the vehicle or has head or
hands in the wheel housing while the ride height is changing.

Activating
<iiiiiii( Before lifting vehicle with jack or lift:
•Switch ignition ON .
• Press ride height control buttons A and C in center dashboard fo r
at least 5 seconds.
•When system is in "jack mode", LEDs on control buttons (A and C) ,
yellow LED for manual mode on level indicator (8) and warning
light for level control in instrument cluster all illuminate.

Switch ignition OFF and lift or jack vehicle.

Deactivating
Press control buttons A and C for at least 5 seconds. Warning light
in instrument cluster, LED for manual mode and control button LEDs
turn OFF.

"Jack mode" is automatically deactivated when vehicle speed

exceeds 3 mph (5 kph) .

Warnings and Cautions

WARNING-
• Most fasteners are designed to be used only once and
become unreliable and may fail when used a second time.
This includes, but is not limited to, nuts, bolts, washers,
circlips, cotter pins, self-locking nuts and bolts. For
replacements, use new parts.
•Do not reinstall bolts and nuts coated with undercoating wax.
Clean the threads with a suitable solvent before installing.
• Replace rusted or corroded bolts, nuts and washers even if not
specifically indicated.
• Do not attempt to straighten or weld suspension struts, wheel
bearing housings, control arms or any other wheel locating or
load bearing components of the front suspension.

CAUTIO~
• To avoid wheel bearing damage, do not move vehicle without
drive axle(s). If vehicle needs to be moved, install an outer joint
in place of the drive axle. Tighten outer joint to 115 Nm (85 ft-
lb) for M14 bolt or 190 Nm (140 ft-lb) for M16 bolt.
• Bonded rubber bushings may only be flexed to a limited extent.
See Curb weight position in this repair group.
• Before performing suspension work on al/road quattro, see
allroad quattro "jack mode" in this repair group.
 Front Suspension 40-3
Front Strut Assembly

FRONT STRUT ASSEMBLY

Front suspension strut,

removing and installing
- Working in engine compartment , remove battery cover and plenum
cover. See 03 Maintenance.

Remove hubcap. For alloy wheels , pull off center cap (use pulling
hook in vehicle tools).

Raise car and support safely.

WARNING-
• Make sure car is stable and well supported at all times. Use a
professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove front wheels.

NOTE -
• Vehicle with headlight vertical aim control: Disconnect vehicle
height sensor arm from control arm.
• In order not to damage lower control arm ball joints, use engine I
transmission jack VAG 1383-A or equivalent to brace control arms.

"'iii( Working in plenum chamber, remove rubber grommets (arrows ) to

gain access to strut upper mounting nuts. Use socket on long
extension to remove nuts.

CAUTIO~
• Do not bend or damage brake lines.

- Working under car, pull ABS wheel speed sensor harness out of
bracket on brake caliper. Be careful not to damage brake lines.

"'iii( Working at tie rod end :

• Remove nut on tie rod end pinch bolt (arrow) and remove bolt.
• Remove bolt from top of tie rod end.

"'iii( Using 8 mm Allen key, work tie rod end shaft back and forth to
release tie rod from wheel bearing carrier.
40-4 Front Suspension
Front Strut Assembly

~ Remove nut (A) on front and rear upper control arm pinch bolt and
remove pinch bolt (8) .

Release upper front and rear control arm outer ends from wheel
bearing carrier.

CAUTION-
• Do not use chisel or similar tool to widen slits in wheel bearing
housing.

Remove nut from lower rear control arm ball joint. Using a suitable
ball joint puller, pop control arm end out of wheel bearing carrier. Be
careful not to damage CV boot.

NOTE-
• If reusing control arm, put collar nut back on flush with ball joint
stud to protect threads before attaching puller.

~ Remove suspension strut lower mount bolt (1) and disengage strut
from lower front control arm .

~ Using a suitable lever arm , pry down on wheel bearing carrier and
remove suspension strut upper mount from upper suspension
bracket.

Disassemble strut and coil spring , replacing components as

needed . See Front strut assembly components and Front strut
assembly details in this repair group.
 Front Suspension 40-5
Front Strut Assembly

~ Installation is reverse of removal. Remember to:

• Position suspension strut so that hole (arrow) in spring seat faces
middle of vehicle. See Front strut assembly details in this repair
group.
•Guide suspension strut upper mount into position in upper
suspension bracket. Install upper mount nuts from above in
plenum chamber. Install rubber grommets and plenum chamber
cover.
• Bolt suspension strut to lower front control arm. Tighten bolt (1) in
curb weight position. See Curb weight position in this repair
group.
•Insert upper control arm ball joints in wheel bearing housing and
press down as far as possible. Install new pinch bolt and tighten
nut (2) .
•Reattach lower rear control arm to wheel bearing housing . Use
4 mm Allen wrench to counterhold ball joint stud , if necessary.
•Insert ABS wheel speed sensor harness into bracket on brake
caliper.
•Mount wheel and tighten .

Tightening torques

Lower rear control arm to wheel bearing 100 Nm (74 ft-lb)

housing
Suspension strut upper mount to upper 20 Nm (15 ft-lb)
suspension bracket
Suspension strut to lower front control arm 90 Nm (66 ft-lb)
Upper control arm to wheel bearing housing 40 Nm (30 ft-lb)
Wheel to wheel bearing hub 120 Nm (89 ft-lb)

Front strut assembly components

1 -~
1. Nut, 60 Nm (44 ft-lb)
2 -- ~
~
I
• Remove using special tool 3353 .
•Replace.
I
3 --~ 2. Upper strut mount
11 3. Washer
4 4. Upper spring seat: See Front strut assembly details in this
repair group.
5. Coil spring
5 •Inspect surface for pitting and damage .
• Match color code when replacing . Check vehicle data sticker.
See Front strut assembly details in this repair group .
6. Bump stop: Insert in upper spring seat.

I M 0-02 14 I 7. Dust sleeve

8. Protective cap
9. Lower spring buffer
• Not in all vehicles.
10. Lower spring seat: See Front strut assembly details in this
repair group .
11. Strut: Match with spring . Check vehicle data sticker. See Front
strut assembly details in this repair group.
40-6 Front Suspension
Front Strut Assembly

Front strut assembly details

Special tools , including a coil spring compressor, a special socket
VAG 3353
and a spring seat angle adjusting gauge, are needed for front strut
disassembly and reassembly.

WARNING-
• Do not attempt to disassemble the struts without a spring
compressor designed specifically for this job.
• Make sure the spring compressor grabs the spring fully and
securely before compressing it.
W00-0200
~ VAG special socket 3353 used in conjunction with Allen key for
removing upper strut nut.

~ VAG special tools needed for safely compressing coil spring ,

loosening upper mount and replacing strut.

8mm
IP=;i:ri+±:+---- Allen
key

VAG
1752n

....----VAG
1752/2

A40-008

~ Vehicle data sticker in spare tire well :

~ , -1-21 90 444 UV 1. Rear axle designation
WA UDA2 4B 1 XN001612 2. Front axle designation
4B5 4VZ SA9 3. Suspension code
A6 Ava . qu at . 2. 8
147 KW TLEV Ao
Match to strut and coil spring codes found in Audi parts data .
t:,W.~~~~~N5K~on1 AHA CUB DPT
See 44 Wheels , Tires, Alignment for more information about
~f~r~·~.~N1~:~~1· LY7M/l Y7M Nl HI BN
suspension codes .
M.· AUSST.tOf>TIONS _X9A BOA C6P GOG H4J3 JOL
M10 G1A lBH 1 AH ~ 2PR
1 N3 ~ 5SG T7F OJM ;:;:; ... 2
1 -----=
.,.,....:.
..;~ ~
- OYW OG7 BUG
:w~i .,. 1LB 3FE @B;- 3
181 8 9,9 9, 9 9, 9 999
 Front Suspension 40-7
Front Strut Assembly

~ Installed position of lower spring seat: Make sure hole (arrow) in

seat is at right angles (90° ± 2°) to axis of lower mounting fork (A ).

~ Installation of spring seats:

Right • Studs in upper spring seats are rotated 11 ° (A) to axis of strut lower
mounting fork .
• Holes (8 ) in lower spring seat face middle of vehicle .

~---)A
---

Left

I Mo- 0215 I

~ Upper coil spring seat: Make sure upper end of spring (arrow) rests
against upper spring seat stop.

A40-002s I
40-8 Front Suspension
Front Suspension Arms

FRONT SUSPENSION ARMS

Front suspensio n
43 1 components
2 1. Bolt M10, 75 Nm (55 ft-lb)
42
2. Was her
41 3. Bolt M1 0 x 62 mm
40 • Replace .
39 • Load suspension when tightening .
See Cu rb weig ht position in this
38 repair group .

37 4. Upper rear control arm

• Replace bushing
5. Bo lt, 5 Nm (4 ft-l b)
6. Bolt
11
7. Self -loc king nut
12 •Replace .
-\ • 50 Nm (37 ft-lb) for steel wheel bearing
13 housing

14 • 45 Nm (33 ft-lb) for aluminium wheel

bearing housing
8. Bo lt M10 x 100
9. Self-loc king nut, 40 Nm (30 ft-lb)
•Replace .
10. Upper front c ontrol arm
25- -- - • Can be removed together with
mounting bracket
24 - - 11. Suspension strut
12. Bolt M12 x 1.5 x 120 mm
23 22 A40-0472 • Replace after disassembly.
• Load suspension when tightening .
See Curb weig ht position in this
repair group.
13. Lower rear control arm
• Replace arm if fluid-filled bushing is
leaky
•Replace.
14. Self-locking nut
• 100 Nm (74 ft-lb) for steel wheel
bearing housing
• 110 Nm (81 ft-lb) for aluminium wheel
bearing housing
15. Wheel bearing housing
16. Backing plate
 Front Suspension 40-9
Front Suspension Arms

Front suspension
43 - - - - - - - - : " ~ 2______ components (continued)
17. Outer CV joint bolt, M14 or M16
42 ------~~ •Replace.
41 - - - - - - - • Tighten in 2 stages . See Front drive
40- - - - - axle, removing and installingin this
repair group .
39- - - - -
18. Bolt, 10 Nm (7 ft-lb)
38- - - 19. Self-locking nut
• 100 Nm (74 ft-lb) for steel wheel
37----.,;r,::-- bearing housing.
• 120 Nm (8g ft-lb) for aluminium wheel
bearing housing .
•Replace.
-~------- 11
20. Bolt M12 x 1.5 x 85 mm
----"-- - - - - - 12 21. Self-locking nut, 90 Nm (66 ft-lb)
- - - 13 •Replace .
22. Stabilizer bar link
- - - 14 •Arrow points in direction of travel.
23. Self-locking nut
•Replace after disassembly.
• 40 Nm (30 ft-lb) plus additional go 0
(1fai turn) .
•Nut has ribs on the bottom , replace
25 ---~~'-__"=H with same.
24. Bolt M12 x 1.5 x 100 mm
24- - •Replace.
•Load suspension when tightening.
23 22 See Curb weight position in this
repair group.
25. Lower front control arm
26. Bolt M12 x 1.5 x 110
• 11 O Nm (81 ft-lb) plus additional go 0
(1fai turn) .
•Replace.
27. Bolt, 75 Nm (55 ft-lb)
•M10X70mm
•Replace .
28. Self-locking ribbed nut
• 100 Nm (74ft-lb) .
•Replace.
29.Clip
• Inserted in lower front control arm .
•Replace .
30. Subframe
31. Bolt, 25 Nm (18 ft-lb)
•Replace .
40-10 Front Suspension
Front Suspension Arms

Front suspension
1 components (continued)
1r-~------- 2
32. Subframe support
42 -----~
33. Self-locking nut
41 - - - - - - - - • 70 Nm (52 ft-lb) plus additional 180°
40----~ (% turn) .

3 9 - - -- - •Replace.
34. Self-locking nut
38--- • 70 Nm (52 ft-lb) plus additional 180°
(% turn) .
37 ----~
•Replace .
35. Bolt
•Vehicle with inner CV joint.
'--T---+t---------- 11 •MS X 48 : 40 Nm (30 ft-lb) .
• M10 X 48: 70 Nm (52 ft-lb).
~-'---------- 12
36. Backing plate
~-- 13
37. Drive axle
----14 • See Front drive axle, removing and
installing in this repair group .
38. Drive axle with triple roller joint

-------~-- 15 39. Bolt, 70 Nm (52 ft-lb)

•Vehicle with triple roller joint.
~-- 16 • M10 X 20 mm. Bolt M10 x 62
•Replace.
25 --~
•Load suspension when tightening.
I
24 ----NrJ See Curb weight position in this
repair group .
40. Bolt M10 x 62
23 22 A40-0472
• Always replace after rem oval.
41. Suspension upper mounting bracket
42. Self-locking nut
• 50 Nm (37 ft-lb) plus additional 90°
(% turn) .
• Always replace after removal.
43. Self-locking nut with flange , 20 Nm
(20 ft-lb)
• Replace after disassembly.
 Front Suspension 40-11
Front Suspension Arms

Front suspension
f>----- 1 components, allroad quattro
1. Bolt
39 -----~ • 45 Nm (33 ft-lb) plus additional 55°

38- - - - - - - - •Replace .

37- - - - - - - - . . 2. Washer

36 _,· 3. Bolt, M10 x 62 mm

&~ ~'~'el •Replace .

35 ~ r •Load suspension when tightening .
See Curb weight position in this
repair group.
4. Upper rear control arm
5. Bolt, 5 Nm (4 ft-lb)
6. Bolt
~---------- 12 7. Self-locking nut, 50 Nm (37 ft-lb)
•Replace.
- - - - - - 13 8. Bolt M10 x 100 mm
- - - - 14 9. Self-locking nut, 40 Nm (30 ft-lb)
•Replace .
10. Upper front control arm
~-----,------ 15 11. Suspension strut

~-- 16 12. Bolt M12 x 1.5 x 120

• 90 Nm (66 ft-lb) plus additional 90°
-@,__~ 17 •Replace .
., ~
•Load suspension when tightening .
i 18
See Curb weight position in this
repair group .
A40-0471 13. Lower rear control arm
14. Self-locking nut, 110 Nm (81 ft-lb)
•Replace.
15. Wheel bearing housing
16. Backing plate
17. Outer CV joint bolt, M16
•Replace .
•Tighten in 2 stages . See Front drive
axle, removing and installing in this
repair group .
18. Bolt, 1O Nm (7 ft-lb)
19. Self-locking nut, 11 O Nm (81 ft-lb)
•Replace.
20. Bolt M12 x 1.5 x 85 mm
21. Self-locking nut, 90 Nm (66 ft-lb)
•Replace.
22. Stabilizer bar link
•Arrow points in direction of travel
40-12 Front Suspension
Front Suspension Arms

Front suspension
40- - - - - i components, allroad quattro
I (continued)
39 -----~ 23. Self-locking ribbed nut
38 ----~ • Replace after disassembly

37 -----~
• 40 Nm (30 ft-lb) plus additional go 0

24. Bolt M12 x 1.5 x 100 mm

36 I

35~-~"
•Replace .
• Load suspension when tightening.
See Curb weight position in this
repair group.
25. Lower front control arm
26. M12 x 1.5 x 140 mm
A----t+- - - - - - - - 11 • 110 Nm (81 ft-lb) plus go 0

•Replace .
~'-------------- 12
27. Bolt, 70 Nm (52 ft-lb)
-\- - -\
. - - - - 13 • M10 X 70 mm
•Replace.
@ - - - 14
I 28. Self-locking nut, 60 Nm (44 ft-lb)
,-' I •Replace .
29. Clip in lower front control arm
•Replace .
30. Subframe
31 . Bolt, 25 Nm (18 ft-lb)
32. Support for subframe
33. Self-locking nut
• 80 Nm (5g ft-lb) plus additional go 0
A40-0471 •Replace .
34. Self-locking nut
•go Nm (66 ft-lb) plus additional go 0
•Replace .
35. Drive axle with triple roller joint
36. Bolt M10 X 20 mm
• 70 Nm (52 ft-lb)
37. Bolt M10 x 62 mm
•Replace .
•Load suspension when tighten ing .
See Curb weight position in this
repair group .
38. Suspension upper mounting bracket
•Replace .
39. Self-locking nut
• 50 Nm (37 ft-lb) plus additional go 0

•Replace.
40. Bolt, 23 Nm (17 ft-lb)
•Replace .
 Front Suspension 40-13
Front Stabilizer Bar

Front suspension control arms

~ Suspension arms are available separately or as a kit. Included in kit
are :
• Upper front control arms
• Upper rear control arms
• Stabilizer bar links
• Lower rear control arms
• Lower front control arms
• Mounting hardware

BentleyPublis See Front suspension components diagrams in this repair group

A60440008 for suspension arm locations and to rque specifications .

Suspension arm components

1. Lower front control arm (right)
2. Lower strut mount (right)
3. Stabilizer bar link (right)
4. Upper rear control arm (right)
5. Stabilizer bar mounting bracket
6. Upper rear control arm (left)
7. Stabilizer bar link (left)
8. Lower strut mount (left)
9. Lower front control arm (left)
10. Outer CV boot (right)
11. Lower rear control arm (right)
12. Axle flange (right)
13. Axle flange (left)
14. Lower rear control arm (left)
15. Outer CV boot (left)

FRONT STABILIZER BAR

Front stabilizer bar, removing and installing

Raise car and support safely.

WARNING -
• Make sure car is stable and well supported at all times. Use a
professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

- Remove engine lower cover. See 03 Maintenance.

~ Remove stabilizer link nut (A) .

- Remove stabilizer link from bar.

- Unscrew mounting bracket nuts (B) and remove stabilizer.

40-14 Front Suspension
Front Stabilizer Bar

- Installation is reverse of removal. Remember to :

•Match stabilizer bar to suspension version.
• Mount bushing and stabilizer bar without grease.
•Attach stabilizer bar links. See Front stabilizer bar links in this
repair group.

Tightening torque

Stabilizer bar bracket to chassis (replace nuts) I 25 Nm (18 ft- lb)

Front stabilizer bar links

From model year 1ggg , stabilizer bar link with bonded rubber
bushings replaces unit with ball joints .

Link with ball joint

1. Link with ball joint
2. Lower front control arm
3. Self-locking nut, 40 Nm (30 ft-lb) plus additional go 0
4. Clip
5. Self-locking nut, 100 Nm (74 ft-lb)
A40-0266
6. Stabilizer bar

Link with bonded rubber bushings

1. Link with rubber bushing (rubber bushing (A) with pressed-on
spacer is bolted to stabilizer)
2. Self-locking nut, 40 Nm (30 ft-lb) plus additional go 0 turn
3. Bolt
4. Lower front control arm
5. Bolt
6. Self-locking nut, 60 Nm (44 ft-lb)
7. Stabilizer bar

A40-0269

~ Link (A) for left side of vehicle

- Link (8) for right side of vehicle

- Arrow on link points in direction of travel.

- Place fixed spacer (1) on stabilizer.

CAUTION-
• To avoid damage, bonded rubber bushings may only be flexed
to a limited extent. Tighten suspension bushing bolts with
1
vehicle in curb weight position. See Curb weight position in

'
this repair group.
A40-0268
 Front Suspension 40-15
Front Drive Axles

FRONT DRIVE AXLES

Front drive axle, removing and installing

Remove hubcap. For alloy wheels pull off center cap (use pulling
hook in vehicle tools) .

- With vehicle standing on its wheels , loosen outer CV joint bolt a

maximum of 90° turn.

Raise car and support safely.

WARNING-
• Make sure car is stable and well supported at all times. Use a
professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove wheel.

- Thread in all five wheel bolts again.

- With assistant operating brake, remove outer CV bolt.

~ Unscrew drive axle bolts (1) from transmission flange .

- Pull ABS wheel speed sensor harness out of bracket on brake

caliper (arrow).

- Pull ABS wheel speed sensor slightly out of wheel bearing housing .

~ Remove nut (A) on front and rear upper control arm pinch bolt and
remove pinch bolt (B) .

Release upper front and rear control arm outer ends from wheel
bearing carrier

CAUTION-
• Do not use chisel or similar tool to widen slits in wheel bearing
housing.
• Do not remove bolts for outer tie rod end. Wheel alignment may
change.

- Swing wheel bearing carrier away from suspension strut.

- Work outer CV joint out of wheel bearing hub and remove drive axle .

- Repair or replace drive axle as necessary. For axle boot

replacement procedure, see CV joint boot, replacing in th is repai r
group.

- When installing , insert outer CV joint into wheel bearing hub first.
40-16 Front Suspension
Front Drive Axles

~ Insert upper control arm ball joints in wheel bearing housing and
press down as far as possible. Install new pinch bolt (B) and ti ghten
nut (A) .

- Bolt drive axle to transmission flange .

Tightening torques
Drive axle to transmission flange:
•MB bolt 40 Nm (30 ft- lb)
• M10 bolt 70 Nm (52 ft-lb)

Upper control arms to wheel bearing housing 40 Nm (30 ft-lb)

- Press ABS wheel speed sensor into wheel bearing housing and
insert harness into bracket on brake caliper.

- With an assistant operating brake, tighten outer CV joint bolt to initial

tightening torque.

CAUT/O~
• Do not allow vehicle to contact the ground when initially
tightening outer CV joint bolt.

Tightening torques
Drive axle to bearing hub (initial torque)
• M14 bolt 115 Nm (85 ft-l b)
• M16 bolt 180 Nm (133 ft-l b)

Mount wheel and tighten .

Tightening torque
Wheel lugs to wheel bearing hub I 120 Nm (89 ft-lb)

- Tighten bolt for drive axle to final tightening torque with vehicle
standing on its wheels.

Tightening torques
Drive axle to bearing hub
(final to rque)
• M14 bolt 115 Nm (85 ft-lb )+ 180°
• M16 bolt 180 Nm (133 ft-lb)+ 180°

CV joint boot, replacing

When replacing CV joint boot, use a complete repair kit including
new boot, clamping bands, special lubricant and axle ci rclip.

If CV joints are worn or defective, a complete rebuilt axle shaft is

available from an authorized Audi dealer.

- Remove drive axle. See Front drive axle, removing and installing
in this repair group.

Place drive axle on workbench in a padded vise.

- Cut off old boot clamps and remove boot.

 Front Suspension 40-17
Front Drive Axles

~ Screw old outer CV joint bolt into end of drive axle until CV joint pops
free of axle circlip.

Remove CV joint and clean old grease off joints and shaft.

Inspect CV joint for galling , pitting and other signs of physical

damage.

NOTE -
• Polished surfaces or visible ball tracks alone are not necessarily
cause for replacement. Discoloration due to overheating indicates
lack of lubricant and the need for a new CV joint.

~ Snap new circlip into groove on end of axle shaft.

Slide new small clamping band , CV boot and large clamping band
on axle shaft.

- Apply special lubricant from CV boot repair kit to CV joint.

- While supporting axle shaft, press inner hub of CV joint on shaft.

Make sure circlip snaps securely in place. Use a rubber mallet to
drive joint on axle shaft, if necessary.

~ Work large end of CV boot into place on joint. Use band clamp pliers
to secure boot clamp.

NOTE -
• Make sure seal beading of boot fits in grooves on CV joint and axle
shaft.

~ Swivel CV joint as far as it will go, thus compressing axle boot. Use
a small screwdriver to "burp" excess air from boot. Be careful not to
damage boot.

Position small end of CV boot in place and tighten small clamping

band over boot end .

Reinstall drive axle using new axle bolt.

40-18 Front Suspension
Front Drive Axles

Front drive axle assembly with inner CV joint

5
1. Circlip
•Replace .
2. Gasket
•Replace.
3. Inner CV joint
•Outside diameter is 100 mm or 108 mm (3.94 in or 4.24 in) ,
depending on engine/transmission combination.
• Replace only as complete unit.
4. Drive axle shaft
5. Clamp
4
•Replace.
6. CV boot
• Check for tears and scuffing .
• Before tightening small end clamp , "burp" CV boot.
7. Clamp
•Replace.
8. Dished washer
•Large diameter (concave side) rests against th rust washer.
9. Thrust washer
N40-0 8 10. Circlip
•Replace.
• Insert in groove on shaft.
11. Outer CV joint
• Replace only as complete unit.
• Drive on shaft until circlip snaps into place .
12. Bolt
•Replace.
• M14 bolt: 115 Nm (85 ft-lb) plus additional 180° (% turn ).
• M16 bolt: 190 Nm (140 ft-lb) plus additional 180° (% turn).
13. Bolt
• M8 x 48 mm: 40 Nm (30 ft-lb).
• M1 Ox 48 mm : 70 Nm (52 ft-lb) .
14. Reinforcing plate
15. Inner CV joint boot.
• Check for tears and scuffing.
• Spread D 454 300 A2 or equivalent sealer on sealing surface
before mounting on CV joint.
 Front Suspension 40-19
Front Drive Axles

Front drive axle assembly with inner

triple roller joint (AAA 2900)
1. Bolt
•Replace.
• M16 bolt: 190 Nm (140 ft-lb) plus an additional 180° (% turn) .
5
2. Outer CV boot
4 • Check for tears and scuffing.
•Before tig htening small end hose clamp , "burp" boot.
3. Clamp (matched to boot)
•Replace.
4. Drive axle
5. Clamp (matched to boot) .
•R eplace .
6. Housing
7. Socket-head bolt
• M 10 x 20 mm : 70 Nm (52 ft-lb) .
8. Triple roller
•Chamfer (arrow) faces splines of drive axle .
9. Circlip
A40-0294
•Repl ace.
• Insert in groove on shaft.
10. Sealing ring
• Repl ace with new seal supplied in repair kit.
11 . Cove r
•Replace.
12. Clamp (matched to boot)
•R eplace .
13. Boot for triple roller joint
14. Clamp
•Replace.
15. Dish ed washer
16. Spacer ring (plastic)
17. Circl ip
•R eplace.
• Insert in ring groove of shaft before installation.
18. Outer CV joint
• Replace only as complete unit.
•Dri ve on shaft until circlip snaps in .
40-20 Front Suspension
Front Drive Axles

Front drive axle assembly inner

triple roller joint (AAR 3300i)
1. Clamp (matched to boot)
•Replace.
2. CV boot for triple roller joint
3. Clamp
•Replace.
4. Circlip
5. Dished washer
6. Spacer ring (plastic)
7. Circlip
•Replace .
• Insert in ring groove of shaft before installation .
8. Outer CV joint
• Replace only as complete unit
• Drive on shaft until circlip snaps in .
9. Bolt
•Replace.
I A4o-o36o I
• M16 bolt: 190 Nm (140 ft-lb) plus additional 180° (112 turn ).
10. Clamp (matched to boot)
•Replace.
11. CV boot for outer CV joint
•Check for tears and scuffing .
•Before tightening small end clamp , "burp" CV boot.
12. Clamp
•Replace.
13. Drive axle
14. Circlip
15. Triple roller connection
•Chamfer (arrow) faces splines of drive axle .
16. Circlip
•Replace.
• Insert in groove on shaft.
17. Socket-head bolt
• M 1Ox 20 mm ; 70 Nm (52 ft-lb) .
18. Housing
 42-1

42 Rear Suspension

GENERAL .. ..... .. ..... .. ...... . . . . .. .. . 42-1 Shock absorber (front-wheel drive) ,

Curb weight position ..... . . .. . ... . . . .. .... 42-1 removing and installing . . . .. ... ... . . .. ... 42-6
allroad quattro "jack mode" ... .... . .. ... ... . 42-2 Shock absorber (quattro) ,
removing and installing ... ... ...... . .. ... 42-8
Suspension codes (part numbers) ...... . . .. . 42-2
Shock absorber (quattro) ,
Warnings and Cautions ... .. .... .... ... .. .. 42-3
disassembling and assembling ... .. .. ... . . 42-9
REAR SUSPENSION . .. .. . . . ..... ... .. .... 42-3 Stabilizer bar, removing and installing . . . . . .. 42-11
Vehicle level senso r (front-wheel drive) .. . . ... 42-3
REAR DRIVE AXLES . . . . .. ..... ..... . .... 42-13
Rear axle components (front-wheel drive) . . ... 42-4
Rear drive axle , removing and installing . ..... 42-13
Shock absorber (front-wheel drive) ... .. .... .. 42-5
Shock absorber (quattro) .. .. ... . . . .... . ... 42-5

GENERAL
This section covers repairs to the rear suspension and related
compon ents . Also see :
• 40 Front Suspension for rear suspension servicing and repair
information
• 44 Wheels, Tires, Wheel Alignment for wheel alignment
specifications

Special tools, equipment and procedures are requ ired for most rear
suspension repair and component replacement. On suspension
components with bonded rubber bushings, tighten fasteners with
vehicle at curb weight position . See Curb weight position in this
repair group.

Wheel alignment is almost always disturbed when suspension

compon ents are n~moved or replaced . Plan on a wheel alignment
after suspension repairs .

Curb weight position

Bonded rubber bushings can only be flexed to a limited extent. Place
suspen sion under load (curb weight position) before tightening
suspension arms with bonded rubber bushings .

~ In this illustration jack stands and wheel ramps are used to place
vehicle at curb weight position . Then tighten suspension arms with
bonded rubber bushings to torque specification.
42-2 Rear Suspension
General

allroad quattro "jack mode"

Prior to jacking or lifting allroad quattro vehicle , set ride height
control to "jack mode" to protect suspension shock absorbers and
struts.

WARNING-
• Make sure that no one is lying under the vehicle or has head or
hands in the wheel housing while the ride height is changing.

Activating

<fiiiiiii( Before lifting veh icle with jack or lift:

•Switch ignition ON .
• Press ride height control buttons A and C in center dashboard fo r
at least 5 seconds.
•When system is in "jack mode", LEDs on control buttons (A and C) ,
yellow LED for manual mode on level indicator (B) and warn ing
light for level control in instrument cluster all illuminate.

- Switch ignition OFF and lift or jack vehicle.

Deactivating

Press control buttons 1 and 3 for at least 5 seconds. Warning light

in instrument cluster, LED for manual mode and control button LEDs
turn OFF.

"Jack mode" is automatically deactivated when vehicle speed

exceeds 3 mph (5 kph).

Suspension codes (part numbers)

The spring/shock absorber combination installed in the veh icle is
documented by part number on the vehicle data sticker. The vehicle
data sticker is located in the spare tire well and in the service
booklet.

c. -1-2190 444 <fiiiiiii( Example of a vehicle data sticker.

WAUOA24B 1 XN001612 1. Rear axle designation

4B5 4VZ SA9 2. Front axle designation
A6 Ava . quat . 2. 8 3. Suspension code
147KW TLEV AS
Match to strut and coil spring codes found in Audi parts data.
AHA l CUB DPT
~f~r~~~Nl=~r· LY7M/i Y7M f Nl H/ BN See 44 Wheels, Tires, Alignment for more information about
M.- AUSST.t0PTION5 _X9A
ti
BOA C6P GOG H4B JOL
*' suspension codes.
MlO QlA 1BH 1AH ~ 2PR
_ . 1 N3 ~ 5SG T7F OJM ~~~
~----,..,
~~~"""'
~ OYW OG7 BUG
·o' *id?~ .
~ · .... - .lt::M~
1LB t3FE ~-
~
1818'"11'19, 9 9, 9 9, 9 999
 Rear Suspension 42-3
Rear Suspension

Warnings and Cautions

WARNING -
• Most fasteners are designed to be used only once and
become unreliable and may fail when used a second time.
This includes, but is not limited to, nuts, bolts, washers,
circlips, cotter pins, self-locking nuts and bolts. For
replacements, use new parts.
• Do not reinstall bolts and nuts coated with undercoating wax.
Clean the threads with a suitable solvent before installing.
• Replace rusted or corroded bolts, nuts and washers even if not
specifically indicated.
• Do not attempt to straighten or weld suspension struts, wheel
bearing housings, control arms or any other wheel locating or
load bearing components of the front suspension.

CAUTIO~
• To avoid wheel bearing damage, do not move vehicle without
drive axle(s). If vehicle needs to be moved, install an outer joint
in place of the drive axle. Tighten outer joint to 115 Nm (85 ft-
lb) for M14 bolt or 190 Nm (140 ft-lb) for M16 bolt.
• Bonded rubber bushings may only be flexed to a limited extent.
See Curb weight position in this repair group.
• Before performing suspension work on al/road quattro, see
allroad quattro "jack mode" in this repair group.

REAR SUSPENSION

Vehicle level sensor (front-wheel drive)

Vehicle with automatic headlight vertical aim control is equipped
with vehi cle level sensor.
1. Bolt
2. Left rear level control system sensor (G76)
•Ch ecked via on-board diagnostics (080).
•Do not remove coupling link from ball head .
3. Self-locking nut, 10 Nm (7 ft-lb)
•Replace
4. Rear axle beam
42-4 Rear Suspension
Rear Suspension

Rear axle components

15 ~ --~ ' (front-wheel drive)
. //I;~\~·
--~
1. Upper spring seat
2. ABS wheel speed sensor bracket
3. ABS wheel speed sensor
4. Coil spring
•See Shock absorber (front wheel drive), removing and
installing in this repair group
•Make sure surface of spring coil is not damaged
• Different types of springs are used for different appl ications
• Make sure bottom end of coil spring rests in spring base as
shown
•(Arrow A) shows direction of travel
5
•(Arrow B) points right
• Bottom turns of spring have markings which must point
backward during installation
5. Wheel bearing
• When replacing , also replace ABS wheel speed sensor
6. Mounting bracket
• After installation check settings and adjust, if necessary
• Use special care when starting bolts
•Do not mix cast and fo rged mounting brackets
7. Nut
• Always replace
8. Bolt M12 x 1.5 x go mm
• Always replace after disassembly
• 110 Nm (81 ft-lb) plus additional go 0
9. Stone impact protection plate for mounting bracket
• Only for rough terrain suspension
10. Bolt, 10 Nm
11. Bolt M12 x 1.5 x 60 mm
• Always replace
• Use special care when starting bolts
• 110 Nm (81 ft-lb) plus additional go 0
12. Axle beam
13. Bolt M14 x 1.5 x 1go mm
• 120 Nm (120 ft-lb) plus additional go 0
• Always replace after disassembly
14. Retaining strap
15. Thread in side member
• Use special care when starting bolts
 Rear Suspension 42-5
Rear Suspension

Shock absorber (front-wheel drive)

11 ~
~ 1. Gas-filled shock absorber
10 --~@ • Individually replaceable

9 ----<8 •Shock absorbers vary with application .

• Dispose of properly
• Check shock absorber for leaks and noises
2. Nut
• Always replace after disassembly
3. Bolt M10 x 90 mm
• Always replace after disassembly
• Only tighten when vehicle is standing on its wheels.

3~
• 50 Nm (37 ft-lb) plus an additional 90°
'-l
-'( c I" . . -. _._,)', - 4. Protective cap
/ • Press on until it stops
5. Protective tube

i
2
6.
7.
Stop buffer
Bolt, 45 Nm (33 ft-lb)
8. Shock absorber upper mount
A4 2-0 127
9. Self-locking nut, 25 Nm (18 ft-lb)
• Always replace after disassembly
10. Installation cap
•Only for factory installation , not used for repairs .
11. Thread in wheel housing

Shock absorber (quattro)

10 ~ 1. Protective cap
9
~
- u --- 1
~
2.
• Preinstalled on shock absorber
Rubber insert

s-fl ..
<@)- 2
~1'L_ 3
3.
4.
• Preinstalled on shock absorber
Spring seat
Spacer ring
• The spacer ring is only present on "Bilstein" shock absorbers.
e 4
Do not install on shock absorbers of a different make.
r
7- -
5. Gas shock absorber
• individually replaceable
•Di sposal of properly.
• Check shock absorber for leaks and noises .
6. Coil spring
•C heck for paint damage , repair if necessary
• After installation , ends should lie in stop the rubber inserts .
7. Spring support with protective tube
• Consists of two parts
8. Buffer stop
I N42--0233 I 9. Shock absorber mount
•Self-locking nuts, 27 Nm
• Always replace
42-6 Rear Suspension
Rear Suspension

Shock absorber (front-wheel drive),

removing and installing
Special tools and equipment
~ 3079 counter hold tool
3079
- Remove installation cap at top of shock absorber.

I W00-0010 I

~ If removing shock absorber from mount, use special tool 3079 to

counterhold shock strut when removing upper nut.

~ Use VAG 1383 A (engine and transmission jack) and VAG 1359/2
(support bracket) to support rear suspension arm .

W00-0120
 Rear Suspension 42-7
Rear Suspension

Removing

Raise vehicle and support safely. Remove wheel .

WARNING-
• Make sure car is stable and well supported at all times. Use a
professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Place engine/transmission jack underneath wheel bearing hub and

raise to relieve coil spring tension .

~ Remove bolt (2) , and lower engine I transmission jack.

- With assistant pulling down rear axle , remove coil sp ring.

- Unscrew bolts (1) at top and remove shock absorbe r.

V.A.G 1383~\ A42-01 24

Installing
- Insert shock absorber in body and tighten to 45 Nm (33 ft-lb).

- With assistant pulling down rear axle, install coil spring .

~ Install lower shock absorber bushing to rear axle bolt.

I CAUTION-
• Use new fasteners.

1. Self-locking nut
2. Bolt
3. Shock absorber

- Tighten lower shock absorber to rear axle bolt with vehicle

suspension loaded.

N 42-0 175 I Tighten ing torque

Shock absorber to rear axle 50 Nm (37 ft-lb) + 90°

I
42-8 Rear Suspension
Rear Suspension

Shock absorber (quattro ),

removing and installing
Raise car and support safely. Remove rear wheel.

WARNING-
• Make sure car is stable and well supported at all times. Use a
professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

<Oiiii{ Counterhold lower guide pin and remove self-locking bolt from brake
caliper housing.

- Remove upper caliper guide bolt and hang caliper from chass is
using stiff wire.

<Oiiii{ Remove clamp (3) for stabilizer bar (2).

1. Axle beam
2. Eccentric bolt

<Oiiii{ Remove stabilizer bar link (arrow) at bar.

Jf- J
A604420 11

<Oiiii{ Remove bolt (2) for link (1 ).

 Rear Suspension 42-9
Rear Suspension

~ Working in wheel well, remove upper shock absorber mounting bolts

(arrows) .

~ Unscrew lower mounting bolt (arrow) for shock absorber and

remove shock absorber.

- To remove sh ock absorber, pull wheel bearing housing down a little.

- Installation is reverse of removal. Remember to tighten suspension

bolts with suspension loaded. See Curb weight position in this
repair group.

Tightening torques
Stabilizer bar clamp to axle beam 25 Nm (18 ft-lb)
Coupling rod to stabilizer bar 50 Nm (37 ft-lb)

Link to wheel bearing housing 70 Nm (52 ft-lb)

+ go 0 turn
Shock absorber to body 45 Nm (33 ft-lb)

Shock absorber to link (always replace bolts) 70 Nm (52 ft-lb)

+ go 0 turn
Brake caliper to bracket (always replace bolts) 30 Nm (22 ft-lb)

Shock absorber ( quattro ),

disassembling and assembling
The following tools are required for this job :

~ Spring compressor (Volkswagen spring compressor kit VAG 1752 or

equivalent) .

I W00-0500 I
42-10 Rear Suspension
Rear Suspension

~ Volkswagen special wrench 3017 A or equivalent.

3017 A

I W00-0264 I
Disassembling

V.A.G 1752/1 ~ Install spring compressor (VAG1752/1 or equivalent) onto co il

spring .

WARNING-
• Make sure spring compressor jaws are fully seated in spring.

- Pre-load coil spring using Spring Compressor VAG1752/1 fa r

enough until top shock absorber mount is free .

- Remove nut from push rod using Volkswagen special wrench 30 17

A or equivalent.

- Remove coil spring and individual parts from shock absorber.

 Rear Suspension 42-11
Rear Suspension

Assembling

Installation is performed in the reverse order of removal , noting the

following :

~ Top and bottom ends of spring must rest against stop of spring
support (arrow).
• Illustration shows lower spring end . Lower spring end must point
toward center of vehicle.

~ Installed position of shock absorber mount (3) :

• Mount bolts (1) must align with axis (2) of bottom shock absorber
bushing (4) .
• Mount bolts (1) face outside of vehicle .

1 1 2
I N42-0235 I
Stabilizer bar, removing and installing
- Raise vehicle and support safely. Remove wheel.

WARNING -
• Make sure car is stable and well supported at all times. Use a
professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

~ Unscrew attachment screws (1) from brake caliper.

42-12 Rear Suspension
Rear Suspension

~ Detach link (1) from stabilizer bar.

~ Remove clamp (3) for stabilizer (2).

1. Axle beam
2. Eccentric bolt

~ Unscrew bolt (3) for shock absorber at lower control arm .

• 1 Control arm
• 2 Parking brake cable
• 3 Bolt for shock absorber
• A Holding clip for parking brake cable

- Pull wheel bearing housing downward along with lower control arm.

~ Push drift (2) or through hole of shock absorber bushing.

- Unscrew lower hex bolt for coupling link and remove stabilizer bar.
 Rear Suspension 42-13
Rear Drive Axles

- Installation is reverse of removal.

Tightening torques
Shock absorber to control arm (use new bolts) 70 Nm (52 ft-lb)
+goo
Coupling link to wheel bearing 55 Nm (41 ft-lb
Coupling link to stabilizer 50 Nm (37 ft-lb)
Stabilizer bar clamp to axle beam 25 Nm (18 ft-lb)
Brake caliper to wheel bearing housing (steel) g5 Nm (70 ft-lb)
Brake caliper to wheel bearing housing 70 Nm (52 ft-lb)
(aluminum) + goo

REAR DRIVE AXLES

Rear drive axle, removing and installing

~ Use VAG 1383 A (engine and transmission jack) to support rear
suspension arm during this procedure.

- With vehicle standing on its wheels , loosen axle collar bolt go 0 .

WARNING-
• Vehicle must be standing on its wheels when loosening and
tightening collar bolt.
• Only loosen collar bolt 90°; otherwise wheel bearing will be
damaged

Raise ca r and support safely.

W00-01 20
WARNING-
• Make sure the car is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

- Remove wheel.

- Secure brake disc using wheel bolts.

- Remove bolt for drive axle .

~ Remove heat shield for drive axle (arrows).

- Unscrew drive axle from differential flange .

42-14 Rear Suspension
Rear Drive Axles

-fiiiiii( Remove Allen bolt (1 ).

- Remove ABS wheel speed sensor (2) from wheel bearing housing .

- Loosen exhaust system in back , and secure to body. See

26 Exhaust System .

-fiiiiii( Support lower control arm with VAG1383 A.

Pound drive axle out of wheel hub with plastic hammer, if necessary.

Remove drive axle.

- When install ing , Place outer CV joint in wheel bearing hub. Install
and tighten differential flange bolts.

- With an assistant operating the brake, install and tighten bolt for
drive axle to initial tightening torque .

CAUTIO~
• Do not allow vehicle to contact the ground when initially
tightening outer CV joint bolt.

Tightening torques
Drive axle to bearing hub (initial torque)
• M14 (use new bolt) 115 Nm (85 ft-lb)
• M16 (use new bolt) 190 Nm (140 ft-lb)
Drive axle to differential flange :
•MS 40 Nm (30 ft-lb)
• M10 70 Nm (52 ft-lb)
Heat shield to chassis 25 Nm (1 8 ft-lb)

- Mount wheel and lower vehicle to ground.

Tightening torque
Wheel lugs to wheel bearing hub 120 Nm (89 ft-lb)

- Tighten drive axle to final torque specification (initial specification

plus an additional 180°).

Tightening torques
Drive axle to bearing hub
(final torque)
• M14 bolt 115 Nm (85 ft-lb) + 180°
• M16 bolt 190 Nm (140 ft-lb) + 180°
 44-1

44 Wheels, Tires, Alignment

GENERAL . . ... . .......... ....... . .. .... . 44-1 WHEEL ALIGNMENT ... . ...... ......... . .. 44-5

WHEELS AND TIRES . . ... ...... .. ... ..... 44-1 TABLES

Suspension codes (part numbers) .... . ...... 44-2 a. W heel alignment data-front-wheel drive .... .. .. . . . . 44-6
TIRE PRESSURE CONTROL SYSTEM .. . .. .. 44-3 b. Wheel alignment data-quattro (V6 engines) . . . . . . ... 44-7
Tire pressure monitor components ... . ...... 44-3 c. Wheel alignment data-quattro (V8 engines) . .. . ... .. 44-8
d. W heel alignment data-allroad quattro ..... . .. .... .. 44-9
Wheels I tires , assembly ove rview ........... 44-3
Tire pressure wheel electronics ,
removing and installing . .. .. . . . ... .. ..... 44-4
Tire pressure reception antenna,
removing and installing ......... .... ..... 44-4
Tire pressure control system , setting .... . .... 44-5

GENERAL
This section covers basic tire , wheel , and wheel alignment
information. Also covered here are wheel alignment specifications
to be used in conjunction with professional alignment tools and
measuring equipment.

WHEELS AND TIRES

<liiiiii{ Wh eels and tires approved by the manufacturer are matched to the
195 I 60 R 14 85 V vehicle and contribute largely to the road handling and driving
characteristics . Replace tires with tires having the same
Tire width I specifications with regard to size, design , load carrying capacity,
in mm - - - - - - - ' · speed rating , tread pattern , tread depth , etc. This information can be
found on the tire sidewall .
Heig ht/width ratio
in %
Audi recommends that tires be rotated front to rear, with the tires
Tire construction: remaining on the same side of the vehicle . For tire rotation
Radial schedules and general tire and wheel service information , see
Rim diameter in inches _ _ _ ____, 03 Maintenance.

Load rating code _ _ _ _ _ _ _ ____. - When installing wheel bolts , they should be snugged down in a
diagonal pattern and then tightened to final torque using the same
Speed rating code letter
pattern .

Tightening torque

Wheel bolt to wheel hub 120 Nm (90 ft-lb)

44-2 Wheels, Tires, Alignmen
Wheels and Tires

Tire mounting
Models covered by this manual are equipped with alloy wheels . Use
tire mounting equipment designed for use with alloy wheels to avoid
damage to the wheel and tire.

Alloy wheel valve replacement

On some models with alloy wheels , metal valve stems are installed
in place of the conventional rubber valve stems. Replace metal
valve stem each time the tire is changed .

Suspension codes (part numbers)

Various suspensions are offered as options. These are identified by
part numbers

The suspension version installed is indicated by the factory weight

code on the vehicle data sticker. The vehicle data sticker is located
in the spare tire well and in the owner's manual.

c. -1-2190 444 ~ Example of a vehicle data sticker.

WAUDA24B 1 1. Rear axle designation

4B5 4VZ 2. Front axle designation
A6 Ava . quat. 2. 8 3. Suspension code
147KW TLEV A5
The following table shows the meaning of the part numbers which
CUB DPT are critical for wheel alignment. (In this example vehicle has USA
NlH/ BN suspension 1 BH.)
• 1BA = standard suspension
• 1BE = sport suspension
• 1BP= rough terrain suspension 1 (curb weight position like 1BA,
but with spring limitation)
• 1BT = rough terrain suspension 1= and slight reinforcement
(about 7 mm raised position)
• 1BB= rough terrain suspension 2 (about 20 mm raised position)
• 1BG = suspension with level control system
• 1BC= special-purpose vehicles (fire department,
medical emergency, police, etc .)
• 1BH = suspension for USA
• 1BO = Audi S6 sport suspension
• 1BJ = suspension for light armor
• 1BY= suspension for allroad (4-wheel air suspension)
• 1BV = sports suspension Audi RS6 quattro
• 2MC = sports suspension Audi RS6 quattro
(sport suspension with variable shock absorber)
• 2ME =sports suspension Audi RS6 quattro
(super sport suspension with shock absorber)
 Wheels, Tires, Alignment 44-3
Tire Pressure Monitoring System

TIRE PRESSURE MONITORING SYSTEM

Some models covered by this manual are equipped with a
sophisticated tire pressure monitoring system. Transmitters in each
wheel send tire pressure information to a control module located in
the left rear of the trunk. If a loss of pressure is detected , a low
pressure warning light is displayed on the instrument cluster.

Tire pressure monitoring components

1. Antenna (4x)
2. Display on instrument panel
3. Tire pressure monitoring control module (J502)
• Left rear of trunk
4. Wheel electronics (4x)

NOTE -
• If self-locking bolt of the wheel electronics is loosened, replace it.
• For safety reasons, damaged wheel electronics or valves must be
replaced.
• Do not clean wheel electronics using a pressure washer or strong
pressurized air stream.

w
•After using tire sealing liquid, the wheel electronics must be
replaced, since a possibility of an incorrect measurement exists
due to deposits of the liquid at pressure sensor.

"'\r4
I A44 -012? I
Wheels I tires, assembly overview
1. Metal valve body
• Supplied complete
• Replace valve insert at every tire change
2. Valve insert
3. Seal
4. Rim
5. Wheel electronics
• Battery service life approx. 7 years
• Remaining service life can be checked with diagnostic tool
• Must be replaced as a complete unit
6. Micro encapsulated bolt (Torx T20) , 4 Nm (3 ft-lb)
7. Union nut, 4 Nm (3 ft-lb)
8. Chamfered washer

A44-0084
44-4 Wheels, Tires, Align ent
Tire Pressure Monitoring System

Tire pressure wheel electronics,

removing and installing
~ Install metal valve with rubber seal through rim from inside.

- Set chamfered washer and union nut on outside and tighten by

hand.

- Secure against turning , using retainer (1) (or 2 mm drill bit) .

Tightening torque
Metal valve to rim 4 Nm (3 ft-lb)

~ Press wheel electronics (1) into position and tighten with self-locking
bolt at rear of valve.

Tightening torque
Wheel electronics to valve 4 Nm (3 ft-lb)
I

Tire pressure reception antenna,

removing and installing
The reception antennas are located behind the wheel housing
liners.

- Turn ignition off.

- Remove wheel.

- Remove the wheel housing liner.

- Disconnect harness connector to antenna.

- Remove threaded connection of antenna to bracket.

- Remove antenna .
 Wheels, Tires, Alignment 44-5
Wheel Alignment

Tire pressure monitoring system, setting

After checking inflation pressures and properly inflating tires
(including the spare) , store the current tire pressures in the
monitoring system .

Switch ignition on and access the start menu from instrument cluster
driver information display.

Move selection arrow to Set by rotating turn I push knob.

Press turn I push knob. Setting menu appears.

Move selection arrow to Tire pressure by rotating the knob.

Press turn I push knob. Submenu Tire pressure appears .

Move selection arrow to Store pressures!.

Press knob and turn . A check mark appears. System responds with
The current tire pressure will be saved.

Move selection arrow to Back.

Press knob to leave tire pressure menu .

NOTE-
• Reset the tire pressure monitoring system after every change in air
pressure and after every wheel change.

WHEEL ALIGNMENT
Have alignment checked if:
• Vehicle not tracking properly
• Tires wearing unevenly
• Suspension damage suspected
•A repair may have altered the alignment

Accurate wheel alignment is best performed by your Audi dealer or

a certified alignment shop. Always include both front and rear axles
when checking alignment.

NOTE -
• Do not align wheels until the vehicle has been driven 1000 - 2000
km (600 - 1200 mi), to allow coil springs to settle.
• Vehicle instability can be caused by the wheels having a residual
imbalance and/or radial runout which is too great.
• Ensure proper attachment and adjustment of measuring
equipment; pay attention to manufacturer's operating instructions.
• If appropriate, have manufacturer of wheel alignment equipment
provide instruction.
• Wheel alignment platform and wheel alignment equipment I
computer may start to deviate over the course of time from their
original position I setting.
• Make sure wheel alignment platform and wheel alignment
equipment and computer is inspected at least once a year
• Treat sensitive alignment equipment carefully and conscientiously
44-6 Wheels, Tires, Alignmen
Wheel Alignment

Table a. Wheel alignment data-front-wheel drive

Suspension (1 BA, Sport susp« nsion Rough terrain Rough terrain Level control
Front axle 1BH, 1BP, 1BC) (1BE) suspension (1 BB) suspension (1 BT) system (1 BG)
Camber - 50' ± 25 ' - 1° 05' ± 25' - 35 ± 25' - 45' ± 25' - 50' ± 25'

Max permissible
difference between 30' 30' 30' 30' 30'
sides
Toe per wheel
(adjustment value in + 1O' ± 2' + 1O' ± )' + 10' ± 2' + 10' ± 2' + 10' ± 2'
start position)

Toe per wheel

(control value in start + 10' ± 5' + 1O' ± ) 1
+ 10' ± 5' + 10' ± 5' + 10' ± 5'
position)
Toe constant per
+ 7' ± 2' + 7' ±;' + 7' ± 2' + 7' ± 2' + 7' ± 2'
wheel (setting)
Toe constant per
+7'±7' + 7' ± ' +7'±7' +7'±7' +7'±7'
wheel (control value)
Toe-out angle at 20°
(The angle of the
outside wheel is less
by this amount. This - 1° 30' ± 30' - 1° 30' ± 30' - 1° 30' ± 30' - 1° 30' ± 30' - 1° 30' ± 30'
may be indicated as
negative on the
alignment computer)
Rear axle
Camber
Maximum
permissible - 1° 30' ± 20' - 1° 30' ± 20' - 1° 30' ± 20' - 1° 30' ± 20' - 1° 30' ± 20'
difference between
sides
Maximum
permissible
30' 30' 30' 30' 30'
difference between
sides
Overall toe + 20' + 15' I - 1O' + 28 + 15' I - 10' + 14 + 15' I - 10' +17+15' /-10' + 26 + 15' I - 1O'
Maximum
permissible deviation
± 15' ± 15' ± 15' ± 15' ± 15'
from longitudinal axis
of vehicle
 Wheels , Tires, Ali gnment 44-7
Wheel Alignment

Table b. Wheel align ment data-quattro (VG engines)

Suspension Sport suspen- Rough terrain Rough terrain Rough terra in Level control
(1 BA, 1 BH , 1 BP, sion (1 BE) suspension suspension suspension system (1 BG)
Front axle 1BC) (1 BB) (1 BR) (1 BT, 1 BJ)
Camber - 50' ± 25 ' - 1° 05' ± 25 ' - 35 ± 25 ' - 40' ± 25' - 45 ' ± 25' - 50 ' ± 25 '
Max permissible
difference 30' 30' 30' 30' 30' 30'
between sides

Toe per wheel

(adjustment value + 10' ± 2' + 1O' ± 2' + 10' ± 2' + 10' ± 2' + 10' ± 2' + 10' ± 2'
in start position)

Toe per wheel

(control value in + 10' ± 5' + 10' ± 5' + 1O' ± 5' + 10' ±5' + 1O' ± 5' + 1O' ± 5'
start position)

Toe constant per

+ 7' ± 2' + 7' ± 2' + 7' ± 2' + 7' ± 2' + 7' ± 2' + 7' ± 2'
wheel (setting)

Toe constant per

wheel (control +7'±7' +7'±7' +7'±7' +7'±7' +7'±7' +7'±7'
value)

Toe-out angle at
20° (Th e angle of
the outside wheel
is less by this
amount. This may - 1° 30' ± 30' - 1° 30' ± 30' - 1° 30' ± 30' - 1° 30' ± 30' - 1° 30' ± 30' - 1° 30' ± 30'
be indicated as
negati ve on the
alignment
computer)
Rear axle

Camber - 40' ± 30' - 40 ' ± 30' - 40' ± 30' - 40' ± 30' - 40' ± 30' - 40' ± 30 '

Maximum
permissible 30' 30' 30'
30' 30' 30'
diffe rence
between sides
Toe per wheel + 8' ± 5' + 8' ± 5' + 8' ± 5' + 8' ± 5' + 8' ± 5' + 8' ± 5'

Maximum
permissible
deviation from ± 10' ± 10' ± 10' ± 10' ± 10' ± 10'
longitudinal axis
of vehicle
44-8 Wheels, Ti res , Align mer t
Wheel Alignment

Table c. Wheel alig nment data-quattro (VS engin ~s)

Suspension (1 BA, Sport sus~ ens ion Sport suspension Rough terrain sus- Level contro l
Front axle 1BH) (1BE, 1 BD) (1 BV, 2ME, 2MC) pension (1 BR) system (1 BG)

Camber - 1° ± 25' - 1° 05 ' 25' - 1° 20' ± 20' - 50' ± 25' - 1° ± 25'

Max permissible
difference between 30' 30' 30' 30' 30'
sides
Toe per wheel
(adjustment value in + 10' ± 2' + 10' ± 2' + 10' ± 2' + 10' ± 2' + 10' ± 2'
start position)

Toe per wheel

(control value in start + 10' ± 5' + 10' ± 5' + 10' ± 5' + 10' ± 5' + 10' ± 5'
position)
Toe constant per
+ 7' ± 2' + 7' ± )' + 7' ± 2' + 7' ± 2' + 7' ± 2'
wheel (setting)

Toe constant per

+7'±7' + 7' ± 71 +7'±7' +7'±7' +7'±7'
wheel (control value)
Toe-out angle at 20°
(The angle of the
outside wheel is less
by this amount. This - 1° 30' ± 30' - 1° 30' :! 30' - 1° 30' ± 30' - 1° 30' ± 30' - 1° 30' ± 30'
may be indicated as
negative on the
alignment computer)
Rear axle
Camber - 60' ± 30' - 60' ±: O' - 60' ± 30' - 60' ± 30' - 1° 1O' ± 30'
Maximum
permissible
30 ' 30' 30' 30' 30'
difference between
sides
Toe per wheel + 8' ± 5' + 8' ± ' + 8' ± 5' + 8' ± 5' + 8' ± 5'

Maximum
permissible deviation
± 10' ± 10' ± 10' ± 10' ± 10'
from longitudinal axis
of vehicle
 Wheels, Tires , Alignment 44-9
Wheel Alignment

Table d. Wheel alignment data-allroad quattro

Front axle Suspension (1 BY)
Camber - 1° ± 25'
Max permissible difference between sides 30'
Toe per wheel (adjustment value in start
+ 10' ± 2'
position)
Toe per wheel (control value in start position) + 1O' ± 5'
Toe constant per wheel (setting) + 7' ± 2'
Toe constant per wheel (control value) +7'±7'
Toe-out angle at 20°
(The angle of the outside wheel is less by this
- 1° 25' ± 30 '
amount. This may be indicated as negative on
the alignment computer)

Rear axle
Camber - 60' ± 30'
Maximum permissible difference between
30'
sides
Toe per wheel + 9' ± 4'
Permissible overall toe + 18' ± 8'
Maximum permissible deviation from
± 10'
longitudinal axis of vehicle

Test requirements
•Check suspension , wheel bearing , steering and steering linkage
for excessive play and damage.
•Tread depth difference of no more than 2 mm on tires per axle.
•Tires inflated to correct pressure .
•Vehicle in curb weight position .
• Fuel tank full.
•Spare tire and vehicle tools installed in appropriate position.
• Container for the windshield/headlight cleaning system is full.
• In vehicles with level control (1 BG) , switch on ignition before
measurement, and wait until vehicle height control process is
complete.
•For vehicles with 4-wheel air suspension (1BY), vehicle must be at
normal leve l. Deactivate level control system. Be sure there is
sufficient pressure in pressure reservoir. Press up and down
buttons in operating unit for level control system simultaneously for
more than 5 seconds until LED indicators light up. Indicator in
instrument cluster will also light up.
•On vehicles with 4-wheel air suspension (1 BY) , check specified
height between center of wheel and bottom edge of fender
(Specification: 402 mm± 5 mm) .
 45-1

45 Antilock Brakes (ABS)

GENERAL . . . . ....... . . ..... . ....... . .... 45-1 ABS HYDRAULIC COMPONENTS .... . .. . .. 45-10
Warnings and Cautions . . .. .. ... ... . .. .. . . 45-1 ASR hydraulic control unit (Bosch 5.3) ,
Antilock brakes (ABS) ...... .. ... . ........ . 45-3 removing and installing .. . . . .. . ... . ... .. 45-1 O
ASR hydraulic pump (Bosch 5.3) ,
ABS COMPONENTS .. . ... . . ............ .. 45-4 removing and installing . ... . .......... . . 45-11
Bosch ABS I ASR 5.3 . . . . ... .... .. ... .. ... 45-4 ESP hydraulic control unit (Bosch 5.7) ,
Bosch ABS I ESP 5.7 ... . .. . .. .. ... . ... . .. 45-5 removing and installing .. . .... . .. ... ... . 45-13
ABS ELECTRICAL COMPONENTS . ......... 45-6 ABS WHEEL SPEED SENSORS ........ . .. 45-14
ASR control module (J104) (Bosch 5.3), ABS front axle components . . . . . . . . . . . . . . . 45-14
removing and installing ... .. .... . . .. ... .. 45-6 ABS front wheel speed sensor,
Steering angle sensor (G85) , removing and installing .. .. ...... .. .... . 45-14
removing and installing . .. ... ...... ... ... 45-6 Front impulse wheel , checking . .. ... . . . .... 45-15
Transverse acceleration sensor (G200) and ABS rear axle components (FWD) ........ . . 45-15
Rotation rate sensor (G202) (Bosch 5.3) ,
ABS rear wheel speed sensor (FWD) ,
removing and installing .. ...... . .... . ... . 45-8
removing and installing ..... .... . . . .. . . . 45-16
Transverse acceleration sensor (G200) and
Rear impulse wheel (FWD) , checking .. . .... 45-18
Rotation rate sensor (G202) (Bosch 5.7) ,
removing and installing .. ... . .. . . ... . . ... 45-9 Rear impulse wheel (FWD),
removing and installing . .. .. . .. ... .. .. .. 45-18
Brake light switch removing and installing .... . 45-9
ABS rear axle components (quattro) .. .. .... 45-19
Parking brake switch ... . . .. .. .... . . . . ... 45-10
ABS rear wheel speed sensor (quattro) ,
removing and installing .. .. ... . . .. .... . . 45-19
Rear impulse wheel (quattro) , checking ...... 45-20

GENERAL
This repair group covers antilock brakes (ABS) . For related
information see :
• 46 Brakes-Mechanical
• 47 Brakes-Hydraulic

Warnings and Cautions

WARNING -
• ABS is a vehicle safety system; appropriate knowledge and
special equipment are necessary to work on the system.
• If ABS and brake system warning lights illuminate, the ABS
system is compromised and wheels may lock up prematurely
when braking.
•Bleed the ABS system after opening brake hydraulic system.
• If an ABS fault is detected by on-board diagnostics, the function
of the brake system may be limited and there is a risk of
accident.
 I

45-2 Antilock Brakes (ABS)

General

WARNING-
• The ABS and brake system warning lights are not capable of
monitoring all brake system functions; visual inspections are
still required for the system.
•Do not use silicone-based brake fluids (DOT 5). This fluid is
incompatible with the brake system and even the smallest trace
can cause severe corrosion.
•Absolute cleanliness is required when working on the ABS
system. Do not use any products that contain mineral oil such
as oil, grease, etc.
• Carefully seal or cover opened components if repairs cannot be
completed immediately. Sealing plugs are contained in factory
supplied repair kit.
• Upon completion of repairs, road test the vehicle so that the
ABS is felt to engage through the pulsing of the brake pedal.
• Do not reuse fasteners that are worn or deformed.

CAUT/O~
• Before working on the ABS, switch ignition OFF and disconnect
the battery ground (-) strap.
• For ABS I ESP system to work properly, make sure all four
wheels are fitted with identical tires. Any differences in the
rolling radius of the tires can cause faults.
• Keep brake fluid off painted surfaces; it removes paint.
•An illuminated ABS warning light indicates a fault in the system .
Check the fault memory with an Audi scan tool or equivalent
before disconnecting the battery.
• Brake fluid absorbs moisture from the surrounding air. Replace
every two years. Use only new brake fluid that complies with
Federal Motor Vehicle Safety Standards 116, DOT 4 Super or
DOT 4 Plus.
• Before doing any electric welding to the vehicle, disconnect the
ABS control module.
•Do not expose the ABS control module to high heat (as in a
drying booth) for a prolonged period. The module may be
exposed to a max. temperature of 95°C (203 °F) for a short
period and to a max. temperature of 85° C (185 °F) for 2 hours.
• Do not let brake fluid enter wiring harness connectors.
•Obtain the anti-theft radio security code (if applicable) before
interrupting power to the radio.
• On vehicles equipped with Audi Telematics by OnStar®, switch
off the emergency (back-up) battery for the telema tic/ telephone
control module prior to disconnecting vehicle battery.
•After reconnecting vehicle battery, re-code and check operation
of anti-theft radio. Also check operation of clock and power
windows according to Owner's manual.
•After reconnecting vehicle battery on vehicles equipped with
Audi Telematics by OnStar®, switch on the emergency (back-
up) battery for the telematic! telephone control module.

I
I
 Antilock Brakes (ABS) 45-3
General

Antilock brakes (ABS)

A6 vehicles are equipped with antilock braking (ABS) . ABS uses
electronic control of brakes and throttle to prevent wheels from
locking during hard braking , thus helping to increase vehicle
direction control and decrease stopping distance.

Basic ABS is supplemented by software and hardware to achieve

additional safety features. The electronic components have self
diagnostic capabilities.

In this repair group ABS versions are referred to simply as ABS

unless a distinction is necessary.

Bosch ABS I ASA 5.3

~ Bosch ABS 5.3 includes the following vehicle stability refinements :

• Electronic brake pressure distribution (EBO) . ABS control
module regulates brake pressure to eliminate rea r wheel lock-up.
EBO control ends as soon as ABS control is applied .
• Electronic differential lock (EDL} As an aid to starting on a slick
surface, EDL automatically brakes the spinning wheel and shunts
driving torque to the wheel with traction . EDL controls slip up to
25 mph (40 kph) in a front-wheel drive vehicle and up to 50 mph
(80 kph ) in a quattro (all-wheel drive) vehicle.
• Antislip regulation (ASR). On front-wheel drive veh icle , if driving
wheels spin during acceleration , ASR regulates wheel spin by
reducing engine torque . This is done through retarding ignition
timing or cyclically shutting down fuel injectors . ASR is effective
across the entire range of speed .

WARNING -
• Bleeding procedure for models with ABS I ASR 5.3 cannot be
accomplished without VAG scan tool 1551 I 1552.

Bosch ABS I ESP 5. 7

~ Beginnin g in 2001 , A6 models are equipped with ABS

supplemented with electronic stability program (ESP). This traction
control system uses acceleration sensors (rotation rate or yaw
sensor an d lateral acceleration sensor) , stee ring angle sensor and
and a hydraulic pump to maintain precise control of the vehicle
under difficult traction conditions. ABS I ESP incorporates ABS I
ASR features (EDL, EBO) in addition to :
•Electronic brake control (EBC) . This feature prevents driven
wheels from locking (and skidding) due to engine braking .
45-4 Antilock Brakes (ABS)
ABS Components

ABS COMPONENTS
Bosch ABS I ASR 5.3
1. ASA traction control hydraulic pump
(V156)
2. Brake pressure sensor 1 (G201) in
ESP pump
3. ABS return flow pump relay (J105)
for Bosch 5.3
11 4. ABS solenoid valve relay (J106)
5. ABS hydraulic unit (N55) and ABS
10 hydraulic pump (V64)
6. Brake fluid level warning switch
(F34)
7. Right front impulse wheel
8. Right front wheel speed sensor (G4S)
9. ABS control module (J104) in pas-
senger footwell
10. Anti-slip control switch (E132) on
center console
6
11. Steering angle sensor (G85) in steer-
ing column
12. Parking brake warning light switch
(F9) on parking brake lever assembly
13. Right rear impulse wheel
14. Right rear wheel speed sensor (G44)
15. Left rear wheel speed sensor (G46)
16. Left rear impulse wheel
17. Transverse acceleration sensor
(G200)
18. Rotation rate sensor (G202)
19. ABS return flow pump relay (J105) on
fuse box
20. ABS solenoid valve relay (J106)
21. Warning light for brake system
(K118) in instrument cluster
22. ABS warning light (K47) in instru-
ment cluster
23. Parking brake indicator lamp (K14) in
instrument cluster
24. Traction control indicator light (K86)
in instrument cluster
25. Brake light switch (F)
26. Left front impulse wheel
27. Left front wheel speed sensor (G47)
 Antilock Brakes (ABS) 45-5
ABS Components

Bosch ABS I ESP 5. 7

1. Bracket for hydraulic control unit
2. Vacuum pump for brake servo
(engines with automatic transmis-
12 sion)
3. ABS control module (J104)
11
4. ABS hydraulic unit (N55)
10 5. Brake pressure sensor 1 (G201) on
hydraulic control unit
9
6. Tightening torque 20 Nm (15 ft-lb)
7. Right front impulse wheel
8. Right front wheel speed sensor (G45)
9. Brake fluid level warning switch
(F34)
10. Instrument cluster
11. Anti-slip control switch (E132) on
center console
12. Steering angle sensor (G85) for ESP
in coil connectorwith slip ring on
6 steering column
• Test with VAS 505 1
13. Parking brake warning light switch
(F9) on parking brake lever assembly
14. Right rear impulse wheel
15. Right rear wheel speed sensor (G44)
16. Transverse acceleration sensor
21 (G200) and rotation rate sensor
(G202) underneath radio
A45-0 132
17. Left rear wheel speed sensor (G46)
18. Left rear impulse wheel
19. Traction control indicator lamp (K86)
in instrument cluster
20. ABS warning light (K47) in instru-
ment cluster
21 . Warning light for brake system
(K118) in instrument cluster
22. Brake light switch (F)
23. Left front impulse wheel
24. Left front wheel speed sensor (G47)
45-6 Antilock Brakes (ABS)
ABS Electrical Components

ABS ELECTRICAL COMPONE NTS

ASA control module (J104) (Bosch 5.3),
removing and installing
- For vehicles equipped with coded anti-theft radio, note radio code.

- Disconnect battery. See 00 Warnings and Cautions.

~ ASR control module (J104) is located under floor covering in front

passenger footwell

- Remove bottom right A-pillar trim. See 70 Interior Trim .

- Loosen screws securing ASR control module (J104).

- Unplug connector from ASR control module (J104) .

- Install new control module in reverse sequence.

Tightening torque
Control module to floor 9 Nm (7 ft-lb)
I

- Connect battery and enter radio code (if applicable ).

Steering angle sensor (G85),

removing and installing
- Set wheels to straight ahead position and remove driver's airbag unit
and steering wheel. See 69 Seat Belts, Airbags .

- Extend steering column out and tilt downward as far as it will go.

~ Remove bolts (1).

- Remove grip (2).

A69-0074 I

~ Remove two Phillips-head screws (arrows) from column trim .

- Remove upper trim panel from steering column (1 ).

NOTE -
• When installing, insert upper shell into hooks of lower shell, swivel
downward and screw in place.

I A69-0072 I
 Anti lock Brakes (ABS) 45-7
ABS Electrical Components

~ Remove screws (2) from lower trim .

- Remove head bolt (1 ).

- Remove lower trim panel (3) from steering column .

I A69-0073 I

~ Steering angle sensor (G85) is installed in housing (1) together with

coil spring .

~ Remove co nnectors (1 and 2) .

~ Carefully lift hooks (arrows) and disconnect steering angle sensor.

- When instal ling the steering angle sensor (G85) :

• Place in center position.
• Mount steeri ng angle sensor until tabs engage.
• Remove transport protection (if applicable).

. -- - ~r-~-

·"l
45-8 Antilock Brakes (ABS)
ABS Electrical Components

<liiiiiiii( Make sure yellow dot is visible in hole (arrow 1) and alignment
marks (arrows) align.

- The remainder of installation is reverse of removal. Remember to :

• Install airbag unit and steering wheel.
• Use Audi scan tool or equivalent to carry out basic setting of
steering angle sensor (G85).

Transverse acceleration sensor (G200) and

Rotation rate sensor (G202) (Bosch 5.3),
removing and installing

NOTE-
• Rotation rate sensor (G202), also called yaw sensor, may be
installed in housing with transverse acceleration sensor (G200).

For vehicles equipped with coded anti-theft radio, note rad io code.

Remove rear seat. See 72 Seats.

<liiiiiiii( Rotation rate sensor (1 )(G202) is located underneath the driver's

seat. It measures the vehicle's rotation about the vertical axis (yaw
rate) .

- To remove transverse acceleration sensor (G200), first remove

ultrasound sensor control module (2)(J347) mounting screws
(arrows).

<liiiiiiii( Remove transverse acceleration sensor (G200) following removal of

ultrasound sensors control module (J347) .

CAUTIO~
• Sensor is sensitive to impact.
• If the sensor is dropped by mistake it may not work properly and
must not be installed into vehicle. Do not use the sensor again.

- The remainder of installation is reverse of removal :

• Install rear seat.
•Connect battery and enter radio code (if applicable).
 Antilock Brakes (ABS) 45-9
ABS Electrical Components

Transverse acceleration sensor (G200) and

Rotation rate sensor (G202) (Bosch 5. 7),
removing and installing
<liiiiiii( The rotation rate sensor (G202) and the sensor for transverse
acceleration are located under the rear seat bench.

NOTE -
• Rotation rate sensor (G202) , also called yaw sensor, may be
installed in housing with transverse acceleration sensor (G200) .

For vehicles equipped with coded anti-theft radio, note radio code.

Removing rear seat. See 72 Seats .

Disconnect connector for sensor.

CAUTIO~
• The sensor is sensitive to impact.
• If the sensor is dropped by mistake it may not work properly and
must not be installed into the vehicle. Do not use the sensor
again.

- The remaining installation steps are carried out in the reverse

sequence :
• Install rear seat.
•Connect battery and enter radio code (if applicable) .

Brake light switch, removing and installing

Brake light switch with rectangular housing

<liiiiiii( Brake light switch with spring clip mount:

1. Brake pedal impact surface
2. Sprin g clip
3. Pedal bracket
4. Brake light switch (F)

- Press spring clip (2) into pedal bracket opposite direction of travel.

- Gu ide switch (4 ) into installed spring clip (2 ) and press/thread it in

1 4 until stop.

- Check dimension a using feeler gauge and twist brake light switch
to dimension a specification if necessary.

NOTE -
• Dimension a : min. 0.5 mm to max. 1.2 mm (0.02 in to 0.05 in)
• To ensure a secure fit, the switch may only be installed once.

A46-01 24 Brake light switch with round housing

Remove dri ver's storage compartment.

Unplug electrical connector on switch .

- Turn brake li ght switch 45° counter clockwise to remove .

45-10 Antilock Brakes (ABS)
ABS Hydraulic Components

"iiiiiii( Installation is reverse of removal. Remember to :

• Pull out plunger of brake light switch as far as it will go (arrow).
• Insert switch into its mounting so that retaining tabs (1 and 2)
engage in corresponding slots and secure with 45° turn .

~ 11 -------t I
•Do not press brake pedal while installing switch .
•Plunger in switch is adjusted automatically when switch is inserted.
•Press and release brake pedal to check brake light function .

2 NOTE-
• To ensure a secure fit, the switch may only be installed once.

A46-0188

Parking brake switch

The parking brake switch informs the ABS control module (J104)
whether or not the parking brake is applied . This information is
required because the parking brake influences ABS and traction
control functions.

ABS HYDRAULIC COMPONENTS

ASR hydraulic control unit (Bosch 5.3),
removing and installing
"iiiiiii( The ASR hydraulic control unit is located on the left side of the
engine compartment.

- Vehicles equipped with anti-theft radio, obtain radio code .

- Switch ignition OFF and disconnect battery. See 00 Warnings and

Cautions.

"iiiiiii( Release connector from control module (1) and disconnect by lifting
up (2).

- Connect bleeder bottle to bleeder screw on left front brake caliper

and open bleeder screw.

- Insert brake pedal depressor between brake pedal and driver's seat.
Depress brake pedal by at least 60 mm (2.4 in).

NOTE-
• Do not remove brake pedal depressor until all brake lines have
been reconnected to the hydraulic control unit.

- Close left front bleeder screw.

NOTE-
• Protect engine compartment from brake fluid spills.

- Disconnect brake line connections at hydraulic control unit.

CAUTIO~
• Do not bend brake lines.
 Antilock Brakes (ABS) 45-11
ABS Hydraulic Components

- Seal brake lines and threaded holes with plugs from repair kit
(part no. 1 HO 698 311 A) .

Remove nuts on hydraulic control unit bracket.

Remove hydraulic control unit.

- When installing , pay particular attention to the following:

• Only remove sealing plugs on new hydraulic control unit when
corresponding brake line is about to be installed .
• If sealing plugs are removed too early, brake fluid can escape. If
this occurs , unit may not be sufficiently filled or adequately bled.
• Bleed brake system. See 47 Brakes-Hydraulic .
• Reconnect battery and enter radio code.

ASR hydraulic pump (Bosch 5.3),

removing and installing
~ The ASR hydraulic pump is located at left of engine compartment
below hydraulic unit.

- Vehicles equipped with anti-theft radio, obtain radio code.

- Switch ignition OFF and disconnect battery. See 00 Warnings and

Cautions.

- Raise vehicle and support safely.

WARNING-
• Make sure the car is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove left front wheel .

Remove left front wheel housing liner.

~ Detach electrical connectors at pump (see arrows) .

~ Unclip attachment strip for cable at bracket.

45-12 Antilock Brakes (ABS)
ABS Hydraulic Components

<Oiiii( Remove coolant expansion tank mounting bolts (arrows) and swin g
reservoir to side.

<Oiiii( Remove bolts (1) for hydraulic fluid reservoir and swing to side .

NOTE-
• Protect engine compartment from brake fluid spills.

<Oiiii( Disengage intake hose on hydraulic unit (1) and remove .

- Remove brake lines (3 and 4) .

- Seal brake lines and threaded holes using plugs from repair kit
(part no. 1HO 698 311 A).

Unclip brake lines from holder.

Remove nut (2).

Remove bolt from securing bracket.

- Working in engine compartment, lift bracket and hydraulic unit out.

- Pay special attention to the following on installation :

• Only remove sealing plugs on new hydraulic control unit when
corresponding brake line is about to be installed. Otherwise, brake
fluid will escape observe paint and corrosion protection measures.
•Bleed brake system . See 47 Brakes-Hydraulic.
• Reconnect battery and enter radio code.

Tightening torque
Coolant expansion tank to chassis 6 Nm (4 ft-lb)
Hydraulic fluid reservoir to chassis 10 Nm (7 ft-lb)
 Antilock Brakes (ABS) 45-13
ABS Hydraulic Components

ESP hydraulic control unit (Bosch 5. 7),

removing and installing
~ The hydraul ic control unit is installed on left side of engine
compartment.

- For vehicles equipped with anti-theft radio, note radio code .

- Switch ignition OFF and disconnect battery. See 00 Warnings and

Cautions.

~ Detach electrical connector from control module in direction of

arrow.

- Insert brake pedal depressor between brake pedal and driver's seat.
Depress brake pedal by at least 60 mm (2.4 in).

NOTE -
• The brake pedal depressor must remain in position until all the
brake lines have been reconnected to the hydraulic unit.
• Protect the engine compartment from brake fluid spills.

- Unscrew brake line connections on hydraulic unit.

I CAUTION-
• Do not bend brake lines.

- Seal brake lines and threaded holes with plugs from repair kit
(part no. 1 HO 698 311 A) .

NOTE -
• Protect the plenum chamber and engine compartment from brake
fluid spills.

~ Remove bolt (1) and pull it out in the direction of arrow. Swing
coolant expansion tank to side.

<iii{ Detach brake lines (1 and 2) from master cylinder and seal with
dummy plu gs from repair kit (part no. 1 HO 698 311 A).
45-14 Antilock Brakes (ABS
ABS Wheel Speed Sensors

~ Detach connectors (1) and unclip brake lines (2) from bracket.

- Remove hydraulic control unit.

- When installing , pay particular attention to the following :

• Only remove sealing plugs on new hydraulic control un it whe n
corresponding brake line is about to be installed.
•Bleed brake system . See 47 Brakes-Hydraulic.
• Reconnect battery and enter radio code.

Tightening torque

Coolant expansion tank to chassis 6 Nm (4 ft-lb)

ABS WHEEL SPEED SENSORS

ABS front axle components

1. Drive axle bolt
• Always replace
2. Clamping sleeve
• Always replace
•Before installing , grease hole in the wheel bearing housing
with lubricating paste G 000 650
•Push into wheel bearing housing up to stop
3. Sealing collar
4. ABS wheel speed sensor
• Install drive axle before installing speed sensor
• Push into clamping sleeve up to stop
5. Drive axle
•Inspect impulse wheel for signs of dirt and damage
• Replace outer CV joint if the impulse wheel is damaged

A45-0055
ABS front wheel speed sensor,
removing and installing
- Raise car and support safely.

WARNING-
• Make sure car is stable and well supported at all times. Use a
professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

- Remove wheel.

~ Remove grommet (1) from the wheel housing .

- Disconnect ABS wheel speed sensor harness connector (2).

- Disconnect ABS wheel speed sensor wiring from reta iners

(arrows) .
 Antilock Brakes (ABS) 45-15
ABS Wheel Speed Sensors

Remove ABS speed sensor from wheel bearing housing .

- When installing pay particular attention to the following points :

• Replace clamping sleeve.
• Before installing speed sensor, install sealing collar.
•Connect ABS wheel speed sensor wiring and fasten grommets to
retainers.
• Turn wheels completely to left and right stop positions and check
ABS wh eel speed sensor wiring clearance.

Front impulse wheel, checking

Raise ca r and support safely.

WARNING -
• Make sure car is stable and well supported at all times. Use a
professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove wheel

Remove ABS wheel speed sensor from wheel bearing housing .

Inspect impulse wheel for signs of damage or dirt.

NOTE -
• If impulse wheel is damaged or dirty remove drive axle. If
damaged, replace outer CV joint together with impulse wheel.

ABS rear axle components (FWD)

1. ABS wheel speed sensor
•Must be replaced when replacing new wheel bearing/hub unit
•Always replace 0 -ring and lubricate with brake cylinder paste
(part no . G 000 65)
2. Clip
3. Axle beam
2 3 4. Cover plate
5. ABS wheel speed sensor impulse wheel
•If damaged or faulty replace with wheel bearing/hub unit
6. Wheel bearing/hub unit
4 5 6 7 8 7. Alle n head bolt, 60 Nm (44 ft-lb)
8. Brake disc
N45-0087
45-16 Antilock Brakes (ABS)
ABS Wheel Speed Sensors

;;;---_' ABS rear wheel speed sensor (FWD),

removing and installing
!I - Lift out rear seat bench .

0 ~ Disconnect ABS wheel speed sensor harness connector and push

out grommet (arrow).

- Raise car and support safely.

WARNING-
• Make sure car is stable and well supported at all times. Use a
professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

~ Disconnect ABS wheel speed sensor wiring from retainers

(arrows) .

- Remove retainer for ABS wheel speed sensor.

~ Pry ABS wheel speed sensor from wheel bearing/hub unit using
80-200 pry lever.

- Before inserting ABS wheel speed sensor, lubricate circumference

of seal with brake cylinder paste.
 Antilock Brakes (ABS) 45-17
ABS Wheel Speed Sensors

<Oiiiii( Insert ABS wheel speed sensor (1) until stop.

- Locating tab (A) faces front on left and rear on right .

- Push ABS wheel speed sensor into wheel bearing housing by hand .

- Insert retainer for ABS wheel speed sensor.

<Oiiiii( Route ABS wheel speed sensor wiring (1) next to brake line (2) on
both sides as shown.

- On left side, maintain clearance of about 2 cm (0.8 in) between heat

shield on the exhaust system and ABS wheel speed sensor wiring.

<Oiiiii( On right side, ABS wheel speed sensor wire (1) must be routed
between fuel lines (2).
45-18 Antilock Brakes (ABS)
ABS Wheel Speed Sensors

Rear impuls1e wheel (FWD), checking

- Raise car and support safely.

WARNING-
• Make sure car is stable and well supported at all times. Use a
professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

~ Remove retainer and pry ABS wheel speed sensor from whee l
bearing/hub unit using 80-200 pry lever.

- Inspect impulse wheel for dirt and damage through mounting hole of
wheel speed sensor.

- If impulse wheel is damaged or dirty, replace together with whee l

bearing/hub unit.

- Install ABS wheel speed sensor.

Rear impulse wheel (FWD),

removing and installing
- Raise car and support safely.

WARNING-
• Make sure car is stable and well supported at all times. Use a
professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

- Remove rear wheel.

~ Remove caliper bolts (A) and use stiff wire to hang brake calipe r.

Remove retainer for ABS wheel speed sensor.

Remove brake disc.

Pry ABS wheel speed sensor from wheel bearing/hub un it using

80-200 pry lever.

~ Remove wheel bearing/hub unit mounting bolts and remove wheel

bearing/hub unit with backing plate.

- If impulse wheel is damaged or dirty, replace together with wheel

bearing/hub unit.

- Install new wheel bearing/hub unit and backing plate to axle beam
and tighten .

- Reinstall brake disc.

- Mount brake caliper to axle beam and tighten.

N45-0085 I - Install ABS wheel speed sensor.

Tightening torques
Brake calipe r to axle 95 Nm (70 ft-lb)
Wheel bearing/hub to axle beam 60 Nm (44 ft-l b)
 Antilock Brakes (ABS) 45-19
ABS Wheel Speed Sensors

ABS rear axle components (quattro)

1. Drive axle bolt
• Always replace
2. Clamping sleeve
• Always replace
• Befo re installing coat hole in the wheel bearing housing with
brake cylinder paste G 000 650
• Push into wheel bearing housing up to stop
3. ABS wheel speed sensor
• Push into clamping sleeve up to stop
4. Drive axle with ABS wheel speed sensor impulse wheel
(all wheel drive)
•Check for dirt and damage.
3 2 • Replace with outer CV joint.
•Outer CV joint is supplied with impulse wheel.

A4 5-0056

ABS rear wheel speed sensor (quattro),

removing and installing
- Switch ignition off.

- Lift out rear bench.

~ Disconnect ABS wheel speed sensor harness connectors and push

out grommet (arrow) .

Raise car and support safely.

WARNING -
• Make sure car is stable and well supported at all times. Use a
professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Pull ABS wheel speed sensor out of wheel bearing housing.

- Disconnect sensor wiring from retainers. Pull wiring downward

together with grommet.

- When installing pay particular attention to the following:

• Replace clamping sleeve.
• Connect ABS wheel speed sensor wiring and snap grommets in
retainers .
 45-20 Antilock Brakes (ABS)
ABS Wheel Speed Sensors

Rear impulse wheel {quattro), checking

- Loosen wheel bolts.

- Raise car and support safely.

WARNING-
• Make sure car is stable and well supported at all times. Use a
professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

- Remove wheel.

- Remove ABS wheel speed sensor out of wheel bearing housing .

- Check impulse wheel for damage or dirt .

NOTE-
• If impulse wheel is damaged or dirty, remove drive axle. If
damaged, replace outer CV joint together with impulse wheel.

/ ~"'
/, ..
~/ ·I
..

I
t

l
!

~I
 46-1

46 Brakes-Mechanical

G ENERAL . . . ....... . .. .. .. ........... ... 46-1 REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . 46-15

Brake discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46- 1 Rear brake assembly, qu attro ......... . .... 46-15
Warnings and Cautions .. ............. .. ... 46-2 Rear brake assembly, front-wh eel drive .... . . 46-15
Rear brake pads and discs,
FRONT BRAKES ..... .. ...... .. . . .. . ..... 46-2
removin g and install ing . . . . ... ... . ... ... 46-16
Front brake assembly (FN-3) . .. . .... .... . . . 46-2
Front brake pads (FN-3) , PARKING BRAKE ....... .... . .... .. . .... . 46-17
removing and installing . . . . . ..... ...... . . 46-3 Parking brake , adjusting . . ..... .. ... . ... .. 46-17
Front brake assembly (FNR-G60) ..... ....... 46-5
BR AKE LIGHT SWITCH . .. . ....... . ..... . . 46-1 9
Front brake pads (FNR-G60) ,
Brake pedal assembly. . . . . . . . . . . . . . . . . . . . 46-19
removing and installing .. .... ... .... ..... 46-6
Brake light switch , adjusting ...... . ... . .... 46-19
Front brake assembly, allroad (H P-2) ... .. .... 46-9

I
Front brake pads allroad (HP-2) , TABLES
removing and installing . ......... .... . .. . 46-9
a. Front brake caliper and disc specifications ... ... .. . . 46-1
Front brake assembly, RS6 (Brembo) . ... . . . . 46-1 2
b. Rear brake caliper and disc specifications . . .... . . . .. 46-2
Damper bracket, installing , RS6 ....... ..... 46- 13
Front brake pads , RS6 (Brembo) ,
removing and installing ... .. . .... .. . .. .. 46-13

GENERAL
Th is repair group covers mechanical brake components including
front and rear brake pads , calipers , brake light switch and parking
brake . For additional brake system information , see:
• 45 Antilock Brakes (ABS) for ABS related components
• 47 Bra kes- Hydraulic for brake calipers , brake fluid bleeding

Brake discs
Inspect discs for cracks , scori ng, glazing and warpage . Replace
discs in pairs if either disc is worn below the minimum thickness or
if any of the above listed defects are found . For brake disc
specifications, see Table a and Table b in this repair group.

Table a. Front brake caliper and disc specifications

~

Brake calipers FN-3 (15") FN-3 (16 ") -F NR-G60 HP-2 (16") Brembo (18 ")
Production number 1LB, 1LE 1 LT, 1LF 1LA , 1LG 1LX, T7Z 1 LJ
-- -- -- --
Brake disc, vented 288 mm 312 mm 32 1 mm 321 mm 365 mm
-
Brake disc, thickness 25 mm 25 mm 30 mm 30 mm 34mm
-- - ---
Brake disc, 23 mm 23mm 28 mm 28 mm 32 mm
wear limit
Brake caliper piston 57 mm 57 mm 60 mm 42 .8 mm 28 .32 mm
-- -
Pad thickness 14 mm 14 mm 14 mm T 4mm -11.4mm
(w/out backing plate)
46-2 Brakes-Mechanical
Front Brakes

Table b. Rear brake caliper and disc specifications

Brake caliper (Lucas) C 38 c 43 (16") c 43 (16") c 43 (16")
-
Production Number 1KD 1KE 1KE 1KZ
Brake di sc, not vented 245 mm 255 mm
--
Brake disc, vented 269 mm 355 mm
Brake disc, thickness 10 mm 10 mm 22 mm 22 mm
Brake disc, wear limit 8mm 8mm 20 mm 20 mm
Brake caTIPe~ n_s__ 38.1 I 36 .0 mm 42.8 I 40.8 mm 42 .8 I 40.8 mm 43 I 41 mm
Pad thickness (w/outbaCking plate) 12 mm 12 mm 12 mm 12 mm
--
Wear limit (w/out backing plate ) 2mm 2mm 2mm 2mm

NOTE-
• Minimum brake disc thickness is also stamped on disc hub.

Warnings and Cautions

WARNING-
• If any of the brake warning lights illuminate while driving, check
brake system immediately
•Brake fluid is poisonous. Wear safety glasses when working
with brake fluid, and wear rubber gloves to prevent brake fluid
from entering the bloodstream through cuts or scratches. Do
not siphon brake fluid by mouth.
• New brake pads require some breaking in. Allow for slightly
longer stopping distances for the first 100 to 150 miles of city
driving, and avoid hard stops.
• Perform brake work under clean conditions with careful
attention to specifications and proper working procedures. If
you lack the skills, the tools or a clean workplace for servicing
the brake system, leave these repairs to an authorized Audi
dealer or other qualified shop.
•After replacing brake components, depress the brake pedal
1 4 firmly several times to seat the brakes in their normal operating
2 3 5 6 7
position. Make sure the pedal is firm and at its normal height. If

~~ l not, further work is required before driving vehicle.

12,, ~
11 . ,, '
. '/z!!j ~ 1

'"
!
~; ,·
CAUTION-
•Brake fluid damages paint. Immediately wipe up any brake fluid
that spills on the vehicle and rinse area with water.
-
~ -~·
2 FRONT BRAKES
/:?
3
........
Jj Front brake assembly (FN-3)
9
.•
1. Brake hose
/
• Do not disconnect when removing brake pads
1 10 2. Protective cap
<:._;>
(' 3. Guide bolt, 25 Nm (18 ft-lb)
I
.rzrc{!c
. 4. Brake line , 15 Nm (11 ft-lb)
I ~ · • Attach to brake caliper.
. " (l c
\· I
• Counterhold brake hose when attaching. Make sure hose is
not twi sted when installed .

A46-0045
 Brakes-Mechanical 46-3
Front Brakes

5. Brake caliper
1 4 2 3 5 7 •Check for free movement by moving from side to side .

~I~ •Use alcohol to clean brake caliper thoroughly of grease and

l
other contaminants before installing new brake pads.
(}
jf:r '~ 6. Ribbed bolt, tightening torques :
12 . • M12 x 1.5 x 35 , 130 Nm (96 ft-lb)
11 • M14 x 1.5 x 35 , 200 Nm (148 ft-lb )
•Clean ribs if reusing . Use thread locking compound .
7. Brake pad carrier
•Bolt to wheel bearing hub.
8. Brake pads
• Replace front brake pads as a set.
• Inne r pad has retaining spring.

10 •Inner pad (with spring) is marked with arrow pointing in

direction of brake disc fo rward rotation when installed. Noise
may result from incorrect installation .
•Rem ove adhesive foil on outer brake pads before installing .
9. Retain ing spring : Pay attention to correct installation position .
• Inse rt in caliper holes .
• Press retaining spring under pad carrier.

WARNING -
• If spring is improperly installed, brake caliper cannot adjust to
compensate for wea r on the outer brake pad. This causes
brake pedal travel to increase.

10. Brake disc

•To replace brake disc, remove brake caliper and pad carrier.
• Lightl y coat contact surfaces between brake disc and wheel
bearin g hub with polycarbamide grease
(VAG part no .G 052 142 A2) .
11. Bracket
• Bolt to brake caliper.
•Make sure locating tab is seated in caliper.
12. Bolt, 10 Nm (7 ft-lb)

Front brake pads (FN-3),

removing and installing
NOTE -
• If reusing brake pads or brake discs, mark them so they can be
installed in their original positions to prevent uneven braking.

Raise car and support safely.

WARNING -
• Make sure the car is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove front wheels .

46-4 Brakes-Mechanical
Front Brakes

~ Using screwdriver, pry off brake pad retaining spring from brake
caliper housing and remove .

Ms-0040 I

~ Remove protective caps from caliper guide bolts.

~ Remove both guide bolts from brake caliper.

- Remove brake caliper and hang from chassis using stiff wire. Do not
allow caliper to hang from brake hose.

- Remove brake pads.

~ Press piston back into caliper using resetting tool .

CAUTION-
• Before pushing caliper pistons back into caliper, siphon off
brake fluid out of brake fluid reservoir. Otherwise, fluid may
overflow and cause paint damage.

NOTE-
• When siphoning brake fluid, use a bleeder bottle that is used
exclusively for brake fluid.

A46-0042 I
 Brakes-Mechanical 46-5
Front Brakes

~ Install complete brake repair kit. Insert brake pad with retaining
spring in brake caliper housing. Make sure arrow on inner pad points
in direction of forward rotation when installed . Noise may result from
incorrect installation .

Remove protective foil on backing plate of outer brake pad.

Install outer brake pad on pad ca rrier.

Install brake caliper housing in pad carrier using both guide bolts.
Install both protective caps .

Tightening torques
Brake caliper to pad carrier 25 Nm (18 ft-lb)

Install retaining spring in brake caliper.

Check caliper for freedom of movement.

Install wheels.

Tightening torques

Wheel to hub I 120 Nm (89 ft-lb)

Check brake fluid and top off if necessary.

Before moving vehicle , depress brake pedal several times firmly to

properly seat brake pads in their normal operating position .

10 Front brake assembly (FNR-G60)

1. Brake pads
• Replace front pads as a set.
• Inner pad (with spring) has wear sensor and harness .
• Outer brake pad provided with adhesive sheet on backing
plate . Remove protective sheet before inserting pad.
2. Brake pad carrier
•Bolt to wheel bearing housing.
3. M14 x 1.5 x 38 ribbed bolt, 200 Nm (148 ft-lb)
•Clean ribs if reusing. Use thread locking compound.
4. Bushing
•Insert into brake caliper housing .
5. Guide bolt , 30 Nm (22 ft-lb)
6. Protective cap
• Attach wear sensor harness .
7. Brake disc
•If worn , replace both on front as a set.
•To replace brake disc, remove brake caliper and pad carrier.
2 1 A46-02 18 • Lightly coat contact surfaces between brake disc and wheel
bearing hub with polycarbamide grease
(VAG part no.G 052 142 A2).
8. Wheel bolts, 120 Nm (89 ft-lb)
9. Brake line connection to brake hose , 15 Nm (11 ft-lb)
46-6 Brakes-Mechanical
Front Brakes

10. Brake line

• Attach to brake caliper.
• Counterhold brake hose when attaching . Make sure brake
hose is not twisted when installed .
•Make sure tabs are properly seated in retainer grooves .
11. Brake line to brake caliper, 17 Nm (13 ft-lb)
12. Brake hose bracket
•Bolt to brake caliper housing .
• Attach brake line.
• Make sure locating tab is seated in caliper.
13. M8 x 16 bolt, 25 Nm (18 ft-lb)
14. Brake caliper
•Do not hang by brake hose . Secure to vehicle using wire. Do
not twist hose.
• Use alcohol to clean brake caliper thoroughly of grease and
other contaminants before installing new brake pads.
15. Retaining spring : Pay attention to correct installation position .
• Engage retaining spring to brake caliper and to outer pad .
• Press retaining spring under pad carrier after it is inserted in
caliper holes.
2 1 A46-0218

WARNING-
• If spring is improperly installed, brake caliper cannot adjust to
compensate for wear on the outer brake pad. This causes
brake pedal travel to increase.

Front brake pads (FNR-G60),

removing and installing
Raise vehicle and support safely.

WARNING-
• Make sure the car is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove front wheels.

~ Secure brake disc with a wheel bolt (arrow).

- Using screwdriver, pry off brake pad retaining spring from caliper
and remove .

Disconnect brake wear sensor connector. Using a screwdriver,

release connector from holder turn ing connector by 90° at same
time. Detach connector and pull upward to unhook wire .
 Brakes-Mechanical 46-7
Front Brakes

~ Detach brake hose from bracket (arrow) .

~ Remove protective caps (1) from caliper guide bolts.

NOTE -
• If necessary, remove brake hose bracket to gain access to upper
guide bolt.

~ Unscrew both guide bolts and remove from brake caliper.

- Remove brake caliper and hang from chassis using stiff wire . Do not
allow caliper to hang from brake hose.

- Remove brake pads.

~ Press piston back into caliper using resetting tool.

CAUTIO~
• Before pushing caliper pistons back into caliper, siphon off
brake fluid out of brake fluid reservoir. Otherwise, fluid may
overflow and cause paint damage.

NOTE -
• When siphoning brake fluid, use a bleeder bottle that is used
exclusively for brake fluid.
46-8 Brakes-Mechanical
Front Brakes

~ Install complete brake repair kit. Insert inner brake pad with retaining
spring and wear sensor into brake caliper piston (arrows) .

~ Install outer brake pad (2) on brake caliper.

~ Place caliper over brake pads and secure to pad carrier with gu ide
bolts. Install protective caps.

Tightening torques
Brake caliper to pad carrier j 25 Nm (18 ft-l b)

Make sure brake hose is not twisted when installed .

Insert retaining spring into brake caliper housing . Pay attention to

correct installation position.
• Insert in both holes of brake caliper housing .
• Press retaining spring under pad carrier after it is inserted in both
holes.

WARNING-
• If spring is improperly installed, brake caliper cannot adjust to
compensate for wear on the outer brake pad. This causes
brake pedal travel to increase.

Reconnect brake pad sensor and attach sensor harness to bracket.

- Check caliper for freedom of movement.

Install wheels.

Tightening torques
Wheel to hub j 120 Nm (89 ft-lb)
 Brakes-Mechanical 46-9
Front Brakes

- Check brake fluid and top off if necessary.

- Before moving vehicle , depress brake pedal several times firmly to

properly seat brake pads in their normal operating position .

Front brake assembly, allroad (HP-2)

1. Brake disc
•Ch eck wear limit
•To replace brake disc , remove brake caliper and pad carrier.
•Lightly coat contact surfaces between brake disc and wheel
bearing hub with polycarbamide grease
(VAG part no.G 052 142 A2) .
2. Brake caliper
• If repair work is necessary, do not hang by brake hose .
Secure to vehicle using wire
3. Pad sensor harness retainer
4. Ribbed washer
5. Ribbed bolt, 190 Nm (140 ft-lb)
•Clean ribs if reusing . Use thread locking compound.
6. Retaining spring
•Sl ide to side (not removable)
7. Spring clip
8. Pad wear sensor harness connector
9. Brake hose
• Do not disconnect when removing brake pads
A46-0117
10. Bolt, 25 Nm (18 ft-lb)
11. Pad sensor connector and brake hose bracket
• Bolt to brake caliper housing.
•Make sure locating tab is seated in caliper.
• Insert pad sensor harness connector.
12. Brake line , 15 Nm (11 ft-lb)
13. Brake pads
• Replace front brake pads as a set.
• Pads are different on left and right sides .
•Once wear limit is reached (limit: 3 mm or 1!'.~ in) , warning light
in instrument cluster illuminates.
• Remove adhesive foil from backing plates on outer brake
pads before installing.

Front brake pads, allroad (HP-2),

removing and installing

NOTE -
• If reusing brake pads or brake discs, mark them so they can be
installed in their original positions to prevent uneven braking.

Raise vehicle and support safely.

WARNING -
• Make sure the car is stable and well supported at all times. A
floor jack is not adequate support.
46-10 Brakes-Mechanical
Front Brakes

- Remove front wheels .

~ Secure brake disc using a wheel bolt.

- Disconnect brake pad wear sensor connector.

~ Disengage connector from bracket using a screwdriver and

simultaneously turn connector 90°. Lift connector up and out and
disengage wire.

~ Use pliers to press upper and lower spring tensioner out of locking
mechanism (arrows). Slide spring aside.

~ Press piston back into brake caliper housing. To do this , slide

floating frame using a screwdriver as shown and press powerfully
outward.

CAUTIO~
• Before pushing caliper pistons back into caliper, siphon off
brake fluid out of brake fluid reservoir. Otherwise, fluid may
overflow and cause paint damage.

NOTE-
• When siphoning brake fluid, use a bleeder bottle that is used
exclusively for brake fluid.
A46-0120
 Brakes-Mechanical 46-11
Front Brakes

~ Use screwdriver to press outer brake pads off brake caliper.

A46-0 121

~ Press floating frame firmly in direction of arrow until stop.

Pry inner brake pads out of caliper pistons. Remove brake caliper
housing .

Use alcohol to clean brake caliper thoroughly of grease and other

contaminants before installing new brake pads.

~ Insert complete brake repair kit. Insert inner brake pads in caliper
piston .

CAUTION--
• Do not damage protective piston boots when installing brake
pads.

NOTE-
• Make sure protrusions on backing plates are securely fitted in
brake pistons.

~ Press floating frame outward until stop.

Remove protective foil on backing plates of outer brake pads.

Make sure protrusions on pad backing plates are securely fitted in

floating frame .

- Check caliper for freedom of movement.

- Remove wheel bolt from wheel hub.

46-12 Brakes-Mechanical
Front Brakes

Install wheels.

Tightening torque

Wheel to wheel hub I 120 Nm (89 ft-lb)

NOTE-
• When installing wheels, make sure rim flange does not rest on
brake caliper. This could push brake pads out of position.

- Check brake fluid and top off if necessary.

- Before moving vehicle , depress brake pedal several times firmly to

properly seat brake pads in their normal operating position .

Front brake assembly, RS6 (Brembo)

1. Brake disc
• Internally ventilated brake disc diameter: 365 mm
• Brake disc thickness: 34 mm
• Wear limit: 32 mm
• Replace front brake pads as a set.
•To replace brake disc , remove brake caliper and pad carrier.
•Lightly coat contact surfaces between brake disc and wheel
bearing hub with polycarbamide grease
(VAG part no.G 052 142 A2).
2. Brake caliper
•See Damper bracket, installing in this repair group.
• Do not disconnect brake hose when changing brake disc.
3. Replace Allen bolts , 110 Nm (81 ft-lb)
4. Brake hose bracket
• Bolt to brake caliper housing.
• Make sure locating tab is seated in caliper.
5. Bolt, 25 Nm (18 ft-lb)
6. Brake line , 15 Nm (11 ft-lb)
N46-0336 • Attach to brake caliper.
• Counterhold brake hose when attaching . Make sure brake
hose is not twisted when installed.
• Make sure tabs are properly seated in retainer grooves .
7. Spring clip
8. Brake hose
• Do not disconnect brake hose when changing brake disc.
9. Pad retaining springs
10. Pad retaining pins
11. Brake pads
• With wear sensor.
• Check thickness.
 Brakes-Mechanical 46-13
Front Brakes

Damper bracket, installing, RS6

When installing damper bracket, check for damage to the surface
and paint black if necessary.

Install both damper brackets so the mounting points on brakes make

full contact with the contour of damper bracket.

NOTE -
• The notch on the damper bracket faces toward wheel rim.
1. Allen bolt MB x 25 , 25 Nm (18 ft-lb)
•Apply thread locking compound when installing.
2. Damper bracket (note different versions) .
A46-0314
3. Notch on damper bracket faces toward wheel rim.

Front brake pads, RS6 (Brembo),

removing and installing
- Raise vehicle and support safely.

WARNING -
• Make sure the car is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

- Remove front wheels.

<liiiiiii( Secure brake disc with a wheel bolt.

<liiiiiii( Detach connector (1) from brake pad wear sensor.

- Slightly lift up positioning tag on lower part of connector (2) and then
turn it through 90°. Remove lower half of connector out of holder.

<liiiiiii( Drive out pad retaining pins (arrows) .

46-14 Brakes-Mechanical
Front Brakes

~ Remove retaining springs (arrows).

- Slide brake pads out of brake caliper.

Press pistons back into caliper housing using resetting tool .

CAUTION-
• Before pushing caliper pistons back into caliper, siphon off
brake fluid out of brake fluid reservoir. Otherwise, fluid may
overflow and cause paint damage.

NOTE-
• When siphoning brake fluid, use a bleeder bottle that is used
N46-0340 I exclusively for brake fluid.

Insert complete brake repair kit. Insert brake pads into brake caliper
housing .

NOTE-
• The brake pads are directional. Note markings.

~ Install retaining springs (arrows). Press retaining springs downward

and drive in pad retaining pins to stop.

I N46-0340 I
~ Insert brake pad sensor connector and harness (arrow) into bracket
at brake caliper. Plug in brake pad sensor connector.

- Check caliper for freedom of movement.

Install wheels.

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

- Check brake fluid and top off if necessary.

I N46-0355 - Before moving vehicle , depress brake pedal several times firmly to
properly seat brake pads in their normal operating position.
 Brakes-Mechanical 46-15
Rear Brakes

REAR BRAKES

Rear brake assembly, quattro

1. Replace self-locking guide bolt, 35 Nm (26 ft-lb)
•When loosening and tightening , counterhold guide pin .
2. Brake pads. Replace as a set.
3. Ribbed bolt, 95 Nm (70 ft-lb)
4. Pad carrier with guide bolts and protective cap
• Supplied with sufficient grease on guide bolts .
•If protective caps or guide bolts are damaged , install repair
kit. Use grease packet supplied to lubricate guide bolts .
5. Ribbed bolt, 95 Nm (70 ft-lb)
6. Brake disc. Replace as a set.
•To replace brake disc, remove brake caliper and pad carrier .
•Lightly coat contact surfaces between brake disc and wheel
bearing hub with polycarbamide grease
(VAG part no.G 052 142 A2).
N46-0 140
7. Brake caliper
• Do not disconnect brake hose when changing brake pads.
•Brake hose to brake caliper, 45 Nm (33 ft-lb).
•Make sure brake hose is not twisted when installed .

4
Rear brake assembly, front-wheel drive
1. Replace self-locking guide bolt, 35 Nm (26 ft-lb)
•Wh en loosening and tightening , counterhold guide pin
2. Brake caliper
• Unbolt caliper when changing brake pads .
•Make sure brake hose is not twisted when installed.
3. Brake pads. Replace as a set.
• Do not disconnect brake hose when changing brake pads.
4. Pad retaining spring
6 ------{ • Always replace when changing pads.

0-3
5. Brake disc. Replace as a set.
•To replace brake disc, remove brake caliper and pad carrier.
5 • Lightly coat contact surfaces between brake disc and wheel
bearing hub with polycarbamide grease
(VAG part no.G 052 142 A2).
------4
• Check degree of wear (wear limit)
6. Replace M1 Ox 1.25 x 20 Allen bolts , 70 Nm (52 ft-lb) plus 90°
7. Pad carrier with guide pin and protective cap
• Supplied as replacement part assembled with sufficient
quantities of grease on guide bolts .
•If protective caps or guide bolts are damaged , install repair
A46-0300
kit. Use grease packet supplied to lubricate guide bolts .
8. Banjo bolt, 40 Nm (30 ft-lb)
9. Brake line with banjo union
• Make sure brake hose is not twisted when installed.
• Unbolt from pad carrier when changing pads.
10. Seals
46-16 Brakes-Mechanical
Rear Brakes

Rear brake pads and discs,

removing and installing

NOTE-
• If reusing brake pads or brake discs, mark them so they can be
installed in their original positions to prevent uneven braking.

In the following procedure, a 1999 Avant quattro is illu strated . Rear

brake pad replacement on a front wheel-drive model is simi lar.

Raise vehicle and support safely.

WARNING-
• Make sure the car is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove rear wheels.

~ Counterhold lower guide pin and remove self-locking bolt from brake
caliper housing.
• If necessary, detach parking brake cable to remove lower guide
bolt.
• Similarly, remove upper caliper guide bolt.

Remove brake caliper and support from chassis using stiff wire. Do
not let caliper hang on hose .

~ Slide brake pads out of brake pad carrier (arrows).

Use alcohol to clean brake caliper thoroughly of grease and other

contaminants before installing new brake pads.

~ Use VAG special tool 3272 or equivalent to screw cal iper piston
inward as far as it will go.
•Make sure tab on tool fits caliper piston slot (arrow).
• Rotate threaded spindle clockwise and knurled section
counterclockwise.

CAUTION-
• Before pushing caliper pistons back into caliper, siphon off
brake fluid out of brake fluid reservoir. Otherwise, fluid may
overflow and cause paint damage.

NOTE-
• When siphoning brake fluid, use a bleeder bottle tha t is used
exclusively for brake fluid.
 Brakes-Mechanical 46-17
Parking brake

~ If brake disc is worn , replace both on rear as a set:

• Prior to removing disc, remove brake pad carrier mounting bolts
and lift off pad carrier.
• Remove brake disc. Prior to installing new disc , lubricate contact
surfaces between disc and wheel hub with polycarbamide grease
(VAG part no. G 052 142 A2) .
• Use new pad carrier bolts with thread-locking compound .

Tightening torque
Pad carrier to hub (use new bolts)
• quattro, M10 x 1.25 x 20 Allen bolt 95 Nm (70 ft-lb)
• Front-wheel drive, ribbed bolt 70 Nm (52 ft-lb) + 90°

- Install complete brake repair kit. Remove protective foil on brake

pad backing plates. Insert brake pads.

Reinstall brake caliper using new self-locking bolts included in repair

kit.

Tightening torque
Brake caliper to pad carrier j 35 Nm (26 ft-lb)

- Check caliper for freedom of movement.

Install wheels.

Tightening torque

Wheel to hub 120 Nm (89 ft-lb)

- Check brake fluid and top off if necessary.

- Before moving vehicle , depress brake pedal several times firmly to

properly seat brake pads in their normal operating position .

PARKING BRAKE

Parking brake, adjusting

Because the rear brakes are automatically self-adjusting ,
readjusting the parking brake is usually not necessary. Adjustment is
only necessary after replacing parking brake cables , rear brake
calipers , rear brake pads or rear brake discs.

Bleed brakes, if necessary, prior to adjusting parking brake. See

47 Brakes-Hydraulic .

Depress brake pedal firmly.

Make sure parking brake lever is released .

Remove rear air vent from center console.

~ Remove any plastic components on parking brake cable

) compensator and discard.

A46-006 1 1-
46-18 Brakes-Mechanical
Parking brake

- Use screwdriver to prevent compensator from turning (center

console removed in illustration).

NOTE -
• quattro: parking brake cable adjusting components are located in
front of rear lower control arms.
• Front-wheel drive: parking brake cable adjusting components are
located in the tunnel on the underside of vehicle.

~ Remove locking component (D).

- Counterhold hex (E) using 13 mm open end wrench and turn

adjusting nut (C) in until stop.
N46-0135 I
- Slide cable adjuster (8) togethe r.

Unscrew adjusting nut until slot for locking component is visible.

Install locking component.

~ Pull both cable sleeve adjusters apart simultaneously until cables

are tensioned . Lever must not lift off at brake caliper during this
process.

- Remove screwdriver from compensator and apply parking brake

firmly 3 times.

NOTE-
• Colored 0-ring (1) must not be visible following successful
installation. This ensures that the parking brake cable adjustment
mechanism is sufficiently protected against dirt and water spray

~ Check parking brake tension and adjust fine adjustment (A) in or

out, if necessary.

A46-0064

~ Turn adjustment until lever lifts slightly from brake caliper.

Note dimension (A). Gap shou ld be visible , but not be wider than
1.5 mm (0.06 in).
 Brakes-Mechanical 46-19
Brake Light Switch

BRAKE LIGHT SWITCH

CAUTION-
• Make sure brake pedal travel is not restricted by thick floor
mats.

Brake pedal assembly

1. Bracket
2. Pivot pin for clutch and brake pedals
•Installation position: Groove (arrow) faces clutch pedal
3. Locking clip
4. Allen bolt, 25 Nm (1 8 ft-lb)
5. Brake pedal
6. Clutch pedal
7. Pin
8. Locki ng clip
9. Clutch master cylinder
10. Allen bolt, 20 Nm (15 ft-lb)
11. Mount
• Instal l in mounting bracket with over-center spring.
12. Over-center spring
• Remove and install together with clutch pedal.
13. Socket-head bolt, 5 Nm (4 ft-lb)
•Secures pivot pin for clutch and brake pedal.
14. Seal
A46-0098
• Do not remove from plastic master cylinder.
15. Torx bolt, 25 Nm (18 ft-lb)

Brake light switch, adjusting

NOTE -
• Before adjusting, make sure pedal cluster is bolted tightly to brake
booster and instrument panel carrier.

Threaded brake light switch

1. Brake light switch

1 2. Nut, M12x1.5
3. Brake pedal
2
NOTE -
3 • A spring washer (not shown in illustration) is installed between nut
(2 ) and pedal bracket.

- Turn brake light switch to adjust inward or outward as necessary to

obtain dimension A = 0.1 - 0.5 mm (0.004 - 0.02 in) . Lock in place
with nut and tighten nut to 4.5 Nm (3 ft-lb) .

A46-oo66 I - Check dimension A again after tightening nut.

46-20 Brakes-Mechanical
Brake Light Switch

Spring-clip mounted brake light switch

1. Brake pedal contact surface
2. Spring clip (insert in pedal bracket from rear)
3. Pedal bracket
4. Brake light switch (F)
•Dimension a: max . 0.7 mm (0.28 in)

NOTE-
• In order to fit tightly, do not install switch more than once.

Adjusting switch
1 4 - Guide switch (4) into installed clip (2) and press in until stop.

NOTE-
• Do not apply pressure to brake pedal.
•Turn back switch if necessary Observe dimension a.

A46-01 24
 47-1

47 Brakes-Hydraulic

GENERAL . ... . ...... . ..... . ... . ...... .. . 47-1 BRAKE MASTER CYLINDER AND BOOSTER .. 47-8
Troubleshooting ...... . .. ... .......... . .. 47-1 Brake master cylinder and booster assembly . . . 47-8
Warnings and Cautions . ... . ... .... . . .... . . 47-2 Brake master cylinder, removing and installing .. 47-8
Brake booster, removing and installing . . . . ... . 4 7-9
BLEEDING BRAKES ..... . . .. . . ........ .. . 47-3
Brake booster vacuum pump assembly 47-12
Tools and techniques ..... . ... . . .. . .. ..... 47-3
Brake booster vacuum pump (V192)
ABS versions . . . ... ..... . . .. . ..... . ...... 47-4
removing and installing .. . ... .... . . . .. . . 47-12
Brake fluid, bleeding or replacing
Brake booster vacuum pressure sensor (G294) ,
Bosch ABS I ASR 5.3 ... . .......... . .. . . 47-5
removing and installing . .. . . . .. . . .... . . . 47-13
Brake fluid , bleeding or replacing
Brake booster vacuum pump relay (J269) ,
Bosch ABS I ESP 5.7 .. ......... .. .. . .... 47-6
removing and installing . . . . . . . .... ..... . 47-13

GENERAL
This repair group covers brake bleeding and replacement
procedures for the master cylinder, brake booster and vacuum
pump. For additional brake system information , see :
I
• 03 Maintenance for brake fluid level check
• 45 Antilock Brakes (ABS) for ABS related components
• 46 Brakes-Mechanical for brake pads, discs and parking brake

Models covered by this manual are equipped with power assisted

four-wheel disc brakes. A vacuum brake booster provides power
assistance to a dual-circuit master cylinder.

Troubleshooting
Brake performance is mainly affected by three factors:
• Level and condition of brake fluid
•Brake system 's ability to create and maintain hydraulic pressure
• Condition of friction components

- Air in brake fluid makes brake pedal tee\ spongy during braking or
will increase brake pedal force required to stop. Fluid contam inated
by moistu re or dirt can corrode components. Inspect brake fluid . If
fluid is di rty or murky, or over two years old , flush and replace it.

- Visually check hydraulic system , starting at master cylinder. To

check function of master cylinder:
•Hold brake pedal down hard with car stopped and engine running .
Make su re pedal feels and stays solid .
• If pedal slowly falls to floor, either brake master cylinder is leaking
internall y, or fluid is escaping from other points .
• If no leaks can be found , brake master cylinder is faulty ; replace it.
47-2 Brakes-Hyd rau lie
General

- Ch eck all brake fluid lines and couplings for leaks, kinks , chafing or
corrosion .

- Check brake booster by pumping brake pedal approximately 10

times with engine off. Hold pedal down and start engine. Pedal
should fall slightl y. If not, before suspecting a faulty brake booster :
• Check for visible faults in vacuum ducting.
• Check brake booster vacuum pump (if applicable).
• Check one-way ch eck valve at hose connection on vacuum
booster.

Warnings and Cautions

WARNING -
• If any of the brake warning lights illuminate while driving, check
brake system immediately.
• Brake fluid is poisonous. Wear safety glasses when working
with brake fluid, and wear rubber gloves to prevent brake fluid
from entering the bloodstream through cuts or scratches. Do
not siphon brake fluid by mouth.
• Perform brake work under clean conditions with careful
attention to specifications and proper working procedures. If
you lack the skills, the tools or a clean workplace for servicing
the brake system, leave these repairs to an authorized Audi
dea ler or other qualified shop.
•After replacing brake components, depress the brake pedal
firmly several times to seat the brakes in their normal operating
position. Make sure the pedal is firm and at its normal height. If
not, further work is required before driving vehicle.
• Do not mix mineral oil products such as gasoline or engine oil
with brake fluid. Minera l oil damages rubber seals in the brake
system.
• Use only new brake fluid conforming to US standard FMVSS
116 DOT 4. Genuine VW I Audi brake fluid conforms to this
specifica tion.
• Observe hazardous waste regulations when disposing brake
fluid as a hazardous waste.
•Do not use DOT 5 (silicone) brake fluid.

CAUTION-
•Brake fluid damages paint. Immediately wipe up any brake fluid
that spills on the vehicle and rinse area with water.
•Brake fluid is hygroscopic (absorbs moisture from the air).
Store in an airtight container.
• Do not fill brake fluid above MAX in fluid reservoir.
• During final road test, perform at least one ABS-controlled
braking operation. Make sure appropriate pulsations are felt at
the brake pedal.
 Brakes-Hydraulic 47-3
Bleeding Brakes

BLEEDING BRAKES
Brake fluid absorbs moisture from the atmosphere and so is said to
be hygroscopic. If moisture content of brake fluid is too high ,
corrosion inside brake system may result. The boiling point of brake
fluid is also considerably lowered , resulting in the possible
vaporization of brake fluid and reduction in braking force under
some conditions.

Brake fluid is also used as the operating fluid for the hydraulic clutch
on vehicles with a manual transmission. Fluid is drawn into clutch
master cylinder via a small fitting in upper part of reservoir. In case
of a hydraulic clutch leak, fluid loss will only be to the level of the
fitting. This retains an adequate reserve for the brake system .

~ Audi specifies use of brake fluid that meets Department of

Transportation (DOT) 4 Super specification in addition to Federal
Motor Vehicle Safety Standard (FMVSS) 116 and Society of
Automotive Engineers (SAE) standard J1703 . DOT 4 Super is also
known as DOT 4+ . Brake fluid meeting this specification is also
available in 30 and 50 liter containers for use in pressure bleeders.

Brake fluid specifications

Audi specification DOT 4 Super (DOT 4+)
Minimum wet boiling point 329°F (165°C)
Dry boiling point exceeds 500°F (260°C)

Bleeding brakes is usually done for one of two reasons : either to

replace old brake fluid as part of routine maintenance or to expel
trapped air in the system that resulted from opening the brake
hydraulic system during repairs.

When adding or replacing brake fluid, add new brake fluid from an
unopened container. If you are certain no air was introduced into the
master cylinder or ABS hydraulic unit, bleed brakes at the calipers
using a pressure bleeder.

Because the hydraulic clutch and the brake system share a common
fluid and reservoir, be sure to bleed the clutch hydraulic system
when replacing the brake fluid.

Tools and techniques

~ To bleed brakes, use special tool VAS 5234 or equivalent pressure
bleeder.

0024434
47-4 Brakes-Hydraulic
Bleeding Brakes

~ A brake pedal prop is also needed for this procedure.

WARNING-
• The ABS system uses electronic controls and a sophisticated
hydraulic unit. Once air enters the hydraulic unit, it cannot be
removed using traditional bleeding methods. For this reason,
pressure bleed the brakes using VAS 5234 or equivalent
pressure bleeder.
• When flushing brake fluid from the system, use extreme care to
not let the brake fluid reservoir run dry. If air enters the hydraulic
unit, use the VAG 1551 or VAG 1552 scan tool and service
tester to bleed the brake system before the vehicle is driven .

A60403018 The design of the ABS hydraulic unit requires that brakes be bleed
in the following (non-traditional) order:
• Right front
• Left front
•Right rear
• Left rear

ABS versions
For effective brake fluid flushing and bleeding , identify the version of
Bosch ABS system installed in vehicle. Bleeding procedure for the
two systems differs.

~ Bosch ABS I ASR 5.3 . System is equipped with hydraulic pump

(V156) , located under ABS hydraulic unit, left side engine
compartment. ABS control module (J104) is separate unit under
floor covering in right footwell.

WARNING-
• Bleeding procedure for models with ABS I ASR 5.3 cannot be
accomplished without VAG 1551 or VAG 1552.

~ Bosch ABS I ESP 5.7. ABS control module (J104) is combined with
ABS hydraulic unit, left side engine compartment. There is no
separate hydraulic pump.
 Brakes-Hydraulic 47-5
Bleeding Brakes

Brake fluid, bleeding or replacing,

Bosch ABS I ASA 5.3
In this procedure, brake calipers are first bled using the pressure
bleeder. Then the ABS I ASR hydraulic pump is bled using the VAG
1551 or VAG 1552 scan tool. The scan tool activates the hydraulic
pump for 10 seconds.

WARNING -
• Bleeding procedure for models with ABS I ASR 5.3 cannot be
accomplished without VAG 1551 or VAG 1552.
• Do not allow the brake fluid reservoir to run completely dry at
any time during this procedure.

Unscrew brake fluid reservoir cap and siphon out as much brake
fluid as possible from fluid reservoir.

WARNING -
• Brake fluid is poisonous. Do not siphon fluid by mouth.

CAUTION-
• Brake fluid damages paint. Immediately wipe up any brake fluid
that spills on the vehicle and rinse area with water.

~ Screw brake bleeder adapter to reservoir. Connect brake bleeder

pressure hose to adapter.

NOTE -
• At least 2 bar (29 psi) of pressure is needed to bleed the ABS
hydraulic unit.

Install brake pedal prop between driver seat and brake pedal and
apply tension.

Raise car and support safely.

WARNING -
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

~ Manual transmission vehicle : Remove clutch slave cylinder bleeder

screw cap. Attach brake fluid collecting bottle hose to bleeder screw
(arrow). Open bleeder and allow approx . 100 cc (4 oz) of fluid to
flow out. Close bleeder and reinstall cap .

- Working at each brake caliper, attach brake fluid collecting bottle

bleeder hose to bleeder screw. Follow this sequence for bleeding :
• Right front
• Left front
• Right rear
• Left rear

- Open bleeder and allow approx. 250 cc (10 oz) of fluid to flow out of
each caliper. Tighten bleeder screws and reinstall caps.
47-6 Brakes-Hydraulic
Bleeding Brakes

~ Connect VAG 1551 or VAG 1552 scan tool to data link connecto r
(DLC, inset) , located under left side dashboard , to left of steering
column .

Perform brake bleeding sequence using scan tool.

Remove brake bleeding apparatus and pedal prop.

~ Check brake fluid level and top off if necessary.

- Check brake pedal pressure and free play.

Brake pedal free play

Maximum pedal play I 1/3of pedal travel

Manual transmission vehicle : Check clutch operation and clutch

pedal free play.

Brake fluid, bleeding or replacing,

Bosch ABS I ESP 5.7
Unlike Bosch ABS I ASR version 5.3 , ABS I ESP version 5.7 does
not incorporate hydraulic pump for traction control (V156). It is not
necessary to bleed the system with VAG 1551 or VAG 1552 scan
tool unless air enters the ABS hydraulic unit.

WARNING-
• Do not allow the brake fluid reservoir to run completely dry at
any time during this procedure.

Unscrew brake fluid reservoir cap and siphon out as much brake
fluid as possible from fluid reservoir.

WARNING-
• Brake fluid is poisonous. Do not siphon fluid by mouth.

CAUTIO~
•Brake fluid damages paint. Immediately wipe up any brake fluid
that spills on the vehicle and rinse area with water.

~ Screw brake bleeder adapter to reservoir. Connect brake bleeder

pressure hose to adapter.

NOTE-
• At least 2 bar (29 psi) of pressure is needed to bleed the ABS
hydraulic unit.
 Brakes-Hydraulic 47-7
Bleeding Brakes

Install brake pedal prop between driver seat and brake pedal and
apply tension.

Raise car and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

~ Manual transmission vehicle: Remove clutch slave cylinder bleeder

screw cap. Attach brake fluid collecting bottle hose to bleeder screw
(arrow). Open bleeder and allow approx . 100 cc (4 oz) of fluid to
flow out. Tighten bleeder and reinstall cap.

- Working at each brake caliper, attach brake fluid collecting bottle

bleeder hose to bleeder screw. Follow this sequence for bleeding :
• Right front
•Left front
•Right rear
•Left rear

- Open bleeder and allow approx. 250 cc (10 oz) of fluid to flow out of
each caliper. Tighten bleeders and reinstall caps.

- Remove brake bleeding apparatus and pedal prop.

~ Check brake fluid level and top off if necessary.

- Check brake pedal pressure and free play.

Brake pedal free play

Maximum pedal play I l/i of pedal travel

Manual transmission vehicle : Check clutch operation and clutch

pedal free play.
47-8 Brakes-Hydraulic
Brake Master Cylinder and Booster

BRAKE MASTER CYLINDER AND BOOSTER

Brake master cylinder and booster assembly

1. T45 Torx, 25 Nm (18 ft-lb)
2. Self-locking nut, 49 Nm (36 ft-lb)
3. Brake master cylinder
4. Brake line, 15 Nm (11 ft-lb)
•to ABS hydraulic unit
5. Brake line , 15 Nm (11 ft-lb)
• to ABS hydraulic unit
6. Seal
•Replace
7. Brake booster
8. Gasket
9. Vacuum hose (with check valve)
• Insert in brake booster
10. Brake fluid reservoir
11. Cap
12. Sealing plugs
13. Fluid supply hose
• to Clutch master cylinder
14. Bulkhead
15. Pedal cluster

Brake master cylinder, removing and installing

WARNING-
• The ABS system uses electronic controls and a sophisticated
hydraulic unit. Once air enters the hydraulic unit, it cannot be
removed using traditional bleeding methods. For this reason ,
pressure bleed the brakes using VAS 5234 or equivalent
pressure bleeder.
• When bleeding brake system, use extreme care to not let the
brake fluid reservoir run dry. If air enters the hydraulic unit, use
the VAG 1551 or VAG 1552 scan tool and service tester to
bleed the brake system before the vehicle is driven.
• Do not disassemble the brake master cylinder. It is not
serviceable.

~ Pull off rubber molding at engine compartment rear bulkhead. Pull

plenum chamber cover forward and remove.

- Unscrew brake fluid reservoir cap and siphon out as much brake
fluid as possible from fluid reservoir.

WARNING-
• Brake fluid is poisonous. Do not siphon fluid by mouth.

CAUTION-
• Brake fluid damages paint. Immediately wipe up any brake fluid
that spills on the vehicle and rinse area with water.
 Brakes-Hydraulic 47-9
Brake Master Cylinder and Booster

Manual transmission vehicle: Disconnect clutch master cylinder

supply hose and seal with plug .

...;( Disconnect brake fluid level warning switch harness connector

(arrow) .

...;( Working below brake fluid reservoir :

• Disconnect brake lines (A) at brake master cylinder. Immediately
seal brake lines and plug brake fluid ports.
• Remove brake master cylinder M16 mounting nuts (B).

- Carefully remove brake master cylinder from brake booster.

- When installing , pay particular attention to the following points :

•When installing brake master cylinder on brake booster, make sure
pushrod is correctly located in brake master cylinder.
•Apply slight pressure to brake pedal to move push rod toward brake
master cylinder; this makes it easier to guide brake master cylinder
onto pushrod.

Flush and bleed brake system. See Bleeding Brakes in this repair
group.

Brake booster, removing and installing

WARNING -
• The ABS system uses electronic controls and a sophisticated
hydraulic unit. Once air enters the hydraulic unit, it cannot be
removed using traditional bleeding methods. For this reason ,
pressure bleed the brakes using VAS 5234 or equivalent
pressure bleeder.
• When bleeding brake system, use extreme care to not let the
brake fluid reservoir run dry. If air enters the hydraulic unit, use
the VAG 1551 or VAG 1552 scan tool and service tester to
bleed the brake system before the vehicle is driven .

...;( Pull off rubber molding at engine compartment rear bulkhead. Pull
plenum chamber cover forward and remove .

Unscrew brake fluid reservoir cap and siphon out as much brake
fluid as possible from fluid reservoir.

WARNING-
• Brake fluid is poisonous. Do not siphon fluid by mouth.

CAUTION-
• Brake fluid damages paint. Immediately wipe up any brake fluid
that spills on the vehicle and rinse area with water.
47-1 0 Brakes-Hydraulic
Brake Master Cylinder and Booster

- Manual transmission vehicle : Disconnect clutch master cyli nder

supply hose and seal with plug.

~ Disconnect brake fluid level warning switch harness connecto r

(arrow) .

Disconnect brake booster vacuum hose.

~ Working below brake fluid reservoir :

•Disconnect brake lines (A) at brake master cylinder. Immediately
seal brake lines and plug brake fluid ports.
• Remove Torx T 45 bolts (8) mounting master cylinder and booste r
assembly to bulkhead.

~ Working in passenger compartment, tilt steering column down and

pull off trim under instrument cluster. Remove steering co lumn tri m
panel fasteners (arrows) .

~ Remove lower trim fasteners (arrows) and pull down trim panels
under steering column to gain access to pedal cluster.
 Brakes-Hydraulic 47-11
Brake Master Cylinder and Booster

- Working under dashboard above pedals, remove brake light switch .

~ Insert disengaging tool (VAG special tool T10006) between brake

pedal and bal l head of brake booster push rod (1 ).
• Pull back on tool and brake pedal simultaneously (2).
•Hold brake pedal securely. Pry retaining tabs from ball head by
pulling lightly on tool (arrow A).
• Keep tens ion on tool so that retaining tabs do not reengage .
• Pull brake pedal from ball head (arrow B) .

- Remove brake master cylinder and booster from plenum chamber.

~ Prior to installation , check and reset brake booster pushrod length .

Brake booster pushrod length

Measurement A :
•Left hand drive (LHD) vehicle 159 ± 0 .5 mm (6.26 ± 0.02 in)
• Right hand drive (RHO) vehicle 173.2 ± 0.5 mm (6.82 ± 0.02 in)

NOTE -
• When measuring, make sure ball head is at right angle to surface
of brake booster.
• Measure from end of ball head to metal base of booster, not to
A41-0023 I gasket.

Installation is reverse of removal. Pay particular attention to the

following points:
• Reinstall and adjust brake light switch and brake and clutch pedal
cruise control vent valve switches.
• Flush and bleed brake system . See Bleeding Brakes in this repair
group.
47-12 Brakes-Hydraulic
Brake Master Cylinder and Booster

2
Brake booster vacuum pump assembly
In 3.0 liter V6 models and all VS models, an electric brake booster
vacuum pump is used to supplement intake manifold vacuum.
1. Pressure sensor (G 294)
2. Brake booster
3. Brake booster vacuum pump relay (J569)
4. Brake booster vacuum pump (V192)
5. Vacuum hose
6. Check valve
7. Vacuum hose
• Connects to engine

I A47-0 131

Brake booster vacuum pump (V192),

removing and installing
If problems with vacuum supply to brake booster are encountered ,
determine cause by means of a vacuum pump function test and leak
test. If a malfunction is found , replace pump.

- Remove protective cover.

~ Unplug electrical connector (arrow).

- Detach vacuum hose from pump.

~ Press clip out of retainer by hand and lift out electric vacuum pump
from above.

- Installation is reverse of removal.

0
0

I A4?-012s I
 Brakes-Hydraulic 47-13
Brake Master Cylinder and Booster

Brake booster vacuum pump pressure sensor

(G294), removing and installing
- Remove plenum chamber cover.

~ Working to left of battery:

• Pull pressure sensor electrical connector (A) downward to
disconnect.
• Remove sensor mounting screws (8) and remove sensor.

NOTE-
• The sensor may also be attached by means of clips.

- Installation is reverse of removal.

Brake booster vacuum pump relay (J569),

removing and installing
~ Brake booster vacuum pump relay is in position 1 in central carrier
relay panel under left side of dashboard . See 97 Fuses, Relays,
Component Location.

I A97-0 127 I
 48-1

48 Steering

GENERAL ... . ................... ...... .. 48-1 Power steering rack components

Power steering fluid 48-1 ( 1999 - 2004) . . . . . . . . . . . . . . . . . . . . . . . . . 48-1 0
Warnings . ..... . ...... . ......... . ...... 48-2 Tie rod , removing and installing . .... .. .. .. . 48-10

STEERING WHEEL AND COLUMN .... ...... 48-3 STEERING PUMP . . . . . . . . . . . . . . . . . 48-12
Steering wheel , removing and installing ....... 48-3 Power steering pump (2.8 liter engine),
removing and installing .......... .... . . . 48-12
Sport steering wheel , removing and installing .. 48-3
Power steering pump (2.7 liter biturbo engine) ,
Steering column assembly
removing and installing . . . ... . . .. .. . .. . . 48-16
(el ect rically adjustable) . . . . ... . .... .. ... . 48-4
Power steering pump (3.0 liter engine),
Steering column stalk switch ,
removing and installing .. . ... .......... . 48-19
removing and installing ..... ....... .. .... 48-4
Power steering pump (allroad quattro VS) ,
Steering column , removing and installing ..... 48-5
removing and installing ........ . .... .... 48-26
STEERING RACK 48-9 Power steering pump (RS6 engine) ,
Power steering rack components removing and installing . .. ... .... . .. ... . 48-31
(1998 models) ...... .. ... ...... . .... . .. 48-9

GENERAL
This repair group includes a description of the steering system , an
overview of steering column and steering system components and
steering wheel removal. For more information , see :
• 45 Antilock Brakes (ABS) for steering angle sensor removal
• 69 Seat Belts, Airbags for airbag procedures

Power steering fluid

~ Working in engine compartment, unscrew power steering reservoir
cap and wipe off dipstick.

- Fully close and reopen cap. Check level on dipstick. See 03

Maintena nce for more information .

Power steering fluid

Capacity 0.85L (0.89qt)
Type Hydraulic oil
G002 000
G002 012

CAUTION-
•Do not use automatic transmission fluid (ATF) .
48-2 Steering
General

Warnings

WARNING-
• Do not remove or repair airbag unit unless you have proper
training, qualifications and tools to do the work safely.
• Disconnect battery ground strap before performing any work on
the airbag system. No waiting time is required after
disconnecting the battery. When connecting airbag system to a
voltage source, no one should be in the vehicle interior.
• Before handling (touching) the airbag unit, the technician must
be electrostatically discharged. This is accomplished by touching
grounded metal like e.g. water pipes, heating pipes or metal
carriers.
•Always install airbag units in the vehicle, as soon as they are
removed from the packaging.
• If installation work is interrupted, immediately return the airbag
unit to its original packaging.
• Do not leave an airbag unit unattended.
• Once removed, lay the airbag down with impact absorbing pad
facing up.
• Do not install airbag units that have fallen onto a hard surface, or
which have signs of damage.
•Airbag units that have not ignited must be returned in original
packaging for proper recycling/disposal. Contact your supplier or
the manufacturer for more information.
• Ignited airbag units can be disposed of with industrial waste.
 Steering 48-3
Steering Wheel and Column

STEERING WHEEL AND COLUMN

Steering wheel, removing and installing

Remove airbag unit. See 69 Seat Belts, Airbags .

Put steering wheel in center position (wheels straight ahead).

- Remove bolt (5) .

- Disconnect connectors (2) and (10) and remove wheel.

- When installing , attach steering wheel in center position (wh eels

straight ahead) .

- Attach electrical connectors (2) and (1 0 ). Make sure you hear plugs
completely engage .

Replace bolt (5) and tighten .

Tightening torque

7 6 Steering wheel to steering column 50 Nm (37 ft-lb)

A69-0067 - Install airbag unit.

Sport steering wheel, removing and installing

- Remove airbag unit. See 69 Seat Belts, Airbags.
2 3
Put steering wheel in center position (wheels straight ahead).

Remove bolt (4) and remove wheel .

- When installing , attach steering wheel in center position (wheels

straight ahead) .

Replace bolt (4) and tighten .

Tightening torque
. ,·
Steering wheel to steering column \ 50 Nm (37 ft-lb)

Install airbag unit.

7 6 5 4
A69 -0066
48-4 Steering
Steering Wheel and Column

Steering column assembly

(electrically adjustable)
The steering column is only available as a complete unit.
1. Shear bolt, 20 Nm (15 ft-lb)
2. Steering column
3. Ignition/starter switch
4. Bolt, 22 Nm (16 ft-lb)
5. Bracket (used for transport)
6. Steering column height adjustment control module (J352)
•No self-diagnosis capability.
• Sliding spline between upper and lower steering column must
not be separated under any circumstances .
• Sliding over a range in excess of 5 cm can lead to steering
column damage.
7. Tolerance adjusting screw, 22 Nm (16 ft-lb)
• Provided with electrically adjustable steering column
• Tighten 4 bolts for attaching steering column to dashboard
brace to torque , before tightening tolerance adjusting screw.
• Do not apply force to steering column or steering wheel while
tightening tolerance adjusting screw.

5 4 A48-0531

Steering column stalk switch,

removing and installing

WARNING-
• Before removing steering wheel, place wheels in straight-
ahead position.
• Observe safety precautions for working on airbags. See 69
Seat Belts, Airbags .
• If these procedures are not observed, the airbag system may
not function properly during vehicle operation.

Remove airbag unit. See 69 Seat Belts, Airbags.

- Remove steering wheel. See Steering Wheel , removing and

installing in this repair group.

- Remove steering angle sensor in vehicles with Electronic

Stabilization Program (ESP). See 45 Antilock Brakes for more
information .

~ Remove bolt (1 ).

- Remove handle (2) .

A69-0074 I
 Steering 48-5
Steering Wheel and Column

~ Remove two Phillips head screws (arrows).

- Remove upper steering column trim (1 ).

A69-0072 I
~ Remove bolts (2) .

- Remove bolt (1 ).

- Remove lower steering column trim (3).

A69-0073 I
~ Disconnect connector (1 ).

- Loosen bolt (2).

Disconnect connector (3) .

Remove steering column stalk switch (4).

1
A69-0076 I
Steering column, removing and installing
The steerin g column is only available as a complete unit. Servicing
is not poss ible .

WARNING -
• Before removing steering wheel, place wheels in straight-
ahead p osition.
• Observe safety precautions for working on airbags. See 69
Seat Belts , Airbags .
• If these procedures are not observed, the airbag system may
not function properly during vehicle operation.
48-6 Steering
Steering Wheel and Column

Remove airbag unit. See 69 Seat Belts, Airbags .

Remove steering wheel. See Steering Wheel, removing and

installing in this repair group.

Remove steering angle sensor in vehicles with Electronic

Stabilization Program (ESP) . See 45 Antilock Brakes fo r more
information.

Remove steering column stalk switch. See Steering column stalk

switch , removing and installing in this repair group.

Disengage steering column adjustment.

~ Release cable ties and connectors located at steering column .

NOTE-
• For vehicles with automatic transmission, locking cable must be
disengaged.

Place selector lever in PARK position .

A48-0061

~ Switch ignition ON (position B) .

Lift locking lever (1) slightly and pull shift interlock cable (2) from
ignition lock housing .

A4s-oo76 I
~ Working at base of steering column , remove nut (1) at steering shaft
universal joint.

Rotate eccentric pinch bolt (Torx TSO) clockwise to relieve tension ,

then remove bolt.

- Disengage steering column adjustment.

M s-0062 I
 Steering 48-7
Steering Wheel and Column

~ Swing universal joint to side.

A48-0043

~ Remove Allen bolts (1) for steering column and remove steering
column.

- Check steering column for damage.

Installing

- Attach steering column to dashboard brace using 4 Allen bolts (1 ).

- Disengage steering column adjustment.

~ Attach steering shaft universal joint to steering rack pinion gear.

- Insert pinch bolt (Torx TSO) through lower part and pretension
counterclockwise . Insert nut and tighten to 30 Nm (22 ft-lb).

Tightening torque
Steering shaft pinch bolt to steering gear \ 30 Nm (22 ft-lb)

NOTE-
• For vehicles with automatic transmission, engage shift interlock
cable.
A4 8-0043
48-8 Steering
Steering Wheel and Column

~ Switch ignition key to ON (position B) .

Place selector lever in PARK.

Insert shift interlock cable (2) in ignition lock housing . Make sure
locking bracket (1) engages.

Shift interlock function check:

The ignition interlock prevents or allows the key and shift mechan ism
to move depending on their respective positions. Follow the steps
below to check the ignition interlock.

- Turn ignition key ON then depress brake pedal and hold:

• Shifting from P must be possible without "snagging" when button
on shift lever is depressed.
• Removing the ignition key must not be possible in any driving
position except in P.

Move shift leve r to P.

•It must be possible to turn Ignition key OFF without binding .

- Remove ignition key.

• It must not be possible to move shift lever from P.

- To continue with procedure, install and position steering column

stalk trim so that gaps in trim are uniform .

~ Tighten socket head bolts (1) for steering column.

Tightening torque

Steering column bracket to dashboard brace I 25 Nm (18 ft-lb)

Vehicles with electrically adjustable steering column:

- Tighten tolerance adjusting screw.

- Connect wiring of servo motors.

- Use cable tie to attach wires to steering column .

All vehicles (continued)

Install steering column trim .

Install steering wheel.

Install airbag module.

 Steering 48-9
Steering Rack

STEERING RACK

Power steering rack components

(1998 models)
1. Bolt, 67 Nm (49 ft-lb)
2 3 4
2. Boot seal

~Jr
I
·~ • Check for tears and scuffing
3. Eccentric pinch bolt, Torx T50
@---- 5
•To release tension , turn clockwise
~1 •To tension , turn counterclockwise
I
4. Steering column
5. Self-locking nut, 30 Nm (22 ft-lb)
• Always replace
7~
I 6. Screw and washer assembly , 7 Nm (5 ft-lb)
1-
::~
'l>
I
J8
r
• For adjusting toe-in
7. Bolt
8. Self-locking nut, 45 Nm (33 ft-lb)
• Always replace
9. Return hose
10. Expansion hose
11. Cylinder bolt , 13 Nm (10 ft-lb)
• Locking screw for centering steering
12. Power steering rack with tie rods
I Ms-0057 I 13. Banjo bolt, 40 Nm (30 ft-lb)
•With integrated check-valve
14. Seal
• Always replace
15. Banjo bolt, 47 Nm (35 ft-lb)
16. Seal
• Always replace
17. Bolt, 35 Nm (26 ft-lb)
18. Steering damper
• V6 models only
19. Socket
20. Rubbe r bushing
•Two-pi ece
21. Nut, tighten to 1O Nm (7 ft-lb)
•To loosen and tighten , counterhold hex on steering damper
piston rod
48-10 Steering
Steering Rack

Power steering rack components

(1999 - 2004)
1. Bolt, 67 Nm (49 ft-lb)
2
2. Boot seal
• Check for tears and scuffing
3. Eccentric pinch bolt, Torx TSO
•To release tension , turn clockwise
•To tens ion , turn counterclockwise

~7
rs 4.
5.
Steering column
Self-locking nut, 30 Nm (22 ft-lb)
• Always replace
~ 8
~!
6. Screw and washer assembly , 7 Nm (5 ft-lb)
• For adjusting toe-in
7. Bolt
8. Self-locking nut, 45 Nm (33 ft-lb)
~--- 11 • Always replace
9. Steering knuckle from wheel bearing housing
10. Pressure line , 40 Nm (30 ft-lb)
11. Return hose
• Note installation position at steering rack
A48-0294 12. Cylinder bolt, 13 Nm (10 ft-lb)
• Locking screw for centering steering
13. Power steering rack with tie rods
14. Seal
• Always replace
15. Banjo bolt, 47 Nm (35 ft-lb)
16. Seal
• Always replace
17. Banjo bolt, 40 Nm (30 ft-lb)
• With integrated check-valve

Tie rod, removing and installing

NOTE -
• Left and right tie rods are identical.
• Tie rod can be removed and installed with steering rack installed.

- Remove front wheel.

<liioiii{ Remove upper bolt (1) and pinch bolt (2) .

- Detach tie rod from steering knuckle .

 Steering 48-11
Steering Rack

~ Unscrew plastic nut (1 ).

- Pry out clip (2) .

- Remove cover for tie rod .

NOTE -
• Shown without wheel bearing housing and strut fo r the sake of
illustration .

~
~

~ A4B-007B
~ Cut rack boot clamps .

- Pull boot as far toward outside as possible .

~ Remove tie rod using special tool VAG 1923 (or equ ivalent) .

- Replace boot or tie rod depending on extent of damage .

- Attach tie ro d to to steering rack.

Tightening torque

Tie rod to steering rack I 100 Nm (74 ft-lb)

- When install ing boot:

•Smaller diameter of boot snaps into groove at tie rod .
• Do not twist boot.
• Replace boot clamps.

- Check alignment.
48-12 Steering
Steering Pump

STEERING PUMP

Power steering pump (2.8 liter engine),

removing and installing
~ Unclip upper engine cover and remove .

~ Remove bolts (arrows) for air filter duct housing at front of lock
carrier and lift air duct out.

~ Disconnect 5-pin connector from ignition coils.

- Disconnect three rear connectors (A ) from ignition coils.

- Remove 4 mounting bolts (arrows).

- Swing ignition coil bracket toward rear.

 Steering 48-13
Steering Pump

~ Counterhold pulley for viscous fan using VAG 3212 spanner and
remove viscous fan using VAG 3312 open-end spanner (left hand
thread).

- Lift viscous fan up and out.

~ Remove electric fan by first removing bolt (1 ).

Release electric fan harness clips on viscous fan air guide.

Rotate electric fan slightly in direction of (arrow) and place fan aside
to right.

NOTE-
• Before removing engine accessory belt, mark direction of rotation
with chalk or felt-tip marker.

~ Turn belt tensioner toward right using a long to rque wrench and 17
mm socket insert.

- When both bores align (arrows) , secure using VAG 3204 drift
(or equivalent).

- Remove accessory belt from belt pulley.

48-14 Steering
Steering Pump

~ Unbolt belt pulley for power steering pump. Counterhold with VAG
3212 spanner.

~ Pinch off intake line and return line using 3094 hose clamps .

~ Remove expansion hose bracket bolts (arrow) on cylinder head .

~ Open clamp (1) and remove fluid supply hose.

- Unbolt expansion hose (2) .

NOTE-
• Be prepared to catch dripping fluid.
 Steering 48-15
Steering Pump

~ Unbolt power steering pump bracket and remove pump together

with bracket.

- Unbolt power steering pump from bracket.

- When install in g, pay particular attention to the following points :

• Before installing a new pump, fill intake side with hydraulic fluid and
turn pump by hand until fluid comes out the pump side.
• Clean any spilled fluid in engine compartment.

Tightening torque

Power steering pump to bracket 22 Nm (16 ft-lb)

~ Install pump together with bracket.

- First tighten front two bolts, and then rear two bolts to
22 Nm (16 ft-lb).

- Install new seals on banjo fitting .

Tightening torque
Power steering pump bracket to engine 22 Nm (16 ft-lb)
I

~ Tighten banjo fitting for expansion hose (2 ).

- Bolt line for expansion hose to cylinder head and tighten to

6 Nm (6 ft-lb) .

- Install intake hose (1) with marking P facing toward pump

- Remove VAG 3094 hose clamps.

Tightening torques
Power steering fluid supply line to pump 47 Nm (35 ft-lb)
Steering fluid clamp to cylinder head 6 Nm (4 .5 ft-lb)

~ Tighten Alle n bolts for power steering pump belt pulley.

Tightening torques
Steering pump pulley to steering pump
l 22 Nm (16 ft-lb)

-
>

• ' , • ( I_ i I
I I
48-16 Steering
Steering Pump
~ First install ribbed belt onto crankshaft pulley and idler wheel. Push
belt onto tensioning roller last.

NOTE-
• Note previously marked direction of rotation of belt and be sure that
it is seated correctly on pulley

Remove VAG 3204 drift.

First install electric fan and then viscous fan .

Tightening torques

Al3-00 18 Viscous fan with VAG 3312 wrench 37 Nm (27 ft-lb)

Viscous fan without VAG 3312 wrench 70 Nm (52 ft-lb)

- Fill and bleed steering system.

- Check steering system for leaks.

Power steering pump (2.7 liter biturbo engine),

removing and installing
Remove front bumper. See 63 Bumpers.

Bring front lock carrier into service position. See 50 Body-Front.

~ Remove bolts (arrows) and remove front engine cove r.

~ Counterhold viscous fan pulley using VAG 3212 spanner wrench

and remove viscous fan using VAG 3312 open-end wrench .

NOTE-
• The viscous fan has a left-hand thread. Unbolt in direction of
arrow.

Lift viscous fan up and out.

NOTE-
• Before removing engine accessory belt, mark direction of rotation
with chalk or felt-tip marker.
 Steering 48-17
Steering Pump

~ To loosen accessory belt, turn tensioner clockwise using 17 mm box

wrench until two holes are aligned (arrows). Lock in position using
VAG 3204 drift.

- Remove accessory belt from belt pulley.

~ Remove turbo pressure duct mounting bolts (1). Remove ducts.

NOTE -
• Pay attention to retaining strips (2).

A13-0177 I
~ Unbolt belt pulley for power steering pump. Counterhold with
VAG 3212 spanner.

~ Pinch off intake line using VAG 3094 hose clamp.

48-18 Steering
Steering Pump

<liiiiii{ Disconnect harness connector at charge air pressure sensor (G31 )

(arrow).

Remove rubber shroud (1 ).

<liiiiii{ Open clamp (arrow) and disconnect intake hose from pump.

- Unbolt pressure line (1 ).

- Remove power steering pump bracket fasteners (2 , 3 and 4 ).

- Remove pump together with bracket.

- Unbolt power steering pump from bracket.

- When installing , pay particular attention to the following points :

• Before installing a new pump, fill intake side with hydraulic fluid and
turn pump by hand until fluid comes out the pump side.
•Clean any areas in engine compartment covered with fluid .

- Bolt pump to bracket.

- Tighten front two bolts first , and then rear two bolts.

Tightening torque
Power steering pump to bracket 22 Nm (16 ft-lb)
 Steering 48-19
Steering Pump

<liiiiii( Install pump together with bracket.

- Install new seals on banjo bolt.

- Tighten banjo bolt for pressure line (1) to 50 Nm (37 ft-l b).

Tightening torques
Power steering fluid supply line to pump 50 Nm (37 ft-lb)

- Install intake hose (align mark P with flash on pump ).

- Remove VAG 3094 hose clamps .

- Tighten Allen bolts for power steering pump belt pulley.

Tightening torques
Power steering pulley to steering pump 22 Nm (16 ft-lb)

- Install viscous fan.

Tightening torques
Viscous fan with VAG 3312 wrench 37 Nm (27 ft-lb)
Viscous fan without VAG 3312 wrench 70 Nm (52 ft-lb)

- Install lock carrier. See 03 Maintenance.

- Install bumper. See 63 Bumpers.

- Fill and bleed steering system.

- Check steering system for leaks.

Power steering pump (3.0 liter engine),

removing and installing
<liiiiii( Remove bolts (arrows) and remove engine cove rs (A) and (8 ).

- Remove cover (C) from power steering fluid reservoir.

48-20 Steering
Steering Pump

~ Disconnect for NC clutch green connector (upper arrow) and

remove lower part of connector from bracket.

- Open wire tie (lower arrow) on line to A/C compressor and let line
hang free .

- Remove right timing belt cover.

~ Cover sharp corners of shroud with tape.

~ Remove electric engine cooling fan by removing bolt (solid arrow).

- Pull sealing lip away from front end slightly in area near electric fan.

- Rotate electric fan slightly in direction of arrow and place fan to side.

~ Pinch off supply line using VAG 3094 hose clamp.

 Steering 48-21
Steering Pump

~ Remove engine lower cover.

NOTE -
• Before removing engine accessory belt, mark direction of rotation
with chalk or felt-tip marker.

~ Remove clamp from refrigerant line .

- Move tensioner in direction of arrow to release tension on

accessory belt.

- Remove accessory belt and release tensioning roller.

~ Pinch off return lines using VAG 3094 hose clamp.

Place pan underneath vehicle to collect steering fluid .

Unbolt expansion hose (1) and intake hose (2) from pump.

Seal connection holes using plugs.

- Remove bolt (3) for power steering pump and bracket.

"iii{ Unbolt belt pulley for power steering pump. Counterhol d with
VAG 3212 spanner.
48-22 Steering
Steering Pump

~ Remove pump mounting bolts (arrows) . Remove pump downward

and out.

- When installing, pay particular attention to the following points:

•Before installing a new pump, fill intake side with steering fluid
and turn pump by hand until fluid comes out the pump side.
•Clean areas in engine compartment contaminated with flu id.
• Return expansion and intake hose to installed position .
• Place pump in bracket from below and hand-tighten all three bolts.
• Install expansion and intake hoses with new seals, but do not
tighten all the way.

- Tighten two front bolts (arrows) .

A4s-02s4 I
~ When installing belt pulley, note that front of pulley is marked "front".

A4s-02ss I
 Steering 48-23
Steering Pump

- Bolt on belt pulley for power steering pump. Counte rhold with
VAG 3212 spanner wrench.

Check and adjust pulley alignment

~ Install VAG 3201 level on A/C compressor pulley.

- Pulley for power steering pump must align with pulley for A/C
compressor.

- If the two pulleys do not align , unbolt pulley for power steering pump.

~ Use shims (available as replacement parts) to adjust pulley with

A/C pulley and steering pump pulley until it aligns .

~ Note installation position of expansion hose. Angle a is

approxim ately 57°.

- Align expansion hose and tighten .

- Install electric cooling fan .

A4s -02s6 I
48-24 Steering
Steering Pump

~ Connect A/C harness and replace wire ties.

~ Remove adhesive tape (installed earlier) .

- Install covers for timing belt, power steering fluid reservoir and
engine.

~ Tighten rear bolt on power steering pump.

~ Note installation position of intake line . Angle bis approximately 90°.

- Align intake line and tighten .

- Remove VAG 3094 hose clamps.

A48-0256 I
 Steering 48-25
Steering Pump

Install accessory belt

"iii{ First install engine accessory belt onto crankshaft pulley and idler
wheel. Push belt onto tensioning roller last.

NOTE-
• Note previously marked direction of rotation of belt and be sure that
it is seated correctly on pulley

A13-0230

"iii{ Swing tensioner in direction of dashed arrow.

Position accessory belt and release tensioning roller.

Install refrigerant line clamp.

Fill and bleed steering system.

- Check steering system for leaks.

"iii{ Install engine lower cover.

48-26 Steering
Steering Pump

ttro VB),
Power steering pum p (allroad qua
removing and installing
~ Remove rear engine cove r (arrows)
.

from reservoir using

- Extract pow er steering hydr aulic fluid
VAG 1358 A or VAG 1782.

~ Attach plate 2024 w out bolt at

A/2 to rear left engi ne lifting eye. Scre
pack ing plate.
ce with bolt M10 x 15 mm with
plate and repla
flanges.
- Remove rubber seal at wing mou nting

~ To stop support bar from dam agin g edge s of wing , inse

r side betw een wing mou nting flang
rt special tool
e and splash
T4004 5 on eithe
panel beneath .

10- 222 A
 Steering 48-27
Steering Pump

~ Position support bar VAG 10-222 A on wing mounting flanges.

- Engage plate 2024 A/2 at spindle of support bar.

- Slightly pretension engine with spindle of support bar, but do not lift.

- Remove left front wheel.

~ Unfasten quick-release fasteners (1 , 2 and 3) and detach lower

engine cover (2 sections) .

~ Remove heat shield (1) for drive axle on left.

- Remove left drive axle. See 40 Front Suspension .

48-28 Steering
Steering Pump

~ Unscrew nuts (1 - 4) for stabilizer bar mounting on left and right.

~ Unscrew nuts (3).

- Remove bolts (1 and 2) and detach engine mount bracket.

~ Disconnect connector (1) at left engine mounting .

- Unscrew nut (2) and detach engine mounting .

NOTE-
• Illustration shows engine removed.

I A1 0- 1511 I

~ Remove bolts (1 and 2) .

- Remove return line from power steering pump (arrow).

 Steering 48-29
Steering Pump

~ Remove hydraulic pressure line banjo bolt (arrow) at power steering

pump.

- Set aside hydraulic pressure line.

NOTE -
• Be prepared to catch dripping steering fluid

I A10-1476 I

~ Remove left engine support (arrows).

~ Disconnect connector (2) at speedometer vehicle speed sensor

(G22).

NOTE-
• Ignore item 1.

~ Loosen lock nut (3) by several turns.

- Screw out as far as possible stud bolt (4).

- Screw out bolts (1) and (2) and detach power steering pump.

- l -

'
A i. L
 -

48-30 Steering
Steering Pump

- Pay particular attention to the following on installation :

•In engine compartment, clean areas contaminated with fluid .
•Before installing new power steering pump, pour in hydraulic fluid
on intake end and crank by hand until fluid emerges on discharge
end .
• Replace 0-ring on drive shaft of power steering pump.
• Replace oil seals.
•Secure all hose connections with standard hose clamps .

- Install engine bracket and screw on subframe.

- Install stabilizer bar.

- Install drive axle.

- Fill and bleed power steering system.

- Check power steering system for leaks .

Tightening torques
Power steering pump to engine 22 Nm (16 ft-lb)

Stud bolt to power steering pump 40 Nm (30 ft-lb)

Lock nut to stud bolt 65 Nm (48 ft-lb)

Engine support to cylinder block 42 Nm (31 ft- lb)

Hydraulic pressure line to pump 47 Nm (31 ft-lb)

Return line to :
• engine support 10 Nm (7 ft-lb)
•coolant pipe 10 Nm (7 ft-lb)

Engine mounting to :
• engine support 23 Nm (17 ft-lb)
• engine bracket 23 Nm (17 ft-lb)
Drive axle heat shield to transmission 23 Nm (17 ft-lb)

I
 Steering 48-31
Steering Pump

Power steering pump (RS6 engine),

removing and installing
- Bring front lock carrier into service position . See 50 Body-Front.

~ Disconnect connector (5) at charge air pressure sensor (G31 ).

- Unfasten hose clamps (3) and (4).

- Detach hoses at air recirculation valves .

- Screw out bolts (1 and 2) and detach air line.

2 1 2 I A10-1388 I

~ Remove air hose (arrows).

NOTE-
• Before removing engine accessory belt, mark direction of rotation
with chalk or felt-tip marker.

~ To loosen accessory belt swing tensioner in direction of arrow.

I A1 3-0522 I
 Steering
Steering Pump

~
- Deta
. .into loc r
Insert VAG 3204 dnft
a ing holes (arrow)
ch accessory belt from to lock tensioner.
power steerin g pump pulley.

~Remove
Co
bol~snterhold with VAG 32~2ms~~~~~rs:eh':,'~ngloosening
b alts (arrows) fr
pump pulley.
and tightening

~Take
- R connectors (arrows) out of holder
emove holder for conn ectors. .

~ Use VAG 3094 hose clamps t o pinch

NOTE-
.
off hydraulic hose
s.

•Be prep ared to catch d nppmg

. . steenng
. fluid.
 Steering 48-33
Steering Pu mp

er
and expansion hose (2) at pow
~ Dis con nec t intake hose (1)
steering pump.

~ Remove bolts (arr ows ) .

p.
- Take out pow er stee ring pum
following on installation:
- Pay par ticu lar attention to the
lic fluid and
p, fill intake side with hyd rau
•Be fore installing a new pum p side .
com es out the pum
turn pum p by hand until fluid
with fluid.
com par tme nt con tam inat ed
•Cle an any area s in eng ine
ition.
suction hose to inst alle d pos
•Re turn expansion hose and
ngs .
• Replace oil seals and 0-ri
s with standard hos e clam ps.
• Sec ure all hose con nec tion

).
scre w in all three bolt s (arr ows
~ Place pum p in bracket and
not tighten
hos es with new sea ls, but do
- Install expansion and intake
all the way.

is mar ked "front".

..;;;;;;( Front of the belt pulley

A4s -02ss I
 50-1

50 Body-Front

GENERAL . .... . .. . .. . .... . ... .. . ...... . . 50-1 FRONT FENDER . ...... . ... .. ... . .... .. . . . 50-4
Front fender end plate, removing and installing . 50-4
FRONT LOCK CARRIER . . . .... . ..... .. .... 50-1
Front fender, removing and installing . . ... .... 50-4
Front lock carrier assembly ... .... . .. ... .. .. 50-1
Front lock carrier service position ............ 50-2

GENERAL
This repair group covers the front lock carrier and front fenders. The
lock carrier can be moved to a convenient service position for
accessing components located in the front of the engine
compartment.

For additional information see :

• 03 Maintenance for lower engine cover removal .
• 63 Bumpers for bumper and bumper cover removal.

W00-0198
FRONT LOCK CARRIER

The radiator support frame in front of the engine is referred to as the

front lock carrier.

A number of repair procedures require that the lock carrier be

unbolted from the frame and moved forward into service position .
I
It is then supported on speci al tools 3369 (or equivalent).

Remove engine covers as needed to free up and gain access to lock

.·. carrier fasteners .

Front lock carrier assembly

1. Lock carrier
2. T orx bolts
5 • 10 Nm (7 ft-lb)

~
4 >-------- 2
3. Bolt and washer assembly
• 50 Nm (37 ft-lb)
4. Bolt and washer assembly
• 50 Nm (37 ft-lb)
5. Bolt and washer assembly
• Remove bolts and install special tools 3369

33~
• 50 Nm (37 ft-lb)

I A50-0325 I
55-6 Hoods and Lids
Trunk Lid

Trunk lid stops, adjusting

- Open trunk lid.

- Press in stop buffer spring pin in direction of arrow using Phi llips-
head screwdriver.

-<iiiiii{ Lock spring pin by turning counterclockwise (arrow A ) .

- Screw in stop buffer (1) until fully home.

- Unscrew stop buffer again in stages.

- Adjust so that lid stops make light contact with rear sill trim when
trunk lid is closed .

- Unlock spring pin by turning clockwise (arrow B).

ASS-006 1 I

Trunk lid striker plate, adjusting

- Loosen striker plate nuts. Retighten nuts until finger-tight (striker
plate should still be movable).

- Carefully close trunk lid until flush with rear side panels.

- Carefully open trunk lid and tighten striker plate nuts .

Tightening torque
Trunk lid striker plate to body 8 Nm (71 in-lb)
I

Trunk lid gap dimensions

NOTE -
• Use 3371 (or equivalent) adjustment gauge to check trunk lid gap.

Trunk lid gap dimensions

Dimension Specification
A 3 + 1/-0 mm (0 .118 +0.039/-0 in)

B 5 + 1/-0 mm (0 .197 +0.039/-0 in)

c 1.5 ± 0 .3 mm (0 .059 ± 0 .012 in)

D Flush with trunk lid

E 1.5 -0 .5/+0 mm (0 .059 -0.019/+0 in)
 Hoods a nd Lids 55-7
Trunk Lid

Trunk lid hinge, removing and installing

Have an assistant support the lid during hinge removal.

- Unclip trunk lid hinge cover from top of hinge and remove.

- If necessary, remove trunk lid gas strut. See Trunk lid strut,
removing and installing in this repair group .

...;;( Loosen top nuts (2) on hinge at trunk lid .

- Remove bottom nuts on hinge at trunk lid .

- Lift trunk lid off hinge and support.

- Remove left and right bolts (7 ) on hinge at body.

- Loosen , but do not remove center bolt on hinge at body.

- Remove hinge (1 ).

- When reinstalling hinge and trunk lid check trunk lid gap. See Trunk
lid , removi ng and installing in this repair group.
A55-0054 I
NOTE -
• For easier adjustment of the trunk lid hinge, use graduations (8)
marked on the hinge and the trunk lid.

Tighten ing torques

Trunk lid hinge to body 21 Nm (15 ft-lb)
Trunk lid hinge to trunk lid 21 Nm (15 ft-lb)

Trunk lid seal , installing

...;;( Align butt joint (A) of the trunk lid seal with the ball socket of the left
hinge (arrow).

- Press seal into place.

55-8 Hoods and Lids
Trunk Lid

9 10 11
Trunk lid lock, removing and installing

~
1. Trunk lid lock
•To remove , swing out hinge arm (2) from operating rod (4)
and unhook from trunk lid lock.
• Remove nuts (3) and remove trunk lid lock.
2. Hinge arm
• After installing trunk lid lock, swing it over operating rod.
3. Nuts, 8 Nm (71 in-lb)
4. Operating rod
5. Nut, 8 Nm (71 in -lb)
6. Handle mechanism
•To remove , remove trunk lid trim .
• Unclip operating rod (4) from handle mechan ism .
4 •Unscrew nuts (5) and remove handle mechanism.
7. Trunk lid lock actuator
8. Lock cylinder
• Remove release handle .
•Remove operating rod.
~5 •Remove lock cylinde r out of handle mechanism .
8 7 6 I A55-0063 I
9. Trunk lid lock motor
10. Screws (2x)
11. Operating rod

Trunk lid lock motor, removing and installing

- Remove trunk lid lining.

~ Unclip operating rod (3 ).

- Remove screws (2) (2x).

- Disconnect harness connector from motor (1 ).

- Installation is reverse of removal.

NOTE -
• Do not unclip operating rod (4) from fulcrum lever (5).
• Make sure the harness connector is connected to the motor before
installation.

A55-0 062 I
 Hoods and Lids 55-9
Tailgate (Avant)

TAILGATE (AVANT)

Tailgate, removing and installing

Remove tailgate trim. See 70 Interior Trim.

Disconnect or remove harness connectors and hoses for tailgate

lock and rear window washer.

- Prop up and secure tailgate in open position.

~ Using screwdriver, lift upper strut retaining spring (3) as shown and
remove gas strut (1) from upper ball stud (2) .

- Lift lower strut retaining spring slightly and pull gas strut (1) off lower
ball stud .

NOTE -
• Before removing tailgate, mark position of hinges to maintain
tailgate alignment.
• Have an assistant support the tailgate during removal.

~ Remove bolts (1) from hinges (2) and remove tailgate.

- To reinstall , align hinges to tailgate using marks made previously

and fasten hinges.

Install tube end of strut towards body.

Press gas strut onto ball stud so that it engages in position .

- Adjust tailgate alignment (if necessary). See Tailgate, adjusting in

this repair group.

Tightening torque
Ball stud to tailgate and body 15 Nm (11 ft-lb)
Hinge bolts to tailgate 21 Nm (15 ft-lb)
3 4

A55-0065 I
55-10 Hoods and Lids
Tai/aate (Avant)

57-2 Doors and Locks

Doors

Front door upper hinge

3 2
1. Bolt, 30 Nm (22 ft-lb)
•Install from inside vehicle
2. Upper door hinge
3. To rx bolt 30 Nm (22 ft-lb)
4. Bolt 30 Nm (22 ft-lb)
• Install from inside vehicle
5. Stud , 23 Nm (17 ft-lb)
6. Cap

5 6 1 A57-0081

Front door lower hinge

1. Lower door hi nge
2. Bolt, 30 Nm (22 ft-lb)
3. Front door
4. Bolt, 30 Nm (22 ft-lb)
5. Torx bolt 30 Nm (22 ft-lb)

Rear door assembly

1. Door component carrier
2. Adjusting plate
3. Bolt w/washer assembly, 30 Nm (22 ft lb)
4. Bolt w/washer assembly, 30 Nm (22 ft lb)
5. Rear door
6. Bolt w/washe r assembly, 30 Nm (22 ft lb)
7. Bolt w/washer assembly, 30 Nm (22 ft lb)

1--- - - - - 2

l '
 Doors and Locks 57-3
Doors

Rear door upper hinge

1. Bolt, 30 Nm (22 ft-lb)
2. Upper door hinge
3. Torx bolt, 30 Nm (22 ft-lb)
4. Stud , 23 Nm (17 ft-lb)
5. Cap

A58-0022 I
Rear door lower hinge
1. Bolt, 30 Nm (22 ft-lb)
2. Lower door hinge
3. Torx bolt, 30 Nm (22 ft-lb)

NOTE -
• Lubrication points indicated by arrows.

A58-0023 I

Door, removing and installing

NOTE -
• Front door removal described, rear door is similar
• To remove component carrier without removing door, see Door
component carrier, removing and installing in this repair group.

Remove bottom section of A-pillar trim. See 70 Interior Trim .

Disconn ect harness connectors at connection point on A-pillar.

Unclip rubber boot between front door and A-pillar and pull wiring
harness out from A-pillar.

""iii( Remove Torx bolts securing upper and lower hinges to door and
remove door with door component carrier.

Installation is reverse of removal. Remember to check door

adjustment. See Door gap, adjusting in this repair group.
57-4 Doors and Locks
Doors

Door gap, adjusting

NOTE-
• First adjust rear door (if necessary).
• Check gap dimensions using 3371 adjustment gauge
(or equivalent) .

Door gap dimensions

Dimension Specification

A 3 + 1/-0 mm (0.118 +0.039/-0 in)

B 4.5 ± 0.5 mm (0 .177 0 .019 in)
A57-0087 I
c 3.5 ± 0.5 mm (0 .138 0.019 in)

A Adjusting door longitudinally

' -
1.
2.
3.
Door hi nge
A-pillar
Door

Adjust door longitudinally by loosening hinge bolts on (A ) at upper

and/or lower door hinge and moving door in elongated holes in hinge
on A-pillar.

NOTE-
2
• Lower door hinge shown.
I A57-0104 I
Adjusting door flush with contour of body
A Adjust door inward or outward by loosening upper and/or lower door

'
hinge bolts (B) and moving door within elongated holes in hinge .

- Adjust the rea r end of door by altering the position of the striker plate
inward or outward .

Tightening torque

Door hinge to A-pillar 30 Nm (22 ft-lb)

Door hinge to door 30 Nm (22 ft-lb)

2
I A57-0 104 I
Adjusting door at striker plate

1 /(~ Use this adjustment only to align doo r inward or outward , not
vertically.

- Loosen bolts (2) and move striker plate (1) until door shell is flush
with contour of body.

Tightening torque

Striker plate bolts to body 20 Nm (15 ft-lb)

I

I ~aa l
2
 Doors and Locks 57-5
Doors

Door component carrier,

removing and installing

NOTE -
• Front door shown, rear door is similar.
• Door can be removed without removing component carrier. See
Door, removing and installing in this repair group.
• Before removing component carrier, mark position with felt-tip pen.

Remove door trim panel. See 70 Interior trim.

Disconnect harness connector and unclip harness from door

component carrier.

"'iiii( Remove component carrier mounting bolts (3 , 9 , 6 , and 4) . Lift

component carrier upward and out of door.

Before installing component carrier, check door adjustment. See

Door gap, adjusting in this repair group.

Insert component carrier into door and align with marks made

~4 previously.

Secure carrier loosely with bolts (3 , 4 , 6 and 9) and adjusting plate

(2 and 7) .

Shut door and check adjustments. See Door component carrier,

adjusting in this repair group.

- When adjustment is correct , tighten component carrier to door in

specified sequence (3 , 9 , 6 , 4) .

Tightening torque
I A57-0080 I
Door component carrier to door 30 Nm (22 ft-lb)
I
Door component carrier, adjusting
If reinstal ling door, adjust door first. See Door gap, adjusting
in this repair group.

Remove door trim panel. See 70 Interior Trim .

"'iiii( Align door component carrier by altering position of adjusting plate

at bottom of door. Make sure sealing lip (2) conforms to contour of
A-pillar and roof frame .

- Adjust door component carrier height.

If height adjustment is correct , loosen securing bolts at bottom of

door component carrier and press carrier (1) in toward center of
vehicle .

Push carrier in slightly further to compress rubber seal.

Position adjusting plate at 8-pillar as necessary.

A57-0 105 I - Tighten lower securing bolts to 30 Nm (22 ft-lb).

NOTE -
• Item 3 is the door glass.
57-6 Doors and Locks
Door Locks

~ Check adjustment using shop-made distance gauge.

1• b • 11

~a
- Make a distance gauge according to dimensions given below using
suitable material (e .g. plastic or wood) :
.._________,_
\
•Dimension a= 3.7 mm (0 .146 in)
•Dimension b = 28 .2 mm (1 .110 in)

- If door component carrier is correctly adjusted , gauge should

contact door window and roof trim molding when applied at a point
approx. 100 mm (3.94 in) from 8-pillar.

/ 1

Door seal, removing and installing

Remove trim panels at top and bottom of A and B-pillars together
with sill trim panel. See 70 Interior Trim .

- Pull door seal off door flange.

~ To install, place end of door seal PVC lip onto flange at marking X
(5 mm , or 0 .197 in) near B-pillar.

Press door seal (1) onto door flange all around door opening .

NOTE-
• Front door shown, rear door is similar.

DOOR LOCKS

Central locking service notes

- Lock actuators in the doors are integrated in the lock and have 2
electric motors.

- Lock actuators cannot be replaced separately.

- The first electric motor locks the door and the second locks the
interior door mechanism .

Locked doors can only be opened electrically from inside the car.

Lock actuators for the fuel filler flap and rear lid each have one
electric motor, and can be replaced separately.

- After an accident that activates an airbag , the control module for

central locking will unlock any active door locks.

- The control module for central locking is located in a protective box

beneath the driver's seat and carpet.

See 96 Interior Lights, Switches, Anti-theftfor locations of central

locking and anti-theft alarm components.
 Doors and Locks 57-7
Door Locks

Door handle and door lock assembly

1. Door handle mount
2. Lock cylinder
3. Fulcrum lever
4. Door handle
5. Door lock
6. Bolt (MS), 20 Nm (15 ft-lb)
7. Locating pin
8. Operating rod
9 -----7 9. Operating rod (door lock)

7 I A57-0090 I

Door lock, removing and installing

Remove door trim panel. See 70 Interior Trim .

Run door window up to top position.

- Disconnect harness connector for central locking at door lock.

~ Disengage operating rod (3).

1 4
- Remove combination bolts (1) and remove door lock (2) in

1 -
downward direction , between door component carrier and front
door shell .

Installation is reverse of removal. Note the following :

• When reinstalling door lock, disengage operating rod (3) at fulcrum
lever clip (arrow) .
• When installing new door lock, disengage operating rod (3) at
sliding sleeve (5).
57-8 Doors and Locks
Door Locks

Door handle, removing and installing

1. Door handle
2. Clip
3. Operating rod
4. Sliding sleeve
5. Locating pin
6. Door lock

- Remove door trim panel . See 70 Interior Trim .

- Run door window up to top position .

- Disengage operating rod at clip (2).

- Remove door handle.

- Installation is reverse of removal. Remember to :

•Attach operating rod to handle at clip (2).
• If installing new door lock, insert operating rod (3) and pull out
locating pin (5) (if equipped).
• Push up sliding sleeve (4) to lock operating rod (3) in place .
6 5 A57-009 1

Fuel flap lock actuator, removing and installing

- Disconnect filler flap lock actuator harness connector.

~ Loosen screws (2) . Push back lock actuator (1) and re move

- Installation is reverse of removal.

 Doors and Locks 57-9
Door Locks

Rear lid lock actuator, removing and installing

1. Release handle
2. Seal
3. Lock actuator
4. Handle mechanism
5. Lock cylinder

- Remove tailgate I trunk lid trim . See 70 Interior Trim .

- Remove lock. See 55 Hoods and Lids.

- Using screwdriver, press in and disengage locating hooks on left

release handle (1) in direction of arrow (A).

- Pull left re lease handle (1) downward out of handle mechanism (4 ).

- Remove Phillips-head screws (B) and remove lock actuator.

- Installation is reverse of removal.

I A55-0060 I
 60-1

60 Sunroof

GENERAL .. ... ... . .. . .. .... . . . . . . ... .. .. 60-1 Sunroof panel , removing and installing .. . .... 60-4
Function ..... ..... .... .... .. .. . . . . . .. .. 60-1 Sunroof trim , removing and installing . . . . . . .. . 60-4
Sunroof motor and switch , accessing . ....... . 60-1 Sunroof panel , adjusting .. . . .... . . .. ... ... 60-5
Sunroof emergency closing ..... . .. ... . . ... . 60-2 Sunroof panel seal , replacing . .......... . ... 60-6
Sunroof motor, setting zero position ...... . .. 60-6
SUNROOF SERVICE . .. . . ... . .. ..... . .. . .. 60-2
Sunroof guide plate , setting zero position ... .. 60-6
Wind deflector, removing and installing . . . ... . 60-2
Sunroof drain hoses , cleaning .. . .. . .... .. .. 60-7

GENERAL
This repair group covers sunroof repai r and adjustment procedures
including sunroof drain hose maintenance. The power sunroof is a
two-way design that tilts open or slides back in the roof.

Function
The su nroof is opened and closed by switching the ignition ON and
turning the rotary sunroof switch to the desired position . Push the
rotary switch to tilt the sunroof up, and pull to return it to closed
position.

The sunroof can also be opened or closed after turning the ignition
OFF, and before opening either front door. Should the sunroof
electronics malfunction or the veh icle lose battery power, the
sunroof can be closed manually. See Sunroof emergency closing

C\6~- ~
in this re pair group.

Sunroof motor and switch, accessing

To access the sunroof motor or rotary switch for testing or service ,
remove the switch panel from the headliner.

~ To access the rotary switch , use a plastic prying tool to pry cover off
switch panel (1) at front of panel (4) and remove switch.

- To access sunroof motor, use a plastic prying tool to pry cove r off
x---2 interior light (3) at back of panel (5).

[ i-3
l ~l l1 1i1 1l l l l l l l l l
I 1
r Hft 11 ff[ 1 11 r r f I

A ?0-022 1
5
60-2 Sunroof
Sunroof Service

Sunroof emergency closing

If the sunroof will not close electrically, it can be closed manually. An
emergency closing tool can be found on the inside of the fuse panel
cover.

~ Using a screwdriver (included in vehicle tool kit) , carefully pry interior

light housing from switch panel.

~ Insert Allen end of closing tool (1) into socket on sunroof motor (2)
as far as it will go. Crank sunroof closed .

SUNROOF SERVICE

Wind deflector, removing and installing

1. Screw w/washer
2. Sunroof motor
3. Frame
4. Wind deflector
5. Wind defector spring

- Slide back sunroof panel to fully open.

2 3 A60-004 5
 Sunroof 60-3
Sunroof Service

~ Press wind deflector (2) out of holder (3) in direction of arrow.

- Pull wind deflector backward and out of roof cut-out.

A60-0035
1

~ Install wind deflector by hooking spring (3) onto retaining pin (2).

- Insert other end of spring into groove of wind deflector.

A60-0037 I
~ Push stop (1) of wind deflector (2) forward below roof cut-out .

- Insert retaining pin of wind deflector into holder (3).

- On opposite side, push deflector in toward center of vehicle and lock

other retaining pin into holder.

A60-0035
1
60-4 Sunroof
Sunroof Service

Sunroof panel, removin g and installing

1. Sliding headliner
2. Sliding headliner spring
3. Lower trim
4. Upper trim
5. Sunroof panel
6. Sunroof panel sleeve
7. Countersunk screw

Remove sliding headliner by removing screws (7) and front and rear.

Push front spring (2 ) forward and rear spring backward off sliding
headliner an d remove springs.

Pull sliding headliner sideways out of opposite guide rail and lift out.

- Open sunroof to tilt position .

- Remove trim on left and right sides. See Sunroof trim, removing
and installi ng in this repair group.
A60-0033

~ Unscrew Torx bolts (T25) on both sides and lift panel out from top.

- Installation is reverse of removal. Remember to :

• Make sure sunroof motor and sunroof guide plate are set to zero
position. See Sunroof motor, setting zero positionand Sunroof
guide plate, setting zero position in this repair group.
•Adjust sunroof panel height (if necessary) . See Sunroof,
adjusting in this repair group.

Ti ghten ing torque

Sunroof faste ners to sunroof panel 4.5 + 0.5 I -0 Nm
(40 + 4.4 I -0 in-lb)
I
A60-0036 I

Su nroof tri m, removing and installing

- Open sunroof to tilt position.

- Push sliding headliner fully back.

~ Unclip lower trim (1) at rear in direction of arrow (A) and slide it
forward (B).

Pull lower trim off guide rail toward center of vehicle .

Unclip upper trim (2) at front and center in direction of dashed arrow.

u-
G

1 A60-0047 I
 Sunroof 60-5
Sunroof Service

~ To install , press lower trim (1) onto upper edge (arrows) of guide rail
(2).

A60-0049

~ Press lower trim (1) backward in direction of arrow until locating

hook locks into actuator (2).

Press upper trim into guide plate.

1
2
A60 -0048

Sunroof panel, adjusting

- To avoid wind noise , adjust sunroof panel at front and rear as shown .

- Check height adjustment at points where rounded corners merge

with strai ght parts of roof cut-out at front and rear.

NOTE -
• Lower arrow points toward front.

~ Sunroof panel should not be higher than the roof at any point at the
E E front or lower than the roof at any point at the rear.
E ~
E
Run sunroof from open position (i.e , not tilted open) to closed
~ 6~ position and adjust according to specifications .

~ ,------11---:r;:::===;t==

V60-0075
60-6 Sunroof
Sunroof Service

Sunroof panel seal, replacing

Remove sunroof panel. See Sunroof panel , removing and
installing in this repair group.

~ Pull seal (2) out of sunroof panel (3) .

1 2 3
- Press new seal into sunroof panel , starting from center of rear edge
of panel.

- To aid installation , lubricate edge of sunroof panel with soapy water.

A60-0042

Sunroof motor, setting zero position

Set sunroof motor zero position before installing motor in frame.

- With sunroof motor removed , attach electrical harness connector to

motor and move rotary control to fully closed position.

Sunroof winds to zero position and cuts out automatically.

- Install motor in this position with sunroof closed.

Sunroof guide plate, setting zero position

Set guide plate zero position before installing sunroof panel. Guide
plate zero position can be checked using a pocket mirror and a
flashlight, with the sunroof panel installed .

Checking zero position

Remove sunroof trim. See Sunroof trim, removing and installing

in this repair group.

Run sunroof panel back and then into closed position .

Push sliding headliner fully back.

- Shine flashlight on sunroof panel and visually check zero position

from the side.

~ Guide plate zero position is correctly set if the square hole in the tilt
mechanism of the guide plate (1) is aligned with the recess (arrow)
in the guide rai l (2) .
 Sunroof 60-7
Sunroof Service

Setting zero position

Remove sunroof panel. See Sunroof panel, removing and

installing in this repair group.

Remove sunroof motor.

Remove sunroof trim. See Sunroof trim, removing and installing

in this repair group.

- Slide guide plates (1) on both sides from rear to front.

~ Align square hole in tilt mechanism of guide plate (1) with recess
(arrow) in guide rail (2) for sliding headliner.

This is ze ro position.

Reinstall sunroof motor.

Reinstall sunroof panel and trim .

Sunroof drain hoses, cleaning

Sunroof drain hoses should be checked periodically. Blocked drain
hoses can allow water to enter the interior of the vehicle . To clean
drain hoses a long cable is needed. An old speedometer inner cable ,
approx . 2300 mm (90 in) long will work for this.

~ Front water drain hoses (1) are routed in the A-pillars and exit
between the door and A-pillar. Cleaning is perfo rmed from sunroof
cut-out .

- Rear water drain hoses (2) are routed in the C-pillars and exit behind
the bumper cove r at side. Remove bumper cover and clean from the
lower end of hose . See 63 Bumpers for more information .

/1 J

......................-·······"'"::::'.,:::.)······
( .
2
I j

(' (
I'

I \
' II
''/ I A60-0050 I
 63-1

63 Bumpers

GENERAL ... . .... .... ......... . .. ... .... 63-1 REAR BUMPER . . .. ........ . ... . ......... 63-3
Rear bumper assembly ... . ..... ... ....... . 63-3
FRONT BUMPER .............. ..... . ..... 63-1
Rear bumper cover, removing and installing 63-3
Front bumper assembly .. . . .... .. . .... .. .. 63-1
Rear crossmember, removing and installing ... 63-4
Front bumper, removing and installing .. .. .. .. 63-2
Front bumper impact absorber,
removing and installing .. .... ...... . ..... 63-2

GENERAL
This repair group covers removal and installation of the front and
rear bumper components. The bumpers consist of a bumpe r cover
and crossmember bolted to impact absorbers . The front bumper
must be removed to extend the lock carrier assembly (radiator
support) into service position . See 50 Body-Front for more
information .

FRONT BUMPER

Front bumper assembly

1. Bumper cover
2. Gu ide
3. Fender
4. Clip
•Bumper cover tab (1) must latch into clip (4)
5. Wh eelhousing liner
6. Screw w/washer
7. Bolt, 23 Nm (17 ft-lb)
8. Air inlet grill
9. Air in let grill
10. Flanged nut, 6 Nm (53 in-lb)

I A63-0026 I
63-2 Bumpers
Front Bumper

Front bumper, removing and installing

NOTE-
• Bumper cover is removed along with crossmember.

Remove front tires.

Loosen fasteners securing front half of wheelhousing liners to

bumper.

- Remove screw w/washer (6) from wheelhousing liner (5) .

~ Unscrew flanged nuts (10) inside wheel housing on both sides.

- Remove bolts (7) and remove bumper cover together with

crossmember toward front.

NOTE-
• Before installing the bumper, make sure expanding clips are in
'lil I place on fenders .
• Make sure bumper cover tabs latch into clips on fenders.
A .. ~3
,s;'' ···· ·~ 2 - To install , align bumper cover onto impact absorbers.

- Latch bumper cover (1) into guide (2).

I
, ::r ~1·1
- Tighten flanged nuts (10) in wheel housing .
•'/."Jill
h /, 1 - Tighten bolt (7) holding bumper cover to impact absorber.
:1.· /1v--
"l 1'
Tightening torque
2 .II
Bumper cover to inner fender 6 Nm (53 in-lb)

Bumper cover to impact absorber 23 Nm (17 ft-lb)

I A63-0026 I

Front bumper impact absorber,

removing and installing
Remove bumper. See Bumper, removing and installing in this
repair group.
I

~ Remove bolts (2) from impact absorber.

0 Remove nut (3) and remove impact absorber.

-1 Installation is reverse of removal.
0
Tightening torques

Impact absorber retaining nut 4 Nm (35 in-lb)

Impact absorber to body 50 Nm (37 ft-lb)

A63-0033 I
 Bumpers 63-3
Rear Bumper

REAR BUMPER

Rear bu mper assembly

2 3
1. Bolt w/washer, 23 Nm (17 ft-lb)
2. Impact absorber
3. Crossmember
4. Lower back panel
5. Self-tapping screw
6. Bumper cover
7. Guide
8. Screw w/washer
9. Wheelhousing liner
10. Flanged nut (2x) , 6 Nm (53 in-lb)
11 . Flanged nut (2x) , 6 Nm (53 in-lb)
12. Seal

I A63-0028 I

Rea r bu mper cover, removing and installing

NO TE -
• Bumper cover is removed independent of crossmember.

Partially remove luggage compartment trim to expose bumper cover

fasteners. See 70 Interior Trim .

.;;;;;( Unscrew flanged nuts (10) accessible through luggage

2 3 compa rtment.

Remove flanged nuts (11) accessible through trunk under taillight.

Remove rear bumper cover.

- Installation is reverse of removal.

I A63-0028 I
63-4 Bumpers
Rear Bumper

Rear crossmember, removing and installing

- Remove bumper cover. See Rear bumper cover, removing and
installing in this repair group.

'-. 1i3
I ! I
-
Remove bolt w/washer (2) from each impact absorbe r (1) and
remove crossmember (3).

Installation is reverse of removal.

Tightening torque
Crossmember to impact absorber 23 Nm (17 ft-l b)
 64-1

64 Door Windows

GENERAL ..... . ................ . . . ...... 64-1 Front door window, removing and installing ... . 64-2
Window motor reinitializing .... . .... .. ... . .. 64-1 Rear door window assembly .... . ... . .. . .. . 64-3
Warnings and Cautions . . ........ . ..... . . . 64-1 Rear window regulator, removing and installing . 64-3
Rear door window, removing and installing .. . . 64-3
DOOR WINDOW GLASS SERVICE . .. ....... 64-2
Front door window assembly .... . ...... . .. . 64-2 WINDOW MOTOR SERVICE . . . . . . . . . . . . . . . . 64-4
Front window regulator, removing and installing. 64-2 Window motor, removing and installing . . . ... . 64-4

GENERAL
This repair group covers replacement of door glass, window
regulator and power window motor. Replacing the windshield or rear
glass requires special glue and tools and is not covered.

For additional information see:

• 57 Doors and Locks for door component carrier
• 70 Interior Trim for interior door panel
• 96 Interior Lights, Switches, Anti-theftfor door window switches

Window motor reinitializing

If the battery is disconnected , the window control module loses its
memory of window current position and disables one-touch
automatic up I down function. To restore one-touch operation:

- Switch ignition ON .

- Use window switches to raise windows to top.

- Operate each window switch in CLOSE direction for 1 second to

reinitiali ze one-touch operation .

Warnings and Cautions

WARNING -
• When working on door window, disconnect the harness
connector to the window regulator to prevent pinching fingers
in the moving window mechanism.
• Wear hand and eye protection when working with broken glass.
• If a window is broken, vacuum all of the glass bits out of the
door cavity Use a blunt screwdriver to clean out any remaining
glass pieces from the window guide.

CAUTIO~
• To avoid damaging interior trim , use a plastic prying tool or a
screwdriver with the tip wrapped with masking tape.
64-2 Door Windows
Door Window Glass Service

DOOR WINDOW GLASS SERVICE

Front door window assembly

1. Door component carrier
2. Window regulator
3. Mount
4. Torx bolt, 4.5 Nm (40 in-lb)
5. Pop rivet (a, b , c , d = 4.8 mm , e = 6.0 mm)
6. Door window

Front window regulator,

removing and installing
Remove door trim . See 70 Interior Trim .

Remove door component carrier. See 57 Doors and Locks.

- Drill heads off pop rivets (5) , knock out rivet stems and detach
window regulator.

- Shake door component carrier so that pop rivet stems fall out.

- To install, fasten rivets (5) in order (a , b, c , d and e) using pop rivet

pliers (note different rivet diameters) .

Front door window, removing and installing

- Run window down to bottom position .

- Remove door trim . See 70 Interior Trim.

- Remove door component carrier. See 57 Doors and Locks.

- Mark longitudinal position of window at both mounts (3) using felt-tip

pen .

- Remove clamp bolts (4) and lift window out of mount (3).

- To install original window, insert window into window regulator and

align with marks made previously.

- Tighten clamp bolts (4).

- To install a new window, insert window into guide and push it back
toward B-pillar as far as it will go.

- Move window upward as far as stop using window regulator without

bolt (4).

- Close mount (3) and tighten clamp bolts (4) .

Tightening torque
Front window clamp bolt to mount 4.5 Nm (40 in-lb)
 Door Windows 64-3
Door Window Glass Service

Rear door window assembly

1. Door component carrier
2. Window regulator
3. Pop rivet (a= 4.8 mm , band c = 6.0 mm)
4. Door window
5. Locating bracket
6. Carrier
7. Bolt, 2.5 Nm (22 in-lb)
8. Buffer
•After inserting , press in clamping pin (9)
9. Clamping pin

Rear window regulator, removing and installing

Remove door trim . See 70 Interior Trim .

Remove door component carrier. See 57 Doors and Locks .

Drill heads off pop rivets (5) , knock out rivet stems and detach

M~I
window regulator.

- Shake door component carrier so that pop rivet stems fall out.
7 6 5 4 I A58 -00 19 I
- To install , install rivets (5) in order (a , b , and c ) using pop rivet pliers
(note different rivets diameters) .

Rear door window, removing and installing

Run window down to bottom position.

Remove door trim . See 70 Interior Trim .

Remove door component carrier. See 57 Doors and Locks.

Mark position of window in vertical and longitudinal directions at

mount using felt-tip pen .

- Remove clamp bolt (7) and lift window out of carrier (6) .

- To install original window, insert window into window regulator and

align with marks made previously.

- Tighten clamp bolt (7).

- To install a new window, insert window into guide and push it fo rward
toward B-pillar.

- Make sure sealing lips of window channel strip are not pressed
downward .

- Run window up to top stop using window regulator without install ing
clamp bolt (7) .

- Tighten bolt clamp bolt (7).

Tightening torque

Rear window clamp bolt to mount 2.5 Nm (22 in -lb)

64-4 Door Windows
Window Motor Service

WINDOW MOTOR SERVICE

Front window motor removal shown . Rear window motor removal is
similar.

Window motor, removing and installing

Remove door trim. See 70 Interior Trim.

Disconnect electrical connecto r from window motor.

~ Remove bolts (arrows) and remove window motor.

- Installation is reverse of removal. Note the following:

• Window regulator motor can be installed or removed with motor
and window in any position .
•After installing motor and wiring , turn ignition ON and OFF.
• lntitalize window motor. See Window motor initializing in this
repair group.

Tightening torques
Window regulator motor to bracket 6.5 Nm (58 in-lb)
 66-1

66 Body-Exterior Equipment

GENERAL ..... .. . . ... . . . . . . .. . ... . .... . . 66-1 EXTERIOR REAR VIEW MIRROR . .. .. . . _ . . . 66-3
Exterior rear view mirror,
WHEEL HOUSING LINERS ... .. ... . .. .... .. 66-1
components and service . . . . . . . . . . . . . . . . . 66-3
Front wheel housing liner assembly .. ....... . 66-1
Exterior mirror housing , replacing ...... . . . . . 66-4
Front wheel housing liner,
Power mirror motor, replacing ....... . . ..... 66-4
removing and installing .. ....... . .. .. ... . 66-2
Rear wheel housing liner assembly . .. . . ... .. 66-2
Rear wheel housing liner,
removing and installing . ..... ... ....... .. 66-3

GENERAL
This rep air group covers wheel housing liners and outside rear view
mirrors. For related information see the following repair groups :
• 63 Bumpers
• 94 Exterior Lights

WHEEL HOUSING LINERS

Front wheel housing liner assembly

1. Fen der
2. To rx bolt (T25) , 1.5 Nm (13 in-lb)
3. Wh eel housing liner, front
4. Expanding nuts (13x)
5. Sil l panel trim

I} I v /
· ~.
I A66-00 60 I
66-2 Body-Exterior Equipment
Wheel Housing Liners

Front wheel housing liner,

removing and installing
- Raise car and support safely. Remove wheel.

WARNING-
• Make sure care is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

' - Release expanding fastene rs (6).

- Remove Torx bolts (2) (3x) .

- Disengage wheel housing liner from fender and pull out in

downward direction .

- Installation is reverse of removal.

I A66-0060 I

Rear wheel housing liner assembly

1. Rear wheel housing liner
3 ~_J~ 2. Self-tappi ng screw, 1.5 Nm (13 in-lb)
7i I~~-
1

I
.J
. I
4
r
1
3.
4.
Expanding nut
Cap nut, 1.5 Nm (13 in-lb)

f(
 Body-Exterior Eq uipment 66-3
Exterior Rear View Mirror

Rear wheel housing liner,

3 removing and installing
Raise car and support safely. Remove wheel.

WARNING -
• Make sure care is stable and well supported at all times. Use
a professional automotive lift or ja ck stands designed for the
purpose. A floor jack is not adequa te support.

Remove screws (2) and cap nut (4).

Pull wheel housing liner out in downward direction and remove .

Installation is reverse of removal.

EXTERIOR REAR VIEW MIRROR

Exterior rear view mirror components

and service
1. Mirror housing
• Can be removed from door without disassembling complete
rear view mirror.
2. Mirror motor
• Before removing , disassemble rear view mirror from door
• Carefully pry off mirror glass and disconnect harness
connectors for mirror heater. Unscrew Phillips head screws
(6) and remove motor unit from mirror housing (1 ).
------ 6 • On vehicles with seat memory , remove door trim panel before
disassembling mirror motor.
3. Door component carrier
4. Socket-head screw , 12 Nm (9 ft-lb)
5. Seal
6. Phillips head screw, 1 Nm (9 in-lb)
7. Mirror glass
•U se special tool 80-200 lever to unclip mirror glass
•P rotect mirror housing from damage by applying fabric
reinforced adhesive tape at top and bottom of housing
8 • Press off mirror glass , first at botto m then at top .
I A66 -0043 I
• To install , insert mirror glass into guide stud and friction finger
into friction spring and press on.
• Press only on center of mirror (always use protective gloves).
8. Friction finger
• When installing mirror glass , friction finger (8) must be
inserted into friction spring (9) in housing
9. Friction spring
66-4 Body-Exterior Equipment
Exterior Rear View Mirror

Exterior mirror housing, replacing

Remove mirror glass. See Exterior rear view mirror components
and service in this repair group.

~ Remove screws (4) .

Press back locking lugs (2) and detach cover (3) downward.

Remove screws (1) at mirror motor.

- Lift off housing (5) upward .

A66-0013 I

Power mirror motor, replacing

- Disconnect battery negative(-) cable .

- Remove mirror glass. See Exterior rear view mirror components

and service in this repair group.

~ Remove screws (1).

- Remove mirror motor harness connectors (if equipped).

NOTE-
• If mirror motor has soldered wiring, electric leads must be
separated individually directly at the housing.

Install wiring in connector housing supplied with replacement part.

NOTE-
• Note configuration of wiring on old motor. See EWD Electrical
Wiring Diagrams .
 69-1

69 Seat Belts, Airbags

GENERAL .. .. . ..... . .. . .. ... ........ .... 69-1 Rear seat belt adjuster, removing . .. . ... . ... 69-7
Child seat anchors .. .... .. . . . .. .. . ....... 69-1 Rear belt floor panel attachment points ....... 69-8
Rear side airbags ........ .. ............. . 69-1 AIRBAGS ..... .. .. ........ ... .. . .. ... . . 69-10
Seat belt inspection . .... ... . ......... . .. . 69-2 Airbag components .. . .... . ... ....... ... 69-1 O
Warnings ... ..... ................... . ... 69-4 Airbag control module (J234) ,
SEATBELTS .. .. .......... ........ ..... . 69-5 removing and installing .. . .... .. .... . .. . 69-10
Component overview . . . . . . . . . . . . . . . . . . . . . 69-5 Driver's front airbag,
removing and installing 69-11
Front seat belt, removing and installing ... .... 69-5
Passenger front airbag ,
Belt latch , removing and installing . . .... . .... 69-6
removin g and installing 69-12
Rear seat belt, removing and installing .... ... 69-7

GENERAL
This repair group covers emergency tensioning (pyrotechnic) seat
belt assemblies and airbag system components. It does not cover
airbag system or pyrotechnic seat belt fault diagnosis or repair.
Service and repair to these systems requires special test
equipment, knowledge and training and should only be carried out
by and authorized Audi Dealer. Before starting repairs involving
these systems, always read and observe all warnings , cautions and

I
notes in this repair group.

Child seat anchors

Vehicle manufactures are required to have an anchorage point
installed in vehicles to facilitate installation of a tether strap for child
seats. Lower anchorages were originally designated as "ISOFIX"
points. Lower anchor points in combination with upper tether anchor
points are known as "Lower Anchor and Tether for CHildren" or
simply "LATCH" points. For information regarding proper installation
of child seats booster seats, infant seats, and restraints , always
consult vehicle owner's manual or authorized Audi dealer.

Rear side airbags

If special situations require , your dealer can disconnect the rear side
airbags upon request. For more information , see your owner's
manual or authorized Audi dealer.
69-2 Seat Belts, Airbags
General

Seat belt inspection

Seat belts should periodically be checked for proper operation , wear
and damage. Check points include visual and operational inspection
of the following :
•Belt webbing .
•Automatic retraction (stop function).
• Belt latch mechanisms.
•Guide stop and seat belt locking tongue
• Anchoring points and components.

WARNING -
• After an accident, be sure to inspect seatbelts carefully and
replace damaged ones.

Belt webbing
Pull belt webbing completely off automatic belt retractor.

Check belt webbing for soiling and wash with mild soap and wate r
solution as needed . Avoid harsh chemical solutions.

<iiiiii{ Inspect webbing for damage.

A. Webbing cut , torn or chafed .
B. Webbing loops on belt edges torn.

A B C. Burned spots from cigarettes or other sources.

D. One side of belt edge deformed , or area of belt edge is wavy or
rolled over.

- A , B - If noted in a post-accident inspection , replace complete belt

assembly and height adjuster where applicable.

- A , B , C , D, - If noted during routine inspection and vehicle has not

c D
been involved in an accident, replace damaged parts as needed .

Automatic retraction (stop function)

Once activated, pyrotechnic seat belts will not retract. These units
are no longer functional and require replacement.

The automatic belt retractor has two locking functions triggered by

either occupant or vehicle movement.

- Function 1 (occupant movement) : Locking is triggered by rapid

unrolling of belt from automatic belt retractor reel (belt extraction
acceleration) .
• To check , pull belt out of automatic belt retractor with firm jerk. Seat
belt should lock while being pulled out. If not, replace seat belt and
belt latch .

NOTE-
• If problems are noted during function test 1, check
mounting/installation position of automatic retractor. Incorrect
installation position can influence operation.
 Seat Belts, Airbags 69-3
General

Automatic retraction (stop function) continued

- Function 2 (vehicle movement): Locking function triggered by a

change in vehicle movement (vehicle-dependent locking function).
•To check , securely fasten belt and drive vehicle on a clear, level ,
even surface to a speed of 12 mph (20 kph) .
•Apply brake pedal fully in a panic-style application .
•Seat belt should lock as vehicle suddenly stops while braking . If
not, replace seat belt and belt latch .

WARNING-
• For safety reasons, perform road test in an area without
traffic, pedestrians, or obstacles such as curbs, light and sign
poles, or parked vehicles.

Belt latch mechanisms

Inspect seat belt latch for cracks and fractures .

•If damaged , replace seat belt and belt latch.

Check operation of seat belt tongue into latch by inserting until an

audible engagement is heard. Pull seat belt webbing forcefully to be
sure of proper engagement in lock mechanism.
• Repeat test at least five (5) times . If seat belt fails to engage even
once , replace seat belt and belt latch.

Check release operation by pressing release button with finger while

seat belt is in a relaxed state. Locking tongue must spring out of seat
belt lock completely and without assistance.
• Repeat test at least five (5) times. If seat belt fails to release even
once , replace seat belt and belt latch .

WARNING -
• Do not lubricate seat belt tongue, buttons, or release
mechanisms to repair noises or stiffness.

~ Inspect seat belt extender (if equipped) lock tongue (2) and belt latch
mechanisms (1) for the same conditions found with seat belt latch
mechanisms and seat belt lock tongue.

Guides and seat belt lock tongue

Inspect all plastic coated seat belt guides and plastic coating on seat
belt lock tongue. Check for deformation , cracking , tearing and wear.
• If damaged , replace seat belt and belt latch .

Anchoring points and components

- Visually inspect and functionally test lock strap, height adjuster and
anchor points on seats , pillars, and floor. Check for deformation ,
secure and correct mounting , and proper operation .
B7L-0321 • If damage is found at components , replace seat belt and belt latch.
• If dam age is found on anchoring points, replace components as
required .
• If damage is found from general wear and not due to accident,
replace only damaged component(s) .
69-4 Seat Belts, Airbags
General

Warnings
~ In addition to the warnings listed below, watch for airbag identifica-
tion tags at various locations around the vehicle interior. The number
and placement of tags varies with vehicle equipment.

WARNING-
• Always disconnect the battery ground(-) strap before starting
to work on airbag or pyrotechnic seat belt systems. Work can
begin immediately after disconnecting battery No waiting time
is needed.
• Never let anyone sit in passenger compartment when the airbag
or seat belt system is being worked on, especially when either
system is being connected to a power source or the battery
• Never test, remove, repair or install airbag units or pyrotechnic
seat belts or work on either system unless you have proper train-
ing, qualifications and tools to do the work safely and correctly
•Always discharge static electricity from your body before
handling or even touching an airbag unit. Place your hands on a
suitable metal object that is grounded such as a water or heating
pipe or metal frame.
• Never use impact wrenches to remove airbag or pyrotechnic
seat belt tensioners.
•Always install airbag unit immediately after removing it from its
shipping container.
• If installation work is interrupted, immediately return airbag unit
to its original packaging.
• Never leave an airbag unit unattended. If work is interrupted, al-
ways return airbag unit to original packaging or shipping conta iner.
• Never place airbag unit on a workbench or other surface with the
side that points towards inside of passenger compartment facing
down. If airbag unit should deploy, it can cause personal injury
Always make sure that the side of the airbag unit that faces
passenger compartment faces up.
• Never install airbag or pyrotechnic seat belt units that have
dropped onto a hard surface, or which have signs of damage.
• Never open or attempt to repair airbag or seat belt tensioner
components; always use new parts (danger of injury).
•Always replace airbag and seat belt tensioner units which have
experienced mechanical damage (dents, cracks).
•Always put airbag units that have not deployed or have not
completely deployed in original airbag shipping container and
mark outside of container so that others will know that there is
still a possibility of airbag deployment.
• Always store and handle airbag units according to all applicable
legal requirements.
• Seat belt pyrotechnic ignition charge does not have an expiration
date, i.e. it has an infinite shelf life and is maintenance free .
• Never treat a pyrotechnic seat belt tensioner unit with grease,
spray lubricants, cleaning products or similar products.
•Do not expose pyrotechnic seat belt tensioner or airbag units to
temperatures above 212°F (100 °C) even for a few seconds.
•Airbag and pyrotechnic seat belt tensioner storage and
transportation are covered under several explosive substance
laws. Always be aware and observant of applicable regulations.
 Seat Belts, Airbags 69-5
Seat Belts

SEAT BELTS

4 Component overview
1. 3-point seat belt with belt height adjuster and belt tensioner
2. Attachment point for belt latch
3. Outer floor panel attachment point
4. 3-point seat belts , rear left and right
5. 3-point seat belts , rear center
6. Center floor panel attachment points

2 6 I A69-0078 I

Front seat belt, removing and installing

1. Belt tensioner
2
2. Belt height adjuster
5 3. Bolt, 55 Nm (41 ft-lb)
7 4. Shouldered nut, 55 Nm (41 ft-lb)
10 5. Upper B-pillar trim
4
6. Lower B-pillar trim
7. Bolt, 23 Nm (17 ft-lb)
8. Bolt, 55 Nm (41 ft-lb)

9 9. Belt tensioner connector

10. Button for height adjuster
I
11. Anti-twist tab
,.
A . ~l

Removing three-point seat belt

- Disconn ect battery negative(-) cable .

Remove si ll trim. See 70 Interior Trim .

1a 3 8 Remove lower belt bolt (3) .

A69-0059 Remove upper B-pillar trim (5) and lower B-pillar trim (6).
See 70 Interior Trim .

Remove shouldered nut (4).

Disconnect connector (9) at belt tensioner.

Remove bolt (8) .

Lift belt tensioner (1 or 1 a) out of tab (11 ).

69-6 Seat Belts, Airbags
Seat Belts

Installing 3-point seat belt:

<iiiiii{ Insert belt tensioner (1 or 1 a) in anti-twist element, as shown in

2~ --- 5
magnified view (11 ).

Install webbing with a 180° turn (arrow) as shown in illustration.

7 . :.
NOTE-
• Arrow (A) points in direction of travel.

Remainder of installation is reverse of removal. After install ing ,

make sure 3-point seat belt is not impeded . Check belt-fastened
sensor (if equipped) using VAS 5051 or equivalent.

Removing belt height adjuster

Remove upper 8-pillar trim (5). See 70 Interior Trim .

Remove shouldered nut (4) and bolt (7).

Lift out belt height adjuster (2).

1a 3 8 Installation is reverse of removal. Check that:

• Belt operates properly after installing trim .
A69-0059 • Height adjuster engages audibly in each of 5 possible positions
(including top position) .
• Height adjustment fitting returns by itself to up position after be ing
pressed .
• After tighten ing shouldered nut, guide fitting automatically settles
in correct direction .

NOTE-
• Do not press button (10) when installing.

Belt latch, removing and installing

Remove seat. See 72 Seats.

<iiiiii{ Remove bolt (2) from belt latch (1) .

Installation is reverse of removal.

NOTE-
•lt is possible that seat occupation recognition and seat belt
fastened sensor have been installed between VIN 4BWN 024500
and 4BWN 033300 that are without function.
• When replacing a seat belt latch on vehicles in the above
mentioned VIN range, install a belt latch without a "belt fastened "
detector.
•On vehicles with a "belt fastened" detector and belt latch switch
(only on drivers side, in models for some countries), remove wires
from red connector housing.

Tightening torque
Lower belt latch bolt 24 Nm (18 ft-lb )
 Seat Belts, Airbags 69-7
Seat Belts

Rear seat belt, removing and installing

1. Belt tensioner
2. Bolt , 55 Nm (41 ft-lb)
3. Belt guide trim
•Large symbol must always face center of vehicle .
4. Belt adjuster trim
5. Bolt, 55 Nm (41 ft-lb)
6. Belt tensioner connector
7. Belt adjuster
8. Tab

- Remove rear seat bench. See 72 Seats .

- Remove bolt (2).

- Unclip belt guide trim (3) .

Pry off belt adjuster trim (4) on left and right at tab (8) .

Remove rear shelf (with folding backrest). See 70 Interior Trim .

- Disconn ect connector (6) at belt tensioner.

A69-0060

- Open cover for luggage compartment side trim .

- Vehicles with CD player and I or subwoofer or similar: Remove

trunk I tailgate side trim . See 70 Interior Trim.

Remove bolt (5).

Installation is reverse of removal. Check belt-fastened sensor

(if equipped) using VAS 5051 or equivalent.

Rear seat belt adjuster, removing

The rear shelf does not have to be taken out in order to remove the
rear seat belt adjuster.

~ Unfasten lower attachment point of rear 3-point seat belt. See Rear
seat belt, removing and installing in this repair group.

- Unclip belt guide trim (3) .

- Pry off belt adjuster trim (2) on left and right at tab (7) .

- Raise arm of belt adjuster (4) with webbing.

69-8 Seat Belts, Airbags
Seat Belts

~ Use screwdriver to press retainer tabs (1) inward and at the same
time pull belt adjuster (2) upward.

- Pull webbing through belt adjuster (2).

~ To install , make sure retainers (1) engage properly.

- Make sure rear stud engages in recess (6).

- Locating element (5) must face center of vehicle.

Tightening torque

Rear belt lower bolt to body 55 Nm (41 ft-lb)

I

Rear belt floor panel attachment points

1. Latch
2. Lap belt
3. Lap belt with retractor
4. Bolt, 55 Nm (41 ft-lb)
• Use OEM bolts.
5. Seal
• Always replace

- Remove rear seat bench . See 72 Seats.

- Remove bolt (4).

- When installi ng, make sure latch and/or lap belt engage(s) in
anti-twist projections.

- Narrow side of latch and/or lap belt must face in direction of travel.
 Seat Belts, Ai rbags 69-9
Seat Belts

Rear seat belt attachment points (Avant)

1. 3-point seat belts, rear left and right (Avant)
2. 3-point seat belt, rear center
3. Center floor panel attachment points

3 2 3

A69-0093

Rear seat belt attachment points (children's bench)

1. Rear 3-point seat belts for children's bench
2. Center rear attachment point for children 's bench
3. Outer rear attachment points

3 2 3

A69-0094
69-10 Seat Belts, Airbags
Airbags

AIRBAGS

Airbag components
1. Airbag unit - drivers side
2. Airbag unit drivers side (sport steering wheel )
3. Airbag control module
4. Not applicable for USA/Canada
5. Passenger airbag unit
6. Not applicable for USA/Canada
7. Side curtain airbag , Sedan
8. Side curtain airbag , Avant
9. Front side airbag
10. Lateral acceleration sensor
11. Rear side airbag (folding backrest)
12. Rear side airbag (fixed backrest)
13 10 9 12 11 12 11 13. Data link connector (DLC)

A69-0229

Airbag control module (J234),

removing and installing
- Disconnect battery negative (-) cable.

- Remove front section of center console. See 70 Interior Trim .

- Remove connecting pieces for air ducts to rear left and right footwell
vents.

~ Through production date August 1999:

• Release retainer on connector (2) .
•Pull connector (2) out of control module (1 ).
•Remove nuts (3) .
• Remove control module

~ From production date September 1999 on :

•Open cable ties (4).
• Remove nuts (3).
• Pull out control module (1 ).
• Release retainer on connector (2) .
• Pull connector (2) out of control module (1 ).
• Remove control module

- Installation is reverse of removal. Note the following:

• If control module is replaced , it must be coded .
• If airbag warning light remains on , erase OTC memory using VAS
5051 or eq uivalent.

Tightening torque

Airbag control module (J234) to body 6 Nm (53 in-lb)

 Seat Belts, Airbags 69-11
Airbags

Driver's front airbag,

removing and installing
1. Steering wheel
2 3
2. Connector for self-canceling ring
3. Connector for airbag unit
4. Bolt (always replace)
•Allen head , 60 Nm (44 ft-lb)
•Hex head , 70 Nm (52 ft-lb)
5. Airbag unit
6. Threaded inserts
4 7. To rx bolts T30 (if equipped) , 7 Nm (62 in-lb)
8. Torx wrench T30
9. Self-canceling ring with slip ring
10. Connector for heated steering wheel

Disconn ect battery negative(-) cable.

Release steering column adjuster. Extend steering column out and

upward as far as possible .

Move steering wheel so that hub and spokes are vertical.

7 6 5
Release one Torx bolt (7) .
A69-0 11 9
Move steering wheel back 1/2 turn and release second Torx bolt (7).

Release electrical connectors from airbag unit.

Lay airbag down with padded side facing upward .

Installation is reverse of removal. Remember to :

•Make sure electrical connectors fully (audibly) engage .
•Reset vehicle equipment (radio, clock , power windows) as per
owner's manual.
• Re-connect battery and switch ignition ON.
• If airbag warning light remains on , erase OTC memory using VAS
5051 or equivalent.

WARNING -
• Make sure no one is in vehicle when reconnecting battery.
69-12 Seat Belts, Airbags
Airbags

Passenger front airbag,

removing and installing
1. Passenger front airbag unit
2. Support
• Must be replaced if airbag has triggered
3. Nut (2x) , 18 Nm (13 ft-lb)
•Must be replaced if airbag has triggered
4. Nut (4x) , 9 Nm (80 in-lb)
• Must be replaced if airbag has triggered
5. Bolts (4x) , 9 Nm (80 in-lb)
• Must be replaced if airbag has triggered
6. Connector
7. Frame for airbag unit
• Must be replaced if airbag has triggered
8. Nut (3x) , 4.5 Nm (40 in-lb)
9. Bolts (3x) , 4.5 Nm (40 in-lb)
10. Bolt (1 x) , 4.5 Nm (40 in-lb)
11. Backing plate

I
4 5 I A69-0068 I
-

-
Disconnect battery negative(-) cable.

Remove glove box . See 70 Interior Trim.

- Disconnect electrical connector (6) . See Disconnecting

passenger airbag connector in this repair group.

WARNING-
• Never disconnect red 2-pin connector on front side of airbag.

Remove nuts (4) and remove airbag unit.

- Set down airbag unit with padded side facing upward.

- Installation is reverse of removal. Remember to :

•Make sure electrical connectors fully (audibly) engage .
• Reset vehicle equipment (radio, clock, power windows ) as pe r
owner's manual.
• Reconnect battery and switch ignition ON .
• If airbag warning light remains on , erase OTC memory using VAS
5051 or equivalent.

WARNING-
• Make sure no one is in vehicle when reconnecting battery

Disconnecting passenger airbag connector

~ Use screwdriver to lift connector (1) for front passenger side airbag
over retaine r tab (2) and pull off connector in direction ot (3) .

A? 0-0 195 I
 70-1

70 Interior Trim

GENERAL . . . .... . .. . ... ... . . . .. . ... . ... . 70-1 PILLAR AND SIDE TRIM .. . ......... . .... 70-14
Upper A-pillar trim , removing and installing .. . 70-14
INTERIOR REAR VIEW MIRROR . ....... . .. . 70-2
Lower A-pillar trim , removing and installing .. . 70-14
Interior rear view mirror,
removing and replacing . .. . . ..... . . . . . . . . 70-2 Sill trim , removing and installing . ... . .. . ... . 70-15
Interior rear view mirror (automatic dimming) , Upper B-pillar trim , removing and installing 70-15
removing and replacing .... .. .. .. . ... .. .. 70-2 Lower B-pillar trim , removing and installing 70-16
Upper C-pillar trim , removing and installing 70-16
STORAGE COMPARTMENTS,
Lower C-pillar trim , removing and installing 70-17
COVERS AND TRIM . ..... .. . . . .. . . ... .. . . 70-3
Upper C-pillar trim (Avant) ,
Steering column trim , removing and installing . . 70-3 removing and installing . . .... . . . . .. ... . . 70-17
Dashboard end trim , Upper D-pillar trim (Avant) ,
removing and installing ... ... . .. ... .. . . . . 70-4 removing and installing . .. . . .. . ...... . . . 70-18
Glove compartment, removing and installing . . . 70-4 Rear shelf (folding backrest) ,
Driver's storage compartment , removing and installing . . . . . . . . . ... .. . . . 70-19
removing and installing . . .. . .. . . . . . . . . ... 70-5 Rear shelf (fixed backrest) ,
Cente r console (front section) , removing and installing . . . . ... . . . . . .. .. . 70-20
removing and installing . ...... .. . ..... . . . 70-5
LUGGAGE COMPARTMENT TRIM . . .. .... . . 70-21
Center console (rear section) ,
removing and installing . . . . . . . .. . .. ..... . 70-6 T runk lid trim , removing and installing .. .. .. . 70-21
Rear vent and duct, removing and installing . ... 70-7 T runk sill trim , removing and installing . . . . .. . 70-21
Center armrest, removing and installing . . . . . . . 70-7 T runk side trim , removing and installing .... . . 70-22
Front ashtray (Concert radio ), Tailgate lid trim (Avant) ,
removing and installing . .. .. . ... ... . . . . .. 70-7 removing and installing . . ... . .. .. . . . . . . . 70-23
Front ashtray (Symphony radio) , Tailgate sill trim (Avant) ,
removing and installing .. .. . .. . . . ........ 70-8 removing and installing ... ... . . .. . ... . .. 70-24
Tai lgate side trim (Avant) ,
DOOR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-9
removing and installing ... . . . .. . . . . . .. . . 70-24
Front door trim components .. . . .. . .. . ... .. . 70-9
Front door trim , removing and installing .... . . . 70-9
Rear door trim components . . . . . ... .. . . .. . 70-11
Rear door trim , removing and installing .... . . 70-12

GENERAL
This repair group covers interior equipment and trim panels,
including center console removal. For interior lights and accessories
see 96 Interior Lights, Switches, Anti-theft .

WARNING -
• Cars covered by this manual are equipped with airbags. When
servicing these components, disconnect the negative (-)
battery terminal. See 69 Seat Belts, Airbags .
70-2 Interior Trim
Interior Rear View Mirror

CAUTIO~
• Prior to disconnecting the battery, acquire radio anti-theft code.
• Read the battery disconnection cautions in 00 Warnings and
Cautions.

INTERIOR REAR VIEW MIRROR

Interior rear view mirror,

removing and replacing
<liiiiii( Rotate mirror (1) 60° to go 0 in direction of arrows (8) until locking
spring releases and remove mirror.

- To install , place mirror at an angle of 60° to go 0 to attachment and

turn until locking spring clicks in place .

A68-02g7

Interior rear view mirror (automatic dimming),

removing and replacing
<liiiiii( Unclip cable channel cover (3) .

- Remove electrical connector from retainer and disconnect.

- Rotate mirror (1) 60° to go in direction of arrows (B) until locking

0

spring releases and remove mirror.

CAUTIO~
• Do not use cable channel (2) to turn mirror.

- To install , place mirror at an angle of 60° to go 0 to attachment and

turn until locking spring clicks in place.

- Reconnect electrical connector. Place connector in retainer and

attach channel cover (3) .

A68-0298
 Interior Trim 70-3
Storage Compartments, Covers and Trim

STORAGE COMPARTMENTS,
COVERS AND TRIM

Steering column trim, removing and installing

- Disconnect battery negative(-) cable .

- Remove driver's airbag . See 69 Seat Belts, Airbags.

- Remove steering wheel. See 48 Steering .

- Extend steering column out and down.

~ Remove sc rews (1) and remove grip (2).

A69-0074 I

~ Remove two screws (arrows) and remove upper trim piece.

A69-0072 I

~ Remove sc rews (2) and bolt (1 ). Remove lower trim piece.

- To install , replace lower section first.

- Insert upper section into hooks on lower section , swivel downward

and secu re.

A69-0073 I
70-4 Interior Trim
Storage Compartments, Covers and Trim

Dashboard end trim ,

removing and installing
~ Use a plastic prying tool or screwdriver with tip wrapped with tape to
unclip left or right side panel end trim .

- To install insert trim toward front and clip back firmly in place.

Glove compartment, removing and installing

7 1. Glove box
2. Connector
3. Bolts (3x)
4. Bolts (2x)
5. Strip
6. Rubber studs
7. Dash board

- Open glove box lid and remove bolts (3 ).

- Remove bolts (4).

2
- Remove glove box downward.

- Disconnect electrical connector (2).

' - To install , position strip (5) with rubber studs (6 ) against dash board

14 3
(
4
(7) from underneath and install glove box.

A68-006 1
 Interior Trim 70-5
Storage Compartments, Covers and Trim

Driver's storage compartment,

rem ovin g and installing
1. Driver's storage compartment
2. Bolts (5x)
3. Connector
4. Footwell light
5. Tabs
6. Data link connector (DLC)

Pull out dashboard molding to rear.

NOTE-
• Steering wheel shown removed for clarity

Unclip instrument panel end trim on drivers side. See Instrument

panel end tri m , removing and installing in this repair group.

Remove bolts (2) and set down driver's storage compartment.

Disconnect electrical connector (3) from footwell light (4) .

Unclip data link connector (DLC) (6) by squeezing together tabs (5).

Installation is reverse of removal.

Center con sole (front section),

removi ng and installing
5 4 6 1. Center console (front section)
2. Trim section
3. Fasteners
4. Fasteners
5. Switch module trim
6. Bolts (4x)
7. Trim cap
8. Nut
9. Retainer

- Remove rear section of center console . See Center console

(rea r section), rem oving and installing in this repair group.

- Open front ashtray and unclip trim section (2) at fasten ers (3)
(Chorus and Concert radios only).

7 8 9 Remove radio. See 91 Radio and Communication .

Remove navigation system controls (if equipped) .

A68-0053
Remove A/C controls. See 87 Heating and Ai r-cond ition ing .

Remove front ashtray. See Front ashtray, removing and

installi ng in this repair group.

Unclip switch-panel trim (5) at fasteners (4) .

Remove console bolts (6).

70-6 Interior Trim
Storage Compartments, Covers and Trim

Pry off trim cap (7) on side of console and remove nut (8).

Pull center console on driver's side over securing pin .

Remove center console to rear.

Installation is reverse of removal. Make sure retainer (9) locks in

place.

Center console (rear section),

removing and installing
7 9 1. Center console (rear section)
2. Mat lining

J 3.
4.

5.
Nut, 10 Nm (7 ft-lb)
Shifter knob
• Twist on I off
Protective boot
( • Unclip upward. Make sure clips lock in place when installing
~------ 8 6. Center console insert
7. Screws (2x)

®---- 3 8. Screw (1 x)
I
9. Mirror adjustment switch
10 10. Parking brake trim
11. Retainer tab
11 _I ·' 12. Stud
I

.
I
;~ Remove rear air vE~nt and rear air duct connecting piece. See Rear
vent and duct, removing and installing in this repair group.
r-~
. - - - 12
Remove center armrest (if necessary). See Center armrest ,
A68-0048
removing and installing in this repair group.

Remove console nut (3).

Remove mat lining (2) upward .

Remove console bolt (8) .

Models with manual transmission :

•Twist off shifter knob (4).
• Unclip protective boot (5) upward .

Unclip center console insert (6 ) upward .

Remove console bolts (7) .

Remove parking brake trim .

Raise rear section of center console (1) at front and detach

connector for mirror adjustment switch (9).

Fully apply parking brake.

Unfasten trim (1 0) from retainer (11) on parking brake .

Raise rear section of center console (1) over stud (12) and pull
center console to mar.
 Interior Trim 70-7
Storage Compartments, Covers and Trim

- Lift out re ar section of center console (1) forward over parking brake .

- Installation is reverse of removal. Remember to :

• Install trim (10) at retainer (11) of parking brake .
•Make su re air ducts are properly installed when installing rear
2 1 section of center console (1 ).

Rear vent and duct, removing and installing

Use or fabricate a suitable tool to remove vent trim (a screwdriver
bent 90° at 6 - 1O mm along its length will work) .

~ Pull rear vent (1) out center console (rear section).

- Disconnect electrical connectors for cigarette lighter, vent light and

rear heated seat (if equipped).

Remove re ar air duct connecting piece (2) from air duct (3 ).

3
A68-0049 Installation is reverse of removal

Center armrest, removing and installing

1. Center armrest
2. Con nector
3. Retai ner tabs
4. Nut, 26 Nm (18 ft-lb)

- Remove rear vent and duct. See Rear vent and duct, removing
and installing in this repair group.

- Models with phone : Disconnect electrical connector (2) by

squeezing retaining tabs (3).

- Remove nut (4) and remove armrest.

- Installation is reverse of removal. Make sure to clamp in connector

(2) on rig ht side between support bracket and center console.

Front ashtray (Concert radio),

removing and installing
- Open radio flap and open front ashtray.

- Starting at bottom , carefully unclip front center console trim.

- Working above radio, carefully unclip switch panel trim .

~ Remove bolts (1 ).
70-8 Interior Trim
Storage Compartments, Covers and Trim

~ Use a screwdriver (2) to pull out retainer tabs (1) on left and right in
direction of arrow.

- Carefully pull A/C control head out slightly toward the rear, and pull
out ashtray downward and toward rear.

- Disconnect electrical connections for cigarette lighter and ashtray

light. Remove ashtray.

~ When installing , make sure guide (1) engages on left and right in
center console.

A68-0090 I

Front ashtray (Symphony radio),

removing and installing
- Remove radio. See 91 Radio and Communications.

- Remove navigation system controls (if equipped) .

- Remove A/C controls and heat controls. See 87 Heating and

Air-conditioning.

~ Press retaining tabs (2) and pull ashtray out forward.

- Disconnect electrical connections and remove ashtray.

- Installation is reverse of removal. Make sure retaining tabs lock in

place.
 Interior Trim 70-9
Door Trim

DOOR TRIM

Front door trim components

1. Door trim
2. Hinged pockets
11 3. Bass loudspeaker
4. Treble speaker
5. Inner connecting piece
6. Outer connecting piece
7. Inner filler piece
8. Outer filler piece
9. Locking knob guide
10. Clip locator
11. Insulation
12. Door courtesy light
13. Central locking switch (drivers side only)
14. Interior door handle
~-- 2 15. Decorative trim
16. Foam seal
A?0-0164 17. Mount for hinged pockets
18. Window switch

Front door trim, removing and installing

4 ~ Remove screws (2) from door trim (1).

A?0-0 150
70-10 Interior Trim
Door Trim

~ Remove window switch unit by inserting screwdriver (3) in hole in

armrest. Press locking tab (2) in direction of arrow (A).

NOTE -
• On models without hole in armrest, use a plastic prying tool to pry
front edge of window switch up slightly and release locking tab.
----- ------,-----:-1-/... ~
::-::::::-::::_::~ Ii.
I 11
I 11
I 11
I 11
I 11

:®
I 11

3 --,-
-~ , /\ (\\ I A?0-0 170 I
11 h J-1 Ir
~ Lift switch unit up. Press retainer tab (2) to release electrical
connector (1 ).

- Lift door trim about 20 cm (8 in) upward and remove from door.

~ Pull bowden cable (1) out of guide (2 ) and detach .

NOTE -
• When installing, make sure hook (3) is facing upward.

3 1
A?0-0 139

~ Disconnect electrical connectors for central locking switch (1 ), door

warn ing light (2) and radio speaker (3).
 Interior Trim 70-11
Door Trim

~ Installation is reverse of removal. Remembe r to :

4
• Make sure door insulation is in place and not damaged .
111. • Press center of door trim on door first.

'./.~
t
•Clip locators (3 and 4) in place .
I 3

·(.I} 2

A?0-0 150

Rear door trim components

1. Rear door trim
2. Hinged pocket
3. Bass speaker

11 4. Treble speaker
5. Inner connecting piece
6. Outer connecting piece
7. Inner filler piece
8. Outer filler piece
9. Locking knob guide
10. Clip locator
11. Insulation
12. Door courtesy light light
16 13. Interior door handle

u-2
14. Decorative trim
15. Foam seal
16. Mount for hinged pockets
17. Window switch

A70-0206
70-12 Interior Trim
Door Trim

Rear door trim, removing and installing

~ Remove screws (2) from door trim (1 ).
4

A?0-0 198

~ Remove window switch by inserting screwdriver in hole in armrest.

Press locking tab (2) in direction of arrow (A).

NOTE-
• On models without hole in armrest, use a plastic prying tool to pry
front edge of window switch up slightly and release locking tab.

~ Lift switch unit up. Press retainer tab (2) to release electrical
connector (1 ).

- Lift door trim about 20 cm (8 in) upward and remove from door.
 Interior Trim 70-13
Door Trim

~ Pull bowd en cable (1) out of guide (2 ) and detach .

NOTE -
• When installing, make sure hook (3) is facing upward.

3 1
A?0-0 139

~ Disconnect electrical connector for door warn ing light (2) and
radio speaker (1 ).

~ Installation is reverse of removal. Remember to:

4 •Make sure door insulation is in place and not damaged .
I
& ! • Press center of door trim on door first.
l !_j/V ~
'., . '/ •Clip locators (3 and 4) in place.
2
, I
··7 3
~ '

t.,...I
I '

A?0-0 198
70-14 Interior Trim
Pillar and Side Trim

PILLAR AND SIDE TRIM

Upper A-pillar trim, removing and installing

1. Upper A-pillar trim
2. Screws (2x)
3. Clips (4x)
4. Flap for roof grab handle
5. Roof grab handle
6. Mounts
7. Groove
8. Seal
9. Pin
10. Mount

3 - Pivot down flap (4) on roof grab handle (5) at groove (7).

- Remove screws (2).

10 2 8
- Unclip A-pillar trim (1 ) , starting at top.

- Pull out trim and rotate upward .

- On models with hands-free telephone function , disconnect

6 connector for hands-free unit.

A?0-01 33 - Installation is reverse of removal. Remember to:

• Carefully route wiring and connector for hands-free telephone unit
from bottom to top (if equipped).
•Move sun visor out of the way and insert trim (1) with clips (3) in
mounts (6) .
• Insert pin (9) in mount (10).
• Clip in trim (1) and install door seal over (A) pillar trim .

Lower A-pillar trim, removing and installing

- Pry out cover (1) and remove screws (2) .

~ Pull lower A-pillar trim in direction of arrow (A) until pin (3) can be
detached from groove (4).

- Pull extension of trim in direction of arrow (8) out of retainers .

- Installation is reverse of removal.

A?0-02 14
 Interior Trim 70-15
Pillar and Side Trim

Sill trim, removing and installing

- Remove lower A-pillar trim . See Lower A-pillar trim , removing in
this repair group.

~ Unclip front sill trim (1 ).

Detach sill trim (1) from lower B-pillar trim (2) at retainer (5).

Unclip rear of sill trim (1 ) .

- Detach sill panel trim from lower B-pillar trim (2) at retainer (4).

- Detach sill panel trim (1) from lower B-pillar trim (2) at retainer (3) .

- Installation is reverse of removal.

Upper B-pillar trim, removing and installing

1. Upper B-pillar trim
2. Clip
3. Height adjuster
4. Mounts
5. Retainer tab
6. Lower B-pillar trim
7. Actu ating button for height adjuster

- Remove outer seat belt attachment point. See 69 Seat Belts,

Airbags .

! lj !1-. I
- Unfasten roof grab handle at upper A-pillar trim. See Upper A-pillar
I I' 11 It
,,_I
I
I

trim, removing and installing in this repair group.

I
1, I
1 ,I - Unfasten roof grab handle and coat hook at upper CI D-pillar trim.
See Upper C-pillar trim, removing and installing in this repair
group.

Pull clips (2) on trim (1) out of mounts (4) at the top.
5 6
Detach retainer tabs (5) upwards from lower B-pillar trim (6).
A?0-0145
- Installation is reverse of removal. Remember to :
• Engage retainers (5) on trim (1) in lower B-pillar trim (6).
• Insert actuating button for height adjuster (7) in height adjuster (3).
• Insert clips (2) on trim (1) in mounts (4).
•Make sure door seal is correctly seated and check operation of
height adjuster.
•Check that height adjuster engages audibly in each of 5 possible
positions (including top position) and that adjuster button always
returns to up position.

NOTE-
• Do not press height adjustment fitting when installing.
70-16 Interior Trim
Pillar and Side Trim

Lower B-pillar trim, removing and installing

1. Lower B-pillar trim
2. Belt guide
3. Guide pins
4. Retainer tabs
5. Mounts
6. Mounts
7. Retainer
8. Push-button switch for trunk lid
9. Push-button switch for interior monitoring

NOTE-
• The outer seat belt attachment point does not have to be removed
when taking out the lower 8-pillar trim.

Remove upper B-pillar trim. See Upper 8-pillar trim, removing

and installing in this repair group.

Remove sill trim. See Sill trim, removing and installing in this
repair group.

Use screwdriver to press retainer tabs (4) outward .

6 5 6 3 4 3
A?0-0 146
Pull up lower B-pillar trim in direction of arrow until it disengages at
belt guide (2).

Disconnect connectors for trunk lid and interior monitoring switches

and remove trim .

- Installation is reverse of removal. Remember to :

• Insert belt guide (2) from top into retainer (7) .
• Insert guide pins (3) and retainer tabs (4) in mounts (5) and (6) .
• Make sure door seal is correctly seated .

Upper C-pillar trim, removing and installing

1. Upper C-pillar trim
2. Screws (2x)
3. Screw (1x)
4. Coat hook
5. Mounts

-? s
'.J /l _
6.
7.
Mount
Seal

t-: 8.
9.
Clips (7x)
Roof grab handle

1~\\
10. Pin
11. Roof grab handle flap

I ' 12. Groove

. \

' - Open out coat hook and remove screw (3) .

Pivot down flap (11) on roof grab handle (9) at groove (12) .

Remove trim screws (2) and unclip C-pillar trim (1 ), starting at top .
A?0-0142
 Interior Trim 70-17
Pillar and Side Trim

Installation is reverse of removal. Remember to :

• Insert trim (1) in rear shelf mounts.
• Insert pin (10) on trim (1) in mount (6).
• Insert clips (8) on trim (1) in mounts (5).
• Clip trim (1) into place.
• Make sure door seal is correctly seated.

Lower C-pillar trim, removing and installing

- Remove sill trim. See Sill trim, removing in this repair group.

- Remove rear seat bench and rear side padding. See 72 Seats.

~ Unclip upper C-pillar trim around lower C-pillar trim .

- Unclip lower C-pillar trim (1) at retaining clips (2) .

- Detach retainer tab (3) from mount (4) and remove trim .

- Installation is reverse of removal. Remember to align guide pin (5).

4 3 1

A70-0213
Upper C-pillar trim (Avant),
removing and installing
1. C-pillar trim
2. Screws (2x)
3. Screw
4. Bolt
5. Coat hook
6. Front partition grille mount
10 11
7. Roof grab handle
8. Roof grab handle flap
9. Groove
10. Rear partition grille mount
11. 0-pillar trim
12. Scre w
13. Clip

13~~\
r•)
14. Screw

~)-1
4 3 2
A?0-0254
70-18 Interior Trim
Pillar and Side Trim

~ Pull down coat hook (5) and remove screw (4) .

Remove screw (3) from front partition mount (6) .

Pull down flap (8) on roof grab handle (7) at groove (9) .
Ir - Remove screws (2).

- Remove screw (12) from rear partition mount (10) .

11 12
- Remove trim plate for seat belt.

- Remove screw (14) .

7
- Unclip D-pillar trim (11) at C-pillar trim (1 ).

- Carefully pull away D-pillar trim (11 ).

- Unclip C-pillar trim (1 ), working from the top downward .

- Installation is reverse of removal. Remember to :

• Push C-pillar trim in behind D-pillar trim.
• Insert clips (1) on trim (13) into mounts .
4 3 2
• Clip trim (1) into place.
A?0-0254

Upper D-pillar trim (Avant),

removing and installing
1. D-pillar trim
2. Mount for cargo area cover
3. Screw
4. Screw
5. Rear partition grille mount
6. Clip

- Remove screw (4) from rear mount (5) for partition grille.
5 -----~

Remove bolt (3) .

Unclip D-pillar trim (1) working from the top downward .

- Lift D-pillar trim out of cargo area side trim .

- Remainder of installation is reverse of removal. Remembe r to :

• Insert D-pillar trim behind cargo area side trim .
• Insert clips (6) on trim (1) in mounts.
• Clip trim (1) into place.

A?0-0255
 Interior Trim 70-19
Pillar and Side Trim

Rear shelf (folding backrest),

removing and installing
1. Rear shelf
2. Clip (3x)
3. Clip (3x)
4. Spring
5. Center brake light
6. Guide
7. Trim
8. Flap

Fold down rear seat backrest.

Unbolt lower attachment points for rear left and right three-point seat
belts. See 69 Seat Belts , Airbags.

Remove rear left and right side padding. See 72 Seats.

Unclip trim (7) and guide (6 ) for rear left and right three-point seat
belts .

- Remove upper C-pillar trim on left and right. See Upper C-pill ar
trim , removin g and installing in this repair group.

- For vehicles with flap in rear shelf: Open flap (8) beneath high -mount
brake light (5) in luggage compartment.

For all vehicles: Unclip center brake light (5) by unfastening spring
(4 ) in luggage compartment.

- On vehicles with electric sun shade, loosen sunshade screws in

luggage compartment.

- Pull rear shelf (1) forward in direction of arrow and unclip rear shelf
at clip (2) .

- Disconnect electrical connector for sun shade (if equipped).

- Remove rear shelf upward and forward .

- Installation is reverse of removal. Remember to:

• Press down rear shelf slightly until clips (3) and springs (4) engage .
•Press in on front edge of self to engage clips (2).
70-20 Interior Trim
Pillar and Side Trim

Rear shelf (fixed backrest),

removing and installing
1. Rear shelf
2. Clip (3x)
3. Clip (3x)
4. Spring
5. Center brake light
6. Guide
7. Trim
8. Flap
9. Bolt (1 x) , 55 Nm (41 ft-lb)
10. Webbing
11. Guide

- Unbolt lower attachment points for rear left and right three-po int seat
belts. See 69 Seat Belts, Airbags.

- Unbolt lower attachment point (8) for center three-point seat belt.
See 69 Seat Belts, Airbags .

- Remove rear seat backrest. See 72 Seats.

- Unclip trim (7) and guide (6) for rear left and right three-point seat
A?0-02 18
belts . See 69 Seat Belts, Airbags .

- Remove upper C-pillar trim on left and right. See Upper C-pillar
trim, removing and installing in this repair group.

- For vehicles with flap in parcel shelf: Open flap (8) beneath high-
mount brake light (5) in luggage compartment.

- For all vehicles: Unclip center brake light (5) by unfastening spring
(4) in luggage compartment.

- On vehicles with electric sun shade, loosen sunshade screws in

luggage compartment

- Pull rear shelf (1) forward in direction of arrow and unclip rear shelf
at clip (2).

- Unclip trim and guide (10) for center three-point seat belt from the
rear.

- Disconnect electrical connector for sun shade (if equipped) .

Remove rear shelf (1) upward and forward .

Installation is reverse of removal. Remember to :

• Press down rear shelf slightly until clips (3) and springs (4) engage .
• Press in on front edge of shelf to engage clips (2) .
 Interior Trim 70-21
Luggage Compartment Trim

LUGGAGE COMPARTMENT TRIM

Trunk lid trim, removing and installing

1. Rear lid trim
2. Screws (2x)
I I
3. Screws (2x)
4. Screws (2x)
5. Bracket for hazard warning triangle

Remove hazard warning triangle .

Remove screws (4) and remove bracket for hazard warning triangle
,I (5) .

- Remove screws (2) .

- Vehicle with emergency release : Unclip cover and remove bolt for
emergency release handle.
----',--- 5
- All vehicles: Remove screws (3) .
.-.L-7Tl:cn~. _ . h r - - - \ - - - 4
Unclip trunk lid trim (1) from underneath and remove trim.

Installati on is reverse of removal.

A70-0 143

Trunk sill trim, removing and installing

2 1. Trunk sill trim
2. Screws (2x)
3. Screws (2x)
4. Fastening rings

- Remove trunk light from sill trim (1 ).

- Remove screws (2) .

- Remove screws (3) from fastening rings (4 ) on left and right.

- Unclip sill trim (1) upward.

- Guide trunk light through opening in trim .

- Installati on is reverse of removal. Make sure seal is correctly seated.

,,~
3 4

A?0-0 144
70-22 Interior Trim
Luggage Compartment Trim

Trunk side trim, removing and installing

6 4 5 3 1. Trunk side trim
2. Cover
3. Clip
4. Clip
5. Clips (2x)
6. Mounts
7. Bolts (2x)
8. Fastening rings
9. Fastening clip

- Remove trunk floor covering.

- Models with split rear seat: Remove respective backrest.

See 72 Seats.

- Remove trunk sill trim . See Trunk sill trim, removing and
installing in this repair group.

9 Remove screws (7) for fastening rings (8) .

Unclip front trunk trim clips (5).

A?0-02 15 Unclip trim clips (3 and 4) and remove cover (2) .

Unclip remaining clips and pull side trim (1) upward out of locating
tabs (9) .

Pull side trim (1) out from behind back panel trim .

Installation is reverse of removal. Remember to insert side trim

behind front trunk trim before replacing clips (5).
 Interior Trim 70-23
Luggage Compartment Trim

Tailgate trim (Avant),

removing and installing
1. Tailgate trim (bottom section)
2. Tailgate trim (top section)
3. Screw
4. Grip molding
5. Rubber buffer (1 Ox)
6. Clip
7. Retainer
8. Light

Tailgate trim bottom section

Remove bolt (3) .

Remove screw behind warning triangle

2
Pull bottom section of trim (1) away from tailgate slightly.

Using a plastic trim tool or screwdriver with tip wrapped with tape ,
release clips (6) (8x) on bottom section of trim (1 ). Start at bottom
right and proceed counterclockwise.

I A?0-0268 I Press out light (3) from behind trim.

Disconnect connector for light (8) .

- To install , locate bottom section of trim (3) at rear window first , and
clip into place .

- Make sure that screw (4) also secures grip molding (3) (shown in
inset A) .

Tailgate trim top section

- Remove bottom section of trim (1 ).

- Unclip retainer tabs (7) on both sides.

Release clips (6) (7x) on top section of trim (2) by pulling sharply
(do not use excessive force) .

- Before installing top section of trim (2) , make sure that rubber
buffers (5) (1 Ox) are installed properly.

- First install top section of trim (2) behind side tailgate flanges .

- Clip in upper tailgate trim (2) into place behind side flanges on
tailgate .
70-24 Interior Trim
Luggage Compartment Trim

Tailgate sill trim (Avant),

removing and installing
~ Remove screws (2) (4x).

Remove sill trim (1 ).

Instal l in reverse order. Make sure tailgate seal is positioned over sill
panel trim.

Tailgate side trim (Avant),

removing and installing
1. Cargo area side trim
2. Cover
3. Fastening rings
4. Screw (2x)
5. Mount for cargo area cover
6. Screw

r
7

~.~1::~, 7. Screw

~./1 \
Remove cargo area cover.

/
' Remove rear seat bench and respective side padding .
<,.
/
/

'/ l\ ~--- 1
See 72 Seats.
2 --~~ I\
II ll.
- Detach seat belt from bottom attachment. Remove belt trim plate.
See 69 Seat Belts, Airbags .

- Remove tailgate si ll trim . See Tailgate sill trim , removing and

installing in this repair group.

- Remove screws (4 ) for fastening rings (3).

- Remove storage cover (2).

A?0-0284 - Remove mounting bracket screw (6).

- Remove bolt (7).

- Unclip rear trim.

- Pull trim slightly toward front , and disconnect conn ector for rear
electrical socket.

- Installation is reverse of removal. Remember to engage cargo area

trim behind side window flange.
 72-1

72 Seats

GENERAL .. . . . .. . . . . ... ..... . ...... . .... 72-1 REAR SEATS .... . . ... ... ... .. . .... . . . . . . 72-4
Seat bench , removing and installing . . . . . . .. . 72-4
FRONT SEATS 72-1
Backrest (fixed) , removing and installing .. . . . . 72-5
Front seat components . . . .. . . . ..... . ... .. 72-1
Backrest (split-folding), removing and installing . 72-6
Front seat, removing and installing . . . . . . .... 72-2
Rear headrest, removing and installing .. . .. . . 72-8
Headrest, removing and installing ........... 72-3
Rear seat side padding , removing and installing 72-8
Seat memory control module,
removing and installing .. .. .. . . .. . .... . .. 72-3 Ch ild ren 's bench (Avant) ,
removing and installing ... . .. .. ... . . . . .. . 72-9
Seat control switch , removing and installing .... 72-4

GENERAL
This repair group covers removing and installing the front and rear
seats. Both driver and passenger seats may be equipped with
airbags .mounted. in the seat backrest frames . Add itional ly, airbags
may be installed 1n the rear seat side upholstery. For airbag
precautions and handling procedures see 69 Seat Belts , Airbags .

WARNING -
• D? not install aftermarket upholstery on any vehicle equipped
with seat mounted airbags. Non-factory upholstery including
"beads "' and "sheepskins" may cause seat mounted airbags to
deploy when they are not supposed to; fail to deploy when they
should; or deploy in some manner other than designed. Serious
injury or death could result.
6 8 2 7 7 5

FRONT SEATS

Front seat components

1. Backrest
2. Seat pan
3. Bolts
4. Oute r si de panel of seat
5. Adju stment knob
6. Bolts
I
7. Bolts, 20 Nm (15 ft lb)

~: 8. Inner side panel of seat

I~
9. Bracket
10. Expandi ng pin
11. Screw

12 13 9 10 11
1 3 14 3 4
12. Con nector
13. Moto r for seat height adjuster

A72-0063 14. Seat adjustment switch

72-2 Seats
Front Seats

Front seat, removing and installing

1. Cover
2. Bolts , 23 Nm (17 ft-lb)
• Self-locking
• Always replace
3. Clip
4 4. Rear rollers
5. Front sliders
• Lubricate with multi-purpose grease

"~ NOTE -
• Removal and installation procedures may vary slightly depending
on vehicle equipment.
~ ~ -- "~
Raise seat to highest position and adjust seat forward .
~ (!} ,~ 3 Remove trim cove rs at rear of inner and outer seat rails .

- Adjust seat backward.

2 Disconnect battery negative (-) cable.

NOTE -
A72-0062 • Obtain radio code before disconnecting battery

Remove trim cover (1) at front of front seat rail.

Remove bolts (2) and release clip (3) .

~ Connect airbag adapter VAS 5094 to wiring harness for side ai rbag.

VAS 5094
WARNING -
• Observe all airbag warnings. See 69 Seat Belts, Airbags .
• Before disconnecting airbag harness connector, discharge
static electricity by briefly grasping chassis or door striker.
• Failure to install VAS 5094 could result in deployment of side
airbag.

Disconnect remaining electrical connectors.

Fold back floor covering at rear around guide rail.

I W00- 068 0 I
Push seat backward out of guide and remove seat.

Installation is reverse of removal. Remembe r to :

• Remove airbag adapter VAS 5094 and reattach electrical
connectors.
• Replace seat mounting bolts with new.

Tightening torque
Front seat to seat rail 23 Nm (17 ft-lb)
I
 Seats 72-3
Front Seats

Headrest, removing and installing

Style 1:

<iiiiii( Press release button (2) fully and lift headrest up and off seat back.

- To instal l, press release button (2) to first stage and slide headrest
down on seat back. Press release button to adjust headrest height.

Style 2:

<iiiiii( Press down on guide sleeve (2) from above.

Press down slightly on headrest (1) to release catch.

Pull headrest up and off seat back .

- To install , slide head rest down on seat back and press on guide
sleeve (2) to adjust headrest height.

A72-0146

Seat memory control module,

removing and installing
Remove driver's seat. See Front seat, removing and installing in
this repair group.

- Working under seat, remove bolts for inner side panel of seat.

Release clip on inner side panel. Push panel forward and remove.
See Front seat components in this repair group for more
information .

<iiiiii( Disconnect control module electrical connectors (4 and 5) .

Remove screw (2).

Press clip (3) in direction of arrow using a screwdriver and remove

control module.

- Installation is reverse of removal.

72-4 Seats
Rear Seats

Seat control switch, removing and installing

- Remove driver's seat. See Front seat, removing and installing in
this repair group.

- Working under seat, remove bolts for outer side panel of seat.

- Release clip on inside of side panel. Push panel forward and

remove. See Front seat components in this repair group for more
information.

<iiiiii{ Remove screws (2) and remove seat control switch.

Installation is reverse of removal .

REAR SEATS

Seat bench, removing and installing

WARNING-
• Observe all airbag warnings. See 69 Seat Belts, Airbags .
•Before disconnecting airbag harness connector, discharge
static electricity by briefly grasping chassis or door striker.

Disconnect battery negative (-) cable.

NOTE -
• Obtain radio code before disconnecting battery

<iiiiii{ Lift front edge of seat bench in direction of arrows (A) and pull
forward (8).

N72-0 12 1

<iiiiii{ Remove harness connector for side airbag (if equipped) from
groove and disconnect.

- Disconnect connector for heated seats (if equipped) and remove

seat bench.

A69 -0 102 I
 Seats 72-5
Rear Seats

~ Installation is reverse of removal . Remember to :

• Connect harness connector fo r side airbags and heated seats
(if equi pped) .
• Slide bench rearward in direction of arrow (A ).
• Guide anchoring eyelets into plastic sleeves (arrow B)
• Avoid damage to plastic sleeves (inset).

N72-0 122

Backrest (fixed) , removing and installing

WARNING -
• Observe all airbag warnings. See 69 Seat Belts, Airbags .
• Before disconnecting airbag harness connector, discha rge
static electricity by briefly grasping chassis or door striker.

1. Fixed backrest
2. Screws (2x) , 8 Nm (71 in-lb)
3. Hooks (4x)

Remove rear seat bench . See Seat bench , removing and

installi ng in this re pair group.

- Remove head rest (if necessary) . See Rear headrest, removing

and installing in this repair group.

Pry out frame for ski bag (if equipped)

·.1v
Disconn ect electrical connectors for side airbags and heated seats
(if equipped).

Remove screws (2 ) (2x) .

I.... - .,. ' ' I ,.

-
Push backrest (1) upward and detach at hooks (3) (4x).

Installation is reverse of removal.

A72-0075
72-6 Seats
Rear Seats

Backrest (split-folding),
removing and installing

WARNING-
• Observe all airbag warnings. See 69 Seat Belts, Airbags .
• Before disconnecting airbag harness connector, discharge
static electricity by briefly grasping chassis or door striker.

1/3 section

Fold both backrest sections forward .

-<!iii( Unclip trim piece (3) from rear in direction of arrow. If necessary,
pry out trim clip from rear through hole.

- Remove bolt (1) and clamp (2).

A72-0071

-<!iii( Lift backrest out of center support bracket (2) in direction of arrow
(A) and pull off fitting (3) in direction of arrow (B).

Disconnect electrical connectors for heated seats (if equipped).

Installation is reverse of removal . Remember to reinstall grommet

(4) on pin (3) if it pulled off during removal.

Tightening torque

Backrest bracket bolt 10 Nm (7 ft-lb)

1, \ 4 3

h~
I

A72-0068
 Seats 72-7
Rear Seats

2/3 section

- Fold both backrest sections forward .

<tiiiiiii( Unclip trim piece (3) from rear in direction of arrow. It necessary, pry
out clip from rear through hole .

- Remove bolt (1) and clamp (2) .

~ ~ 1

='I

A72-0070

<tiiiiiii( Lift backrest out of center support bracket in direction of arrow (A )

and pull off fitting (3) in direction of arrow (8).

Disconnect electrical connectors for heated seats (if equipped).

Installation is reverse of removal. Remember to reinstall grommet

(4) on pin (3) if it pulled off of fitting during removal.

Tightening torque
Backrest bracket bolt 10 Nm (7 ft-lb)

I
It/~
II ..

'J
,.I t\_ ' t
~I

~
3 1

A72-0069
72-8 Seats
Rear Seats

3 2 Rear headrest, removing and installing

) 1. Rear backrest
2. Outer headrest

I _ ~4 3.
4.
Center headrest
Guide piece with release button for outer headrest

#JIQff/ I
~ ·-. ·, --- ~--=------~'1-~~ 5. Guide pieces with release buttons for center headrest

B . ' - -
-

~ -
- -·- (

I i l( ~ - To remove outer headrest (2) , press release button (4) on left guide
piece and pull out in direction of arrow (A).

I - To remove inner headrest (3) , press release buttons (5) on both

guide pieces and pull out in direction of arrow (8) .

- Installation is reverse of removal. Note that front and rear headrests

are not interchangeable.
5

A72 -0076

Rear seat side padding,

removing and installing

WARNING-
• Observe all airbag warnings. See 69 Seat Belts, Airbags .
• Before disconnecting airbag harness connector, discharge
static electricity by briefly grasping chassis or door striker.

1. Side padding
6 5 3 4
2. Bolt, 8 Nm (71 in-lb)
3. Nut, 50 Nm (37 ft-lb)
4. Bolt
5. Washer
6. Dished washer
7. Retainer

Remove rear seat bench . See Rear seat bench, removing and
installing in this repair group.

Remove lower bolt (2) and on side padding (1 ).

NOTE-
• Bolt (2) is only installed on vehicles with side airbag

Disconnect electrical connector for side airbag (if equipped).

2 7 Remove nut (3) on striker pin (4) together with washer (5) and
dished washer (6) .
A72-0074
Pull side padding out of bottom retainer (7).

Installation is reverse of removal. remember to :

• Press side padding into bottom retainer (7).
•Adjust stri ke r pin (4) and tighten nut (3).
 Seats 72-9
Rear Seats

Children's bench (Avant),

removing and installing
~ On Avan t models, a rear facing children 's bench seat in the luggage
compartment is an option .
1. Children 's bench
2. Mounts
3. Head of locking mechanism
4. Locking lever
5. Securing lever

Release children's bench using locking levers (4 ).

Press both securing levers (5) upwards in direction of arrow (C ).

- Guide bench out of mounts (2) and remove bench.

- To install , guide locking mechanism heads (3) onto mounts (2) .

Make sure heads seat fully.

Lock bench with locking levers (4 ) in direction of arrow (A ).

I A72-0 126 I
 87-1

87 Heating and Air-conditioning

GENERAL ...... .. . ... . .... . . . .... . . . ... 87-1 CLIMATE CONTROL COMPONENTS ... . . . . . . 87-9
Climate control ... . . .. . ....... ... ..... . . . 87-1 Climate control components
Troubleshooting .. . . ... .. .. . . ... . .... ... . 87-2 in engine compartment . . .. .. . .......... 87-11
Warnings and Cautions 87-3 Climate control components in dashboard . .. . 87-13

A/C FLUIDS AND CAPACITIES .......... . . . 87-4 CLIMATE CONTROL REPAIRS 87-16
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87-4 Blower, removing and installing ......... . . . 87-16
Refrigerant oil ... .... ..... . ...... . ..... .. 87-4 A/C compressor with clutch ,
removing and installing . . ........ . .... . . 87-16
CLIMATE CONTROL AND A/C compressor with regulator valve ,
ENGINE COOLING CONTROLS ..... . .... . .. 87-5 removing and installing .... .... . ..... . . . 87-17
A/C and heater control panel ..... ... ...... . 87-5 Heater core , removing and installing 87-18
Climate control and engine cooling
fuses and relays . . .. ... ... .. ..... .. ... . 87-6 TABLES

Engine cooling fan and blower controls ... ... . 87-7 a. Ai r-conditioning troubleshooting .... . . . ..... . . . .. . 87-2
b. A/C system refrigerant (R134a) capacities . ......... 87-4
CLIMATE CONTROL OPERATION ........ . .. 87-8
c. A/C system refrigerant oil (PAG) capacities . .... .... 87-5
A/C system schematics . . . . . . . . . . . . . . . . . . . 87-8
d. A/C and heater component locations . .. .. . ....... . 87-9
Air distribution ....... . ...... .... ........ 87-9

GENERAL
This rep air group covers interior ventilation and air-conditioning. For
addition al information , see :
• 03 Mai ntenance for engine accessory (A/C compressor) drive belt
and dust and pollen filter service
• 19 Cooling System for cooling system fan replacement
• EWD Electrical Wiring Diagrams

Some A/C or heater system repairs procedures require that the A/C
refrigerant charge be evacuated . A/C system evacuating and
rechargi ng procedures are beyond the scope of this manual.

Climate control
~ The climate control system (A/C and heater) automatically regulates
the interior temperature. The left and right sides (driver and
passeng er sides) are controlled separately. Either side may be
adjusted manually.

Setting the system at 75°F (23°C) on both sides turns automatic

climate re gulation ON.

A604 8700 1a
87-2 Heating and Air-conditio
General

Troubleshooting
If the on-board diagnostics (OBD 11) system recognizes malfunctions
in the climate control system , it sets diagnostic fault codes (DTCs).

~ Access fault memory with VAG scan tool or equivalent plugged into
DLC plug (inset) under left side dashboard .

Table a provides common symptoms and possible corrective

actions to aid in diagnosing simple faults in the A/C system .

Table a. Air-conditioning troubleshooting

Symptom Probable cause Corrective action
Blower does not work. Blower fuse blown . Inspect blower fuse. See Climate control and engine cooling
fuses and relays in this repai r group.
Blower resistor (power stage) fa Test blower resistor. Replace if necessary.
Blower motor wiring faulty. Troubleshoot electrical harness. Repair as necessary.
Blower motor faulty. Test motor. Replace if necessary.
Blower does not operate Blower resistor (power stage) fa Test blower resistor. Replace if necessary.
in lower speeds. Blower switch faulty. Replace A/C and heating control panel.
Air-conditioning system A/C compressor not engaging . Check A/C compressor clutch electrical connector. Repair or
does not produce cold reconnect as necessary.
air or produces low Refrigerant charge too low or to Test A/C system pressures . Repair as necessary.
volume .
Temperature control flap malfun Test temperature control flap and motor. Repair or replace as
necessary.
Evaporator iced up. Shut A/C off and allow to thaw.
Pressure switch faulty. Test pressure switch and replace if necessary.
Ai r-condition ed air Mold growing in A/C evaporator nes. Apply disinfectant using evaporator cleaning wand .
smells musty.
A/C compressor noisy. Loose A/C compressor or mount g Tighten A/C compressor and mounting bracket bolts .
bracket.
Refrigerant lines contacting each other Reposition and realign refrigerant lines.
or othe r components.
A/C compressor noisy A/C system overcharged with Discharge refrigerant and recharge correctly.
immediately after refrigerant.
switching ON or when
driving around corners.
Water sprays out of Evaporator drain not functioning . Check evaporator housing drain hose for correct routing. Make
dashboard vents . sure it is not kinked .
Check evaporator housing drain valve .
 Heating and Air-conditioning 87-3
General

Warnings and Cautions

WARNING-
• Wear hand and eye protection (gloves and goggles) when
working around the A/C system. If refrigerant oil comes in
contact with your skin or eyes:
-Remove contact lenses, if worn.
-Do not rub skin or eyes.
-Immediately flush skin or eyes with cool water for 15 minutes.
-Rush to a doctor or hospital. Do not induce vomiting.
• Work in a well ventilated area. Switch on building exhaust I
ventilation system when working on the A/C system.
• If you inhale refrigerant oil, breathe fresh air immediately and
then seek medical attention.
• Do not expose any component of the A/C system to high
temperatures (above B0°C I 176°F) . Excessive heat could burst
the system.
• Keep refrigerant away from open flames . Poisonous gas is
produced if it burns. Do not smoke near refrigerant gases for the
same reason.
• The A/C system is filled with refrigerant gas which is under
pressure. Pressurized refrigerant in the presence of oxygen may
form a combustible mixture. Do not introduce compressed air
into any refrigerant container.
• Electric welding near refrigerant hoses causes refrigerant to
decompose. Discharge system before welding.
• Dispose of refrigerant oil as hazardous waste.

CAUTIO~
• US la w requires that any person who services a motor vehicle
air-conditioner is properly trained and certified, and uses
approved refrigerant recycling equipment. Technicians must
complete an EPA-approved recycling course to be certified.
• It is recommended that all A/C service be left to an authorized
Audi dealer or other qualified A/C service facility
• State and local governments may have additional requirements
regarding A/C servicing. Always comply with state and local
laws.
• Leak test and repair any A/C system which is known to lose its
charge.
•Do not top off a partially charged refrigerant system. Discharge
system, evacuate and then recharge system.
• Do not use R 12 refrigerant, refrigerant oils or system
components in R134a system. Component damage and system
contamination results.
• Refrigerant oil (PAG oil) is extremely hygroscopic (wate r-
absorbent). Do not store in open container.
• The mixture of refrigerant oil and refrigerant (Rt 34a) attacks
some metals and alloys (for example, copper) and breaks down
certain hose materials. Use only hoses and pipes that are
identified with a green mark (stripe) or the lettering "R 134a".
• Immediately plug open connections on A/C components and
pipes to prevent dirt and moisture contamination.
 I
87-4 Heating and Air-conditio1 11ng
AIC Fluids and Capacities

CAUTION-
• Do not steam clean AIC condensers or evaporators. Use only
cold water or compressed air.
• Do not reuse refrigerant oil.
• Do not store refrigerant oil in vicinity of flames, heat sources or
strongly oxidizing materials.
• In case of fire, use carbon dioxide (C0 2 ) extinguisher or sprayed
water jet on AIC components.
•After refilling or testing refrigerant lines, replace protective caps.
They serve as additional seals.
• In winter, run the AIC compressor at least 1O minutes each
month to maintain a film of oil on its moving parts and to ensure
seal integrity
• If a new compressor is installed or an old compressor is
charged with fresh refrigerant, turn over the compressor by
hand approx. 10 revolutions. This ensures that the compressor
is not damaged when activated.

A/C FLUIDS AND CAPACITIES

Refrigerant
The air-conditioning refrigerant in Audi A6 models is R134a , know n
chemically as tetraf/uoroethane. As it contains no chlorine , it is
considered harmless to atmospheric ozone if accidentally
discharged. Nevertheless, strict regulations govern the handl ing and
disposal of automotive refrigerants . Be sure to read Warnings and
Cautions in this group if working with A/C and heating components.

Refrigerant capacities for different models are shown in Table b.

Table b. A/C system refrigerant (R134a) capacities

Engine, production date Capacity in grams (oz)
V6 engine
11 I 1997 - 08 I 1998 850 + 50 (30 + 2)
08 I 1998 - 04 I 1999 750 + 50 (26 + 2)
All except 3.0 liter, 04 I 1999 on 650 + 50 (23 + 2)
3.0 liter 550 + 50 (19 + 2)
V8 engine
to 03 I 1999 550 + 50 (19 + 2)
03 I 1999 - 02 I 2000 650 + 50 (23 + 2)
02 I 2000 on 550 + 50 (19 + 2)

Refrigerant oil
A synthetic oil , polyalkylene glycol (PAG) , is used to lubricate the
A/C compressor. This type of oil is highly hygroscopic (attracts
water). Be sure to immediately reseal an opened container after use.

VAG recommends a PAG oil with a specific part number for each
type of A/C system used .

I
 Heating and Air-conditioning 87-5
Climate Control and Engine Cooling Controls

PAG oil recommendation

Denso compressor G 052 300 A2
Sanden compressor G 052 154 A2
Zexel compressor G 052 154 A2
or G 052 200 A2

A new A/C compressor is filled at the factory with refrigerant oil. If

installing a new compressor, recharge with refrigerant using A/C
recharging equipment. Do not reuse oil from old compressor.

Refrigerant oil capacities for different models are shown in Table c.

Table c. A/C system refrigerant oil (PAG) capacities

Engine, production date Capacity in cc (oz)
V6 engine
All except 3.0 liter 250 + 50 (8 .5 + 1.7 oz)
3.0 liter 220 + 50 (7.4 + 1.7 oz)

VB engine
All with timing belt 250 + 50 (8 .5 + 1.7 oz)
allroad quattro (engine code BAS) 220 + 50 (7.4 + 1.7 oz)

CLIMATE CONTROL AND

ENGINE COOLING CONTROLS

A/C and heater control panel

<Oiiiii( Climate control system automatically regulates interior temperature :
1. Left seat heater control
2. Recirculation OFF
3. A/C compressor OFF
4. Recirculation ON
5. Windshield defroster
6. Automatic setting : 23°C (75°F)
7. Interior air temperature sampling vent
8. Blower fan speed display
9. Rear window defogger
14 15 16 17 18
10. A/C and heater air directed to windshield defroster vents
A6048700 1
11. A/C and heater air directed to dashboard vents
12. A/C and heater air directed to footwell vents
13. Right seat heater control
14. Left side temperature setting
15. Decrease left side temperature
16. Increase left side temperature
17. Decrease blower fan speed
18. Inc rease blower fan speed
19. Decrease right side temperature setting
20. Increase right side temperature setting
21. Right side temperature setting
87-6 Heating and Air-conditioni , g
Climate Control and Engine Cooling Control

Climate control and engine cooling

fuses and relays
~ Main fuse panel, left end of dashboard.

Tabled. Climate control and engine cooling fuses

Function Fuse# Amperage
Climate control 5 10
Outside mirror heating 9 10
Climate control 15 10
Blower 25 30
Rear window defogger 26 30
Seat heater 44 30

~ 13-fold relay panel , underneath left side dashboard , trim panel

re moved .
• A/C clutch relay (J44) (arrow)

See 97 Fuses, Relays , Component Locations for access

information .

~ 8-fold relay panel , underneath left dashboard , trim panel removed .

• 2: Engine cooling fan relay, high speed (J101)
• 3: Engine cooling fan relay (J26)
• 14: Engine cooling fan fuse , 60A (S26) , 2002 - 2004 allroad quattro
• 19 and 20: Engine cooling fan fuse , 40A (S42)
• 21 : Engine cooling fan control module fuse , 5A (S 142)

See 97 Fuses, Relays, Component Locations for access

information .

~ 3-fold relay panel in E-box, under plenum chamber cover.

• 1 b : After-run coolant pump relay (J 151)
1a 4a
See 97 Fuses, Relays, Component Locations for access
information.

A60424005
 Heating and Air-conditioning 87-7
Climate Control and Engine Cooling Controls

Engine cooling fan and blower controls

<iiii{ Engine cooling fan switch (arrow) at radiator outlet pipe , right lower
radiator.

<iiii{ Engine cooling fan series resistor (N39) (arrow) , underneath left
front of engine .

<iiii{ Blower motor control module (J 126) (inset), behind glove

compartment on evaporator housing , left of blower motor.

NOTE -
• Audi identifies electrical components by a letter and/or a number in
the electrical schematics. See EWD Electrical Wiring Diagrams.
These electrical identifiers are listed in parentheses as an aid to
electrical troubleshooting.
87-8 Heating and Air-conditio mg
Climate Control Operation

CLIMATE CONTROL OPERATION

11

A/C system schematics

~ A/C refrigerant circuit, compressor with clutch :
12 I
1. A/C compressor
I
i 2. Compressor clutch (N25)
i
i 3. Refrigerant oil drain plug , 30 Nm (22 ft-lb)
i
7
13 ~ lI 4. High pressure relief valve , 10 Nm (7 ft-lb)
± I 5. Threaded junction
14~~ I
6. A/C pressure switch (F129)
Low . . . . High
pressure i pressure High pressure sensor (G65)
15 I 7. A/C condenser

- · --- · - ·--'
I 8. Connector, 15 Nm (11 ft-lb)
9. Sealing cap
~---------4 10. High pressure service port
.-.Lr---=....,_------3 11. Restrictor
12. A/C evaporator
l+------2
13. Low pressure service port
14. Sealing cap
1 I A87-0147 I 15. Receiver-dryer (accumulator)

~ A/C refrigerant circuit , compressor with regulator valve:

12 11
1. Compressor regulator valve (N280)
2. A/C compressor
- - - 10
3. Belt pulley
13 ED--9 4. Refrigerant oil drain plug , 30 Nm (22 ft-lb)
5. High pressure relief valve , 10 Nm (7 ft-lb)
6. Threaded junction
7. High pressure sensor (G65)
14 ~ ± 8
8. A/C condenser
15 --{§Jmcu I 9. Sealing cap
Low - - Hi gh
pressure ' pressure 10. High pressure service port

16 ~7 11. Connector
12. Restrictor
~-- 6
13. A/C evaporator
,-----------5
14. Low pressure service port
1~--~,---------- 4
15. Sealing cap
1~---- 3 16. Receiver-dryer (accumulator)

I A87-0329 I
 Heating and Air-conditioning 87-9
Climate Control Components

Air distribution
~ Evaporator housing components and airflow:
A. Dust and pollen filter element in plenum chamber
B. Rig ht front footwell
C. Blower (V2)
D. A/C evaporator
E. Heater core
F. Aux iliary heater element (Z35) (not for US market)
G. Left I right side divider
H. to Dashboard vents
I.
J. to Windshield vents
K. to Rear footwell vents
L. to Footwell vents
c M. Wi re mesh
1. Air flow flaps
2. Fresh air I recirculated air flap
3. Temperature flap 1
4. Temperature flap 2
I A87-0208 I
5. Center vent flap
6. Defroster flap
7. Footwell flap

CLIMATE CONTROL COMPONENTS

A/C and heating component locations are described in Table e and
shown in illustrations.

Table e. A/C and heater component locations

Component Code Location

A/C and heater control module J255 A/C and heater control panel in center dashboard
J301

A/C compressor Left front engine compartment

A/C compressor clutch N25 On A/C compressor, left front engine compartment

A/C compresso r regulator valve N280 On A/C compressor, left front engine compartment

A/C high pressure sensor G65 Right front engine compartment (2002 - 2004)
A/C pressure switch F129 Right side of A/C condenser (1998 - 2001)

Air flow (back pressure) flap motor V71 Near blower motor fresh air intake

Air flow flap motor position sensor G113 Part of air flow (back pressure) flap motor

Blower control module J126 In heating and A/C duct between evaporator housing and blower motor
Blower motor V2 In evaporator housing behind glove box

Blower motor control module J126 Under right side dashboard, to left of blower motor

Blower motor resistor N24 Under right side of dashboard , on blower motor

Center air flow flap motor V70 Right side of evaporator housing , lowest position

Center air flow flap motor sensor G112 Part of center air flow flap motor
 87-10 Heating and Air-conditio1 ~ing
I Climate Control Components

Table e. A/C and heater component locations

Component Code Location
Compressor clutch relay J44 13-fold relay panel underneath left side dashboard
Defroster flap motor V107 Right side of evaporator housing , topmost position
Defroster flap motor sensor G135 Part of defroster flap motor
Evaporator temperature sensor G263 Center of A/C and heater housing , under right side of dashboard
Footwell temperature sensor G192 A/C and heater housing , under right side of dashboard
Fresh air intake duct temperature sensor G89 Behind instrument panel , above blower motor housing , near fresh air
intake duct
'
Interior temperature sensor G56 On A/C and heater control panel
Interior temperature sensor fan V42 On A/C and heater control panel
Left footwell vent temperature sensor G192 Left side of A/C and heater housing , under center of dashboard
Left temperature regulator flap motor V158 Left side of evaporator housing , above heater core
Left temperature regulator sensor G220 Part of left temperature regulator flap motor

'
Left vent temperature sensor G150 In ducting behind dashboard vents
Recirculation flap motor V113 In plenum chamber, rear of engine compartment (2002 - 2004)
Right temperature regulator flap motor V159 Right side of evaporator housing , center position
Right temperature regulator sensor G221 Part of right temperature regulator flap motor
Right vent temperature sensor G151 In ducting behind dashboard vents
Heating and Air-conditioning 87-11
Climate Control Components

Climate control components

in engine compartment
1. Air extraction vents
• Under left and right rear bumper
• Free air movement through vents
necessary for vehicle ventilation
2. A/C compressor with clutch
• Left front of engine
3. Compressor clutch (N25)
• Front of A/C compressor
4. A/C condenser
• In front of radiator
5. Outside air temperature sensor (G17)
• Behind front bumper
6. A/C pressure switch (F129)
• 1998 - 2001
7. Receiver - dryer (accumulator)
• Under right headlight
8. Evaporator housing drain valve
• Underneath veh icle
9. Restrictor
• In refrigerant line
10. Service connection , high pressure
side
• Reinstall cap after repairs
11. Service connection , low pressure
side
A60487002 I • Reinstall cap after repairs
12. Dust and pollen filter
• See 03 Maintenance for replacement
procedure
13. Air flow flap motor (V71)
• Includes back pressure flap motor
position sensor (G113)
14. Recirculation flap motor (V11)
87-12 Heating and Air-condit oning
Climate Control Components

Climate control components

in engine compartment
1 (continued)
15. Sunroof with solar sensors
16. Air quality sensor (G238)
• In dust and pollen filter housing
17. Engine cooling fan control module
(J293)
• V6 3.0 liter engine
• In front of engine at cooling fan
18. A/C high pressure sensor (G65)
• 2002 - 2004
19. A/C compressor with regulator valve
• Left front of engine
20. A/C compressor regulator valve
(N280)
• Side of A/C compresso r

A60487003
Heating and Air-conditioning 87-13
Climate Control Components

Climate control components

in dashboard
1. Left temperature flap motor (V158)
•With temperature sensor (G220)
2. Footwell temperature sensor (G192)
3. Auxiliary heater (Z35) (not for US
market)
4. Heater core
5. A/C shut-off switch
• Controlled by ECM
6. Data link connector (DLC)
7. Left vent temperature sensor (G150)
8. Left dashboard vent
9. Left side window defroster vent
10. Outside air temperature display
(G106)
11. Windshield defroster vent
12. Sunlight photo sensor (G107)
87-14 Heating and Air-conditi ning
Climate Control Components

Climate control components

28 in dashboard (continued)
13. A/C control panel (E87)
14. Interior temperature sensor (G56)
and sensor fan (V42)
15. Evaporator housing (A/C and heating
unit)
16. Footwell vent
17. Center vent flap motor (V70)
•With temperature sensor (G 112)
18. Right temperature flap motor (V159)
•With temperature sensor (G221 )
19. Defroster flap motor (V107)
•With temperature sensor (G 135)
20. Blower (V2)
21. Right vent temperature sensor
(G151)
22. Right dashboard vent
23. Right side window defroster vent
24. Air intake duct temperature sensor
(G89)
25. Air flow flap motor (V71)
15 • With back pressure flap motor position
sensor (G 113) or recirculation flap
motor position sensor (G143)
•Up to 2001
26. Blower control module (J126)
I A87-0186 I 27. Evaporator housing drain
28. Center dashboard vent
 Heating and Air-conditioning 87-15
Climate Control Components

Climate control components

in dashboard
29. Sealing plug
•From 2002
30. Evaporator vent temperature sensor
(G263)
•From 2002
31. Recirculation flap motor (V113)
•From 2002
32. Air flow flap motor (V71)

I
• With back pressure flap motor position
,) sensor (G 113)
•From 2002

29 30
A87-0480
87-16 Heating and Air-conditio 1ng
Climate Control Repairs

CLIMATE CONTROL REPAIRS

Blower, removing and installing

Remove glove compartment. See 70 Interior Trim.

<liiiiii( Working under right side dashboard:

•Separate harness connector (A).
•Remove blower mounting screws (B) .
•Pull blower (C) out of evaporator housing in direction of arrow.

- Prior to installing new blower, carefully compare length of blower

wheel blades. Two versions are used , with one approx. 10 mm
(1/J in) shorter.

Installation is reverse of removal.

A/C compressor with clutch,

removing and installing
Following manufacturer's instructions, connect an approved
refrigerant recovery I recycling I recharging unit to A/C system and
discharge system.

WARNING-
• Do not attempt to discharge or charge the AIC system without
proper equipment and training. Damage to the vehicle and
personal injury may result.

Raise car and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove engine lower cover. See 03 Maintenance.

Remove engine accessory belt. See 03 Maintenance. Mark belt

with direction of rotation if it is to be reused .

<liiiiii( Detach refrigerant lines from compressor: Remove bolts A and B .

CAUTION-
• Immediately seal off open refrigerant lines and ports.

Unbolt compressor from bracket.

Installation is reverse of removal. Be sure to replace 0-ring seals C

and D.

Tightening torque
Compressor to engine bracket 25 Nm (18 ft-lb)
Refrigerant line to compressor 25 Nm (18 ft-lb)
 Heating and Air-conditioning 87-17
Climate Control Repairs

Prior to starting engine, rotate compressor manually approx. 1o

revolutions to lubricate internal components.

Start engine with climate control OFF. Wait until idle is stable . Then
switch A/C ON and allow to run at least 10 minutes at idle.

- Recheck accessory belt alignment.

A/C compressor with regulator valve,

removing and installing
Following manufacturer's instructions, connect an approved
refrigerant recovery I recycling I recharging unit to A/C system and
discharge system .

WARNING-
• Do not attempt to discharge or charge the AIC system without
proper equipment and training. Damage to the vehicle and
personal injury may result.

Place lock carrier (radiator support frame) in service position. See

50 Body-Front.

Remove oil filter.

Raise car and support safely.

WARNING -
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove engine lower cover. See 03 Maintenance.

Remove engine accessory belt. See 03 Maintenance. Mark belt

with direction of rotation if it is to be reused.

~ Working at side of compressor, remove regulator valve mounting

bolts (arrows) from compressor. Tie regulator valve safely to side.

CAUTIO~
• Immediately seal off open refrigerant lines and ports.

Unbolt compressor from engine bracket.

Installation is reverse of removal.

• Install one washer (8) on each bolt (A).
• Check that bushings (C) are seated correctly.

Tightening torque
Compressor to engine bracket 25 Nm (18 ft-lb)
Regulator valve to compressor 25 Nm (18 ft-lb)

- Check refrigerant lines for correct placement.

Prior to starting engine, rotate compressor manually approx. 10

revolutions to lubricate internal components.
87-18 Heating and Air-condit oning
Climate Control Repairs

- Start engine with climate control OFF. Wait until idle is stable. Then
switch A/C ON and allow to run at least 1O minutes at idle .

Recheck accessory belt alignment.

Heater core, removing and installing

CAUTION-
• To avoid personal injury, be sure the engine is cold before
opening the cooling system.

- Vehicle with power seats: Move seats all the way back.

~ Open engine hood and pull off rubber molding at engine

compartment rear bulkhead. Pull plenum chamber cover forward
and remove.

- Disconnect battery cables and remove battery. See 27 Battery,

Alternator, Starter.

CAUTION-
• Be sure to have the radio anti-theft code before disconnecting
the battery

1998 model : Remove complete windshield wiper assembly. See 92

Wiper and Washers .

~ Working in plenum chamber:

•Remove insulating grommet.
• Loosen screw (A) approx . 1O mm (1/x in) or remove .

- Loosen coolant reservoir cap to release cooling system pressure .

~ Use coolant hose pinch-off clamps (special tool VAG 3094 or

equivalent) to clamp off heater core hoses (A and B) . Disconnect
both hoses.

NOTE-
• Mark the hoses so that they can be reattached correctly:
Hose A: Coolant supply from cylinder head
Hose B: Coolant return to coolant pump

AB?-0215 I
 Heating and Air-conditioning 87-19
Climate Control Repairs

~ Place container under heater core connection and use compressed

air to blow out coolant.
• Remove rubber grommet (arrow) .

~ Working in passenger compartment , tilt steering column down and

pull off trim under instrument cluster. Remove steering column trim
panel fasteners (arrows) .

~ Remove lower trim fasteners (arrows) and pull down trim panels
under stee ring column to gain access to left side of evaporator
housing.

~ Working at left side of evaporator housing underneath dashboard:

•Unscrew screw (A) and remove bracket (8) .
•Loosen clamps (C) .
• Pull heater core (D) out of evaporator housing slightly.
• Pull coolant lines (E) off heater core.
• Remove heater core.

CAUTION-
• Be prepared to catch dripping coolant.
87-20 Heating and Air-condit ning
Climate Control Repairs

"'iiiii( If brake pedal mounting bracket interfered with heater core removal:
• Remove dashboard end covers on left and right.
•Loosen dashboard cross brace mounting fasteners (arrows) on
left and right. This allows dashboard and pedals to be moved
sufficiently out of the way for heater core removal.

CAUTION-
• The pedal assembly in 1998 models may interfere severely
with heater core removal. In that case, the entire dashboard
may need to be removed.

Installation is reverse of removal. Bear in mind:

• Replace heater core hose clamps and sealing 0- rings.
• Install hose clamps so that they do not contact and rattle against
evaporator housing.
• Fill and bleed cooling system . See 19 Cooling System . Check
system for leaks.

I .r
 9-1

9 Electrical System-General

GENERAL ... ... . .. .. . .... .. ........ .. ... 9-1 ELECTRICAL TROUBLESHOOTING .. . ... ... . . 9-3
Warnings and Cautions .. .. ... .... . .... . ... 9-1 Voltage and voltage drop ...... . ... . .. . . . . .. 9-4
Continuity, checking . . .. . . .. ... . .. . . . . . .... 9-5
Bus SYSTEMS . . ... ... . ..... . .... . ....... 9-2
Short circuits .. . . . .. .. . .... .. .. ... . .... .. 9-5

GENERAL
This rep air group presents a brief description of the principal parts of
the electrical system , including the bus systems. Also covered here
are basic electrical system troubleshooting tips .

Audi A6 models are equipped with a 12-volt, direct current (DC) ,

negative-g round electrical system. The voltage regulator maintains
the voltage in the system at approximately 12 volts. All circuits are
grounded by direct or indirect connection to the negative(-) terminal
of the battery.

All electrical circuits except those required for starting and operating
the engine are protected by fuses . For a full listing of fuses and fuse
locations , see 97 Fuses, Relays , Component Locations .

Also see:
• 27 Battery, Alternator, Starter
• 57 Doors and Locks
• 64 Door Windows
• 96 Interior Lights, Switches, Anti-theft
• EWD Electrical Wiring Diagrams

Warnings and Cautions

Please read the following before doing any work on your electrical
system .

WARNING-
• Airbags and pyrotechnic seat belt tensioners utilize explosive
devices. Handle with extreme care. Refer to the warnings and
cautions in 69 Seat Belts, Airbags.
• The ignition system of the car operates at lethal voltages. If you
have a weak heart or wear a pacemaker, do not expose yourself
to ignition system electric currents. Take extra precautions when
working on the ignition system or when servicing the engine
while it is running or the key is ON. See 28 Ignition System for
additional ignition system warnings and cautions.
• Keep hands, clothing and other objects clear of the electric
radiator cooling fan when working on a warm engine. The fan
may start at any time, even when the ignition is switched OFF
9-2 Electrical System-General
Bus Systems

CAUTIO~
• Do not disconnect the battery with the engine running.
•Switch the ignition OFF and remove the negative(-) battery
cable before removing any electrical components. Connect and
disconnect electrical connectors and ignition test equipment
leads only while the ignition is switched OFF
• Relay and fuse positions are subject to change and may vary
from car to car. If questions arise, an authorized Audi dealer is
the best source for the most accurate and up-to-date
information.
• Use a digital multimeter for electrical tests. Switch the multimeter
to the appropriate function and range before making test
connections.
•Many control modules are static sensitive. Static discharge
damages them permanently Handle the modules using proper
static prevention equipment and techniques.
• To avoid damaging harness connectors or relay panel sockets,
use jumper wires with flat-blade connectors that are the same
size as the connector or relay terminals.
• Do not try to start the engine of a car which has been heated
above 176°F (B0 °C) (for example, in a paint drying booth). Allow
it to cool to normal temperature.
• Disconnect the battery before doing any electric welding on the
car. Do not wash the engine while it is running, or any time the
ignition is ON.
• Choose test equipment carefully Use a digital multimeter with at
least 10 MD. input impedance or an LED test light. An analog
meter (swing-needle) or a test light with a normal incandescent
bulb may draw enough current to damage sensitive electronic
components.
• Do not use an ohmmeter to measure resistance on solid state
components such as control modules.
•Disconnect the battery before making resistance (ohm)
measurements on a circuit.

Bus SYSTEMS
Audi A6 vehicles are electrically complex. Many vehicle systems
and subsystems are interconnected or integrated . In addition , the
requirements of second generation on-board diagnostics (OBD 11 )
are such that there are many more circuits and wires in the vehicle
than ever before . The components must exchange large volumes of
data with one another in order to perform their various functions .

To handle this complexity effectively, the A6 makes extensive use of

control module networking using controller area network (CAN) bus
systems. Signals are shared digitally among several control
modules on a CAN-bus, eliminating the need for separate
connections for each pair of control modules. The use of bus
communication for controls and accessories reduces wiring
complexity and improves system response time.

The CAN-bus consists of a pair of wires twisted together to ensure

reliable communication among modules without conflicts or
interference. The two wires are referred to as CAN-high and CAN -
low.
 Electrical System-General 9-3
Electrical Troubleshooting

Data transfer over a the CAN-bus is similar to a telephone

conference. A control module on the bus transmits a stream of data
which other modules receive at the same time . Each control module
then decides to use or ignore this data.

The benefits of the bus method of data transfer are as follows :

•As data and programs are modified and extended , only software
modifications are necessary.
• Continuous verification of transmitted data leads to low error rate .
•Sensors and signal wires can be simplified or eliminated due to the
transmittal of multiplexed digital data.
• Control modules transfer data at a high rate.
• Control module sizes and connector sizes are smaller.
• CAN-bus conforms to international standards. This facilitates data
interchange between control modules of different manufacture.

As of 2000 , the A6 CAN-bus systems consisted of the following:

• Drivetrain CAN-bus : 500k baud transfer rate
• Convenience CAN-bus: 1OOk baud transfer rate
• Infotainment CAN-bus: 1OOk baud transfer rate

""iii( Drivetrain CAN-bus

1. ABS I ES P control module (J 104)
2. Engine control module (ECM) (J271)
3. Instrument cluster control module (J285)
4. Steering angle sensor (G85)
A604900 1 5. Autom atic transmission control module (J217)

ELECTRICAL TROUBLESHOOTING
Four things are required for current to flow in any electrical circuit:
• Voltage sou rce
• Wires or connections to transport voltage
• Load or device that uses electricity
• Connection to ground

Most problems can be found using a digital multimeter (volt I ohm I

ammeter) to check the following:
• Voltage supply
• Breaks in the wiring (infinite resistance I no continuity)
• A path to ground that completes the circuit

Electric current is logical in its flow, always moving from the voltage
source toward ground . Electrical faults can usually be located
through a process of elimination. When troubleshooting a complex
circuit , separate the circuit into smaller parts. General tests outlined
below may be helpful in finding electrical problems. The information
is most helpful when used with wiring diagrams.

Be sure to analyze the problem . Use wiring diagrams to determine

the most likely cause. Get an understanding of how the circuit works
by following the circuit from ground back to the power source .

When making test connections at connectors and components , use

care to avoid spreading or damaging the connectors or terminals .
9-4 Electrical System-Gener al
Electrical Troubleshooting

Some tests may require jumper wires to bypass components or

connections in the wiring harness. When connecting jumper wires ,
use blade connectors at the wire ends that match the size of the
terminal being tested. The small internal contacts are easily spread
apart, and this can cause intermittent or faulty connections that can
lead to more problems.

Voltage and voltage drop

Wires , connectors , and switches that carry current are designed
with very low resistance so that current flows with a minimum loss of
voltage. A voltage drop is caused by higher than normal resistance
in a circuit. This additional resistance actually decreases or stops
the flow of current. Excessive voltage drop can be noticed by
problems ranging from dim headlights to sluggish wipers . Some
common sources of voltage drops are corroded or dirty switches,
dirty or corroded connections or contacts , and loose or corroded
ground wires and ground connections.

A voltage drop test is a good test to perform if current is flowing

through the circuit but the circuit is not operating correctly. A voltage
drop test helps pinpoint a corroded ground strap or a faulty switch.
Normally, there should be less than 1 volt drop across most wires or
closed switches . A voltage drop across a connector or short cable
should not exceed 0.5 volt.

A voltage drop test is generally more accurate than a simple

resistance check because the resistances involved are often too
small to measure with most ohmmeters. For example, a resistance
as small as 0.02 n would results in a 3 volt drop in a typical 150 amp
starter circuit. (150 amps x 0 .02 n = 3 volts).

Keep in mind that voltage with ignition key ON and voltage with
engine running are not the same. With ignition ON and engine OFF
(battery voltage) , voltage should be approximately 12.6 volts. With
engine running (charging voltage) , voltage should be approximately
14.0 volts. Measure voltage at battery with ignition ON and then with
engine running to get exact measurements.

Voltage, measuring

from Battery
~ Connect digital multimeter negative lead to a reliable ground point
on car.
+

nn
L~
Fuse box
NOTE-
• The negative (-) battery terminal is always a good ground point.

Battery voltage - Connect digital multimeter positive lead to point in circuit you wish to
measure .
Swi tch
- Voltage reading should not deviate more than 1 volt from voltage at
battery. If voltage drop is more than this , check for a corroded
connector or loose ground wire.
No voltage
r . ..,
I 9I Load

L .. ..J

0013238a
 Electrical System-General 9-5
Electrical Troubleshooting

fro m Battery
Voltage drop, testing
+
Check voltage drop only when there is a load on the circuit , such as
when operating the starter motor or turning on the headlights. Use a
Fuse box digital multimeter to ensure accurate readings .

~ Connect digital multimeter positive lead to positive (+) battery

terminal or a positive power supply close to battery source.

Switch
U.c' ll - Connect digital multimeter negative lead to othe r end of cable or
switch being tested.

- With power on and circuit working , meter shows voltage drop

Load
(difference between two points). This value should not exceed 1 volt.

Maximum voltage drop in an automotive circuit , as recommended by

the Society of Automotive Engineers (SAE), is as follows :
• O volt for small wire connections
0013239a
• 0.1 volt for high current connections
• 0.2 volt fo r high current cables
• 0.3 volt fo r switch or solenoid contacts

On longer wires or cables , the drop may be slightly higher. In any

case , a voltage drop of more than 1.0 volt usual ly indicates a
problem .

Brake pedal in rest position Continuity, checking

! ~. Use continuity test to check a circuit or switch. Because most

Brake
light switch
rn
w
automotive circuits are designed to have little or no resistance , a
circuit or part of a circuit can be easily checked for faults using an
ohmmeter. An open circuit or a circuit with high res istance does not
allow current to flow. A circuit with little or no res istance allows

r current to flow easily.

When checking continuity, turn ignition OFF. On circuits that are

powered at all times, disconnect battery. Using the appropriate
wiring diagram , test circuit for faulty connections , wires , switches,
relays and engine sensors by checking for continuity.
Brake pedal depressed
~ Example : Test brake light switch for continu ity :

1 •With brake pedal in rest position (switch open ) there is no

Bra ke
lig ht switch
~
LI
continuity (infinite n ).
• With pedal depressed (switch closed) the re is continuity
(0 0 ).

f "'
Short circuits, testing
Short circuits are exactly what the name implies . Current in the
circuit takes a shorter path than it was designed to take. The most
common short that causes problems is a short to ground where the
insulation on a positive(+) wire wears away and the metal wire is
exposed . When the wire rubs against a metal part of the car or other
ground source, the circuit is shorted to ground . If the exposed wire is
live (positive battery voltage) , a fuse blows and the circuit may be
damaged .
9-6 Electrical System-Gener
Electrical Troubleshooting

Short circuits are often difficult to locate and may vary in nature .
Short circuits can be found using a logical approach based on
knowledge of the current path .

Use a digital multimeter to locate short circuits.

CAUTION-
• In circuits protected with high rating fuses (25 amp and
greater), wires or circuit components may be damaged before
the fuse blows. Check for wiring damage before replacing
fuses of this rating. Also, check for correct fuse rating.

from Battery
Testing with ohmmeter
+ - Remove blown fuse from circuit and disconnect cables from batte ry.

~I
I Fuse box
Disconnect harness connector from circuit load or consume r.

~ Using an ohmmeter, connect one test lead to load side of fu se

r-nnnl
'
;J.
Short-circuit terminal (terminal leading to circuit) and other test lead to ground .
~
to ground
If there is continuity to ground , there is a short to ground .
Switch
If there is no continuity, work from wire harness nearest to fuse I
relay panel and move or wiggle wires while observing mete r.
Load disconnected
Continue to move down harness until meter displays a reading . Th is

_l_ r!1
I
L
I
_J
Load

-
is the location of the short to ground .

Visually inspect wire harness at this point for any faults . If no faults
are visible , carefully slice open harness cover or wire insulation for
0013241
further inspection . Repair any faults found .

Testing with voltmeter

- Remove blown fuse from circuit. Disconnect harness connector

from circuit load or consumer.

NOTE -
• Most fuses power more than one consumer. Be sure all consumers
are disconnected when checking for a short circuit.

~ Using a digital multimeter, connect test leads across fuse term inals.
fro m Battery Make sure power is present in circuit. If necessary switch ignition
+ ON .

rl-,I
I Fu se box
If voltage is present at voltmeter, there is a short to ground .

If voltage is not present, work from wire harness nearest to fuse I

Short-circuit
relay panel and move or wiggle wires while observing meter.
to ground
Continue to move down harness until meter displays a reading . Th is
Switch
is the location of the short to ground.

Visually inspect wire harness at this point for any faults . If no faults
Load disconnected are visible , carefully slice open harness cover or wire insulation fo r
further inspection . Repair any faults found .

'f'
I
L _J
I Load

001 3 240a
/

I J
-
 90-1

90 Instruments

GENERAL . ............................ . 90-1 INSTRUMENT CLUSTER REPAIRS ... . ... ... 90-4
Instrument cluster .. .......... .. .... . ..... 90-1 Instrument cluster, removing and installing . . .. 90-4
Instrument cluster and warn ing lights . . ....... 90-2 Instrument cluster details ....... .. ......... 90-5
Driver information ........ .. ........ . ..... 90-3
On-board diagnostics ............. .. ... . .. 90-3
Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4

GENERAL
This repair group covers the instrument cluster and warning lights.

See 91 Radio and Communication for information about the

navigation system.

Instrument cluster
~ The instrument cluster consists of
• Engine oil temperature gauge
• Tachometer with clock
• Engine coolant temperature gauge
•Fuel gauge
• Multifunction indicator (MFI) screen
• Electronic speedometer, odometer, trip odometer
•Voltmeter

Warning and indicator lights in the speedometer and tachometer

faces are LEDs which cannot be serviced separately. An LED
malfunction requi res instrument cluster replacement.

The instrument cluster supplements various warning light displays

with acoustic warnings.
90-2 Instruments
General

Instrument cluster and

4 7 warning lights
5 6
1. Electronic throttle (EPC)
2. Malfunction indicator light (MIL)
3. Headlights and side marker lights on
4. Tachometer
5. Self-leveling suspension
malfunction (allroad quattro)
6. Anti-slip regulation (ASR) or
electronic stabilization program
(ESP)
7. Electronic immobilizer on
8. Left turn signal indicator
9. Engine coolant temperature gauge
10. High beams on
19 20 21 22 23 11.Fuelgauge
A604 90002 12. Right turn signal indicator
13. Airbags malfunction
14. Anti-lock braking (ABS) malfunction
15. Speedometer
16. Brake fluid low or parking brake on
17. Charging system malfunction
18. Seat belts not buckled
19. Clock
20. Left setting button:
•Clock
• Auto check system
• Trip odometer
21. Driver information display
22. Right setting button:
• Service interval
• Trip odometer
23. Odometer and service indicator

NOTE-
• Warning light placement and other functions vary slightly among
models.
 Instruments 90-3
General

Driver information
~ The driver information display in the center of the instrument cluster
provides useful driver information and service reminders , including:
• Service interval
• Auto-check system
• Outside air temperature
• Trip computer
• Automatic transmission gear shift position
• Radio frequency
•Door open indicator
•Speed warning

If equipped , the driver information display doubles as the navigation

display. See 91 Radio, Communication .

~ Use the reset button on the wiper I washer switch (arrow) to zero
functions such as driving time , average mileage or average speed .

~ 2002 - 2004: Select or reset driver information display using Menu

button on center console , to the right of the parking brake handle.

On-board diagnostics
If the on-board diagnostics (OBD 11) system recognizes instrument
cluster malfunctions relating to odometer or speedometer
calibration , the trip odometer displays dEF.

~ Before performing troubleshooting or inspection , access fault

memory with VAG scan tool or equivalent plugged into DLC plug
(inset) under left side dashboard .
90-4 Instruments
Instrument Cluster Repairs

Cautions

CAUTIO~
• Switch the ignition OFF and remove the negative (-) battery
cable before removing any electrical components.
• Connect and disconnect electrical connectors and ignition test
equipment leads only while the ignition is OFF
• Only use a digital multimeter for electrical tests.
• To avoid damaging plastic interior trim, use a plastic prying tool
or a screwdriver with the tip wrapped with masking tape.

INSTRUMENT CLUSTER REPAIRS

Instrument cluster, removing and installing

It is not necessary to remove steering wheel to remove instrument
cluster.

- If replacing cluster with new, note odometer reading on old cluster.

- Adjust steering wheel backward and down .

- Switch ignition OFF. Disconnect battery negative cable .

CAUTIO~
•Prior to disconnecting the battery, read the battery
disconnection precautions in 27 Battery, Alternator, Starter.

~ Press in sides of instrument cluster lower trim (insert) to disengage

from dashboard . Lift out trim .

A90-0070 I

~ Remove cluster mounting screws (arrows)

- Tilt instrument cluster rearward and cut wire ties at rear. Unclip
connectors securing latches and detach connectors.

- Installation is reverse of removal. If new cluster is installed , use VAG

scan tool or equivalent for coding and adaptation functions :
• Code new cluster to vehicle version and equipment level.
•Adapt odometer reading .
•Adapt electronic immobilizer functions to engine control module
(ECM).

I A90- 0081
 Instruments 90-5
Instrument Cluster Repairs

Instrument cluster details

B c 1 2 3 A
~ 1998 - 1999: Lights 1, 2 , 3 are 1.2 W replaceable bulbs:
1. High beam indicator
2. ASR I ESP indicator
3. Malfunction indicator light (MIL)
A . 32 -pi n connector, blue , basic functions
B. 32-pin connector, green , additional functions
C. 20-pin connector, red , driver information screen

- All other indicator lights are LEDs. In case of failure , replace

instrument cluster.
A90-0074 I

~ 2000 and later: All indicator lights are LEDs . In case of failure ,
replace instrument cluster.
A. 32-pin connector, green , basic functions
B . 32-pin connector, blue , additional functions
C . 32-pin connector, grey , driver information screen
D. 4-pin connector, black, remote clock (not connected in US)

I A90 -0130
1
 91-1

91 Radio and Communication

GEN ERAL . . ... .. . .. . ... . . . ... . . . .. . . . . . 91-1 TELEPHONE ... . .... . . . .. . . .. .. . .. . . . .. 91 -10
On-board diagn osti cs . ... . .. .. . . . .. ... . ... 91-2 Hands-free telephone components . . ... . . .. 91-1 O
Cautions . ... . .. . . . .. . .. .. . . . . .. .. . .. . . . 91-2 Dig ital cellular telephone components . .. . .. . 91-1 O
RADIO . .. . . .. . . . . . .. . . . ... .. .. . . . . .. . .. 91-3 NAVIGATION ... . ... . . . . . . ... .. .... . . . . . 91-11
Radio power supply .. ... .. . ... .. .. .. .. . . . 91-3 Navigation system components . . .. .. . . .. .. 91-11
Sound system components , sedan (1998 - 2001) 91-4 Navigation display . ... .. .. . . .. . ... . . .. .. 91-11
Sound system components, sedan (2002 - 2004) . 91-4 Navigation function selector . . . . . . . .. . . .. .. 91-12
Sound system w ith satellite radio Navigation control module .... . .. . . . . . .. .. 91-12
(SOARS) , sedan . . .. .. . . . . ... .... . . . .. . 91-5
TELEMATICS .. .. ... .... ... . . ... ..... .. . 91-12
Radio connections . ... . ...... . . . . . . . .. . .. 91-5
T elematics components . . . . . . . . . . . . . . . . . . 91-13
Radio pin assignm ents , basic . .. . ... .. .. .. . 91-6
Bose® amp lifier pin ass ignments . . . .. . . ... . . 91-7 MULTIFUNCTION STEERING WHEEL . ... ... 91-13
Satellite rad io pin assig nments . . . . . . .. . . . . . 91-8 Multifunction steering wheel , 1998 - 2001 91 -14
Rear win dow antenna connections (sedan) .. .. 91-8 Multifunction steering wheel , 2002 - 2004 .. . . 91 -14
Side window antenna connections (Avant) . .. . 91-8 Multifunction steering wheel
Radio , removin g and installing .. . .. . ...... . . 91-9 control module (J453) .. .. . ... . .. . ...... 91-1 4

GENERAL
This repair group covers Audi A6 factory instal led sound systems .
Also descri bed are the optional telephone , Tele matics , navigation
system and multifunction steering wheel.

The basic and premium Audi A6 sound systems ce nte r on the

Concert radio and the Symphony radio. The radio is coded to the
vehicle using VAG scan tool or equivalent. Coding is based on other
equipment installed such as telephone , CD changer, navigation or
amplifie r.

If you plan to install an aftermarket system, see Cautions in this

repair group.

See also EWD Electrical Wiring Diagrams.

91-2 Radio and Communicati n
General

On-board diagnostics
If the on-board diagnostics (080 11) system recognizes malfunctions
in the radio or communication systems, it sets diagnostic fault codes
(DTCs) .

~ Access fault memory with VAG scan tool or equivalent plugged into
DLC plug (inset) under left side dashboard.

Cautions
Read the following cautions and the additional warnings and
cautions in 97 Fuses, Relays , Component Locationsbefore doing
any work on your electrical system .

CAUTIO~
• The radio is wired to the vehicle alarm system. If the alarm
system is armed, removing the radio activates the alarm even
if the proper tools are used. Do not attempt to remove the
radio without disarming the alarm.
• The factory installed connectors are designed for the genuine
Audi radio. If installing a different radio, remember that it may not
fit properly into the space provided, the electrical connections
may not be compatible and different terminals may be needed.
• The factory installed radio is electronically linked to the
instrument cluster, ignition, alarm and data link circuits.
• Prior to disconnecting the battery, read the battery disconnection
precautions in 27 Battery, Alternator, Starter.
• Switch the ignition OFF and remove the negative (-) battery
cable before removing any electrical components.
• Connect and disconnect electrical connectors and ignition test
equipment leads only while the ignition is OFF
• Only use a digital multimeter for electrical tests.
• To avoid damaging plastic interior trim, use a plastic prying tool
or a screwdriver with the tip wrapped with masking tape.
 Radio and Communication 91-3
Radio

RADIO
Audi A6 sound system components and options are as follows :
• Basic 140 watt ten speaker system
•Premium 200 watt ten speaker system
• Concert in-dash radio
•Symphony double-height (double-DIN) radio
• Bass, midrange and treble speakers in doors
• Subwoofer behind trunk or luggage compartment right side trim
• Bose® amplifier behind trunk or luggage compartment right side
trim
•CD changer behind trunk or luggage compartment left side trim
•Satellite radio behind trunk or luggage compartment left side
storage box
•Antenna
-Sedan : Rear window
-Avan t: Side rear windows
•Antenna amplifiers
-Sedan : Behind left and right D-pillar trim
-Avant: Below left and right luggage compartment side trim
•Antenna selection control module
-Sedan : Underneath rear parcel shelf trim
-Avant: Under headliner near roof antenna
•Satellite radio antenna on roof

Radio power supply

~ In main fuse panel , left end of dashboard.

ISound system fuse rating

Fuse 37
91-4 Radio and Communicatio
Radio

Sound system components, sedan

2 3 4 (1998 - 2001)
1. Radio (R) in center dashboard
2. Subwoofer (R100) in right rear trunk behind trim
3. Amplifier (R12) in right rear tru nk behind trim , Bose®
4. Antenna ampl ifier behind left D-pillar trim
5. CD changer (R41)
6. Rear treble I midrange speakers (R34, R35) in rear door upper
trim
7. Rear bass speakers (R15 , R17) in rear door lower trim
8. Front treble I midrange speakers (R26 , R27) in front door
upper trim
9. Front bass speakers (R21 , R23) in front door lower trim

NOTE-
9 8 7 6 5 • Audi identifies electrical components by a letter and/or a number in
the electrical schematics. See EWD Electrical Wiring Diagrams.
These electrical identifiers are listed in parentheses as an aid to
electrical troubleshooting.
A91-0302
•Avant (station wagon) sound system layout and components are
similar.

2 3
Sound system components, sedan
6 7 8
(2002 - 2004)
1. Radio (R) in center dashboard
2. Subwoofer (R100) in right rear trunk behind trim
3. Amplifier (R12) in right rear trunk behind trim , Bose®
4. Antenna amplifier (R82) behind right upper D-pillar trim
5. Antenna amplifier (R83) behind right lower D·pillar trim
6. Antenna amplifier (R85) behind left upper D-pillar trim

() 7. Antenna selection control module (J515) underneath left side

parcel shelf
8. Antenna amplifier (R84) behind lower D-pillar trim
9. CD changer (R41)
10. Rear treble I midrange speakers (R34, R35) in rear door uppe r
trim
11. Rear bass speakers (R15 , R17) in rear door lower trim
13 12 11 10 9 12. Front treble I midrange speakers (R26 , R27) in front door
upper trim
A91-0248
13. Front bass speakers (R21 , R23) in front door lower trim

NOTE-
• Avant (station wagon) sound system layout and components are
similar.
 Radio and Communication 91-5
Radio

Sound system with satellite radio (SOARS),

2 3 4 5 7 8 sedan
1. Radio (R) in center dashboard
2. Subwoofer (R100) in right rear trunk behind trim
3. Amplifier (R 12) in right rear trunk behind trim , Bose®
4. Antenna amplifier (R82) behind right upper 0-pillar trim
5. Satellite antenna (R182) on roof
6. An tenna amplifier (R83) behind right lower 0-pillar trim

~ c~ 7.
8.
Antenna amplifier (R85) behind left upper 0-pillar trim
Antenna amplifier (R84) behind left lower 0-pillar trim
9. CD changer (R41)
10. Satellite tuner (R146)
11. Antenna selection control module (J515) underneath left side
parcel shelf
15 14 13 12 11 10 9 12. Rear bass speakers (R15 , R17) in rear door lower trim
13. Rear treble I midrange speakers (R34, R35) in rear door upper
trim
A9 1-1034
14. Front bass speakers (R21 , R23) in front door lower trim
15. Front treble I midrange speakers (R26 , R27) in front door
upper trim

NOTE -
•Avant (sta tion wagon) sound system layout and components are
similar.

Radio connections
8 4
At rear of radio:
1. Antenna connection socket for radio (HF wire)
2. ZF-wire
3. Radio switch block
4. Connector 1, 20-pin , black
5. Connector 2 , 8-pin , brown
6. Connector 3, 8-pin , black
5
7. Connector 4, 10-pin, red
u
8. Anti-theft alarm system ground (1998 - 2001)
9. Fuse

2 7 3 6 9
A 9 1-0222
91-6 Radio and Communicatio
Radio

Radio pin assiignments, basic

Connector 1, 20-pin, black
1. Line output, left rear
2. Line output, right rear
3. Line output, ground
4. Line output, left front , Bose®
5. Line output, right front, Bose®
6. Switched power for speakers
Switched power for amplifier, Bose®
7. CAN-bus high (infotainment) , 2002 - 2004
I A91-0079 I 8. Radio clock, 1998 - 2001
9. Radio frequency data signal , 1998 - 2001
10. Radio frequency display enable signal , 1998 - 2001
CD ground , 2002 - 2004
11. Steering wheel remote control , 1998 - 2001
12. CAN-bus low (infotainment) , 2002 - 2004
13. CD display signal in
14. CD display signal out
15. CD clock
16. Power supply (B+) , CD changer
17. Switched power supply, CD changer
18. Ground , CD changer
19. Line output, left, CD changer
20. Line output, right, CD changer

Connector 2, 8-piin, brown

1. Right front speaker signal
2. Right front speaker ground
3. Left front speaker signal
4. Left front speaker ground

Connector 3, 8-piin, black

1. GALA (vehicle speed signal) , 1998 - 2001
Bose® coding , 2~002 - 2004
2. Telephone muting , 1998 - 2001
Anti-theft ground , 2002 - 2004
3. K or L line, on-board diagnostics
4. Radio switching connection to ignition switch , 1998 - 2001
5. Automatic antenna control , 1998 - 2001
6. Switch illumination 1998 - 2001
7. Power supply (B+)
8. Ground
 Radio and Communication 91-7
Radio

Connector 4, 1O pin, red

1. Telephone muting
2. Terminal 15, navigation only, 1998 - 2001
3. Telephone (NF+) , without navigation
4. Telephone (NF-) , without navigation
5. Navigation (NF+)
6. Navigati on (NF-)
7. Navigation control wire
8. Not used
9. Display illumination, terminal 58d , 1998 - 2001
10. CD changer ground , 1998 - 2001

Bose® amplifier pin assignments

1. Not used
2. Not used
3. Not used
4. Not used
5. Not used
6. Line input from radio , ground
7. Line input from radio , right rear
8. Line input from radio , left rear
9. Line input from radio , right front
A91-1 0 16
10. Line input from radio , left front
11. Not used
12. Not used
13. Power (B+)
14. Not used
15. Not used
16. Left front speaker ground
17. Left front speaker power
18. Right front speaker power
19. Right front speaker power
20. Left rear speaker power
21. Left rear speaker ground
22. Right rear speaker power
23. Right rear speaker ground
24. Switched power
91-8 Radio and Com munica ion
Radio

Satellite radio pin assignments

A A. Conn ector, 8-pin :
1. CAN-bus high (infotainment)
2. CAN-bus low (infotainment)
3. CD in , left
4. CD in , right
5. Grou nd NF (radio)
6. Left channel NF
7. Right channel NF
1 8 8 2
8. Ground (CD)
I A91- 1007 B. Connector, 8-pin :
1. Power
2. Ground
6 2 c. Satellite antenna, brown
D. Satellite antenna, green

Rear window antenna connections (sedan)

1. FM antenna 1
2. FM antenna 2
3. Auxiliary heater antenna (if applicable)
4. FM antenna 3
'1
5. FM antenna 4
6. AM antenna

...

5 4 3
A9 1-0 11 4

Side window antenna connection (Avant)

~ On Avant (station wagon ), FM antennas 1 - 3 are in the side rear
windows :
1. FM antenna 1 on right rear window
1. FM antenna 2 on left rear w indow
2. FM antenna 3 on left rear window

FM antenna 4 and AM antenna are on roof.

If equipped with satellite radio (SOARS) with antenna on roof, the

following side window configuration is used :
1. FM antenna 1 on right rear window
1 2
2. FM antenna 2 on right rear window
A9 1-0 152
1. FM antenna 4, AM antenna on left rear window
2. FM antenna 3 on left rear window
 Radio and Communication 91-9
Radio

Radio , removing and installing

- Obtain radio anti-theft security code.

Switch ignition OFF. Disconnect battery negative cable.

CAUTION-
• Prior to disconnecting the battery, read the battery
disconnection precautions in 27 Battery, Alternator, Starter.

...;;{ Use VAG special tools for radio removal:

T10057 • VAG T10057 consists of 4 prying hooks for Symphony radio
removal.
• VAG 3344 consists of 2 prying hooks for Concert radio removal

I W00 -1042 I
...;;{ Concert radio: Insert special tools 3344 (arrows) into front of radio
and rele ase from center dashboard .

...;;{ Symphony radio: Insert special tools T10057 (arrows) into upper
and lower slots in front of radio and release from center dashboard .

EH
Pull radio out and detach connectors and antenna cable.
lr"F~
II
-; - · · 8
_ B
_LO•_D. ..._ Prior to reinstalling radio, remove special tools from panel.
~CA N __J - - ·- - ··

- Attach electrical connections and antenna.

- Slide radio into center dashboard frame until it engages firmly.

- Reconnect battery and activate anti-theft coding .

91-10 Radio and Communicati n
Telephone

TELEPHONE
The telephone is an option supplied in two versions :
•Hands-free telephone , 1998 - 2001
• Digital cellular telephone, 2002 - 2004, used in conjunctio n with
Telematics

2 Hands-free telephone components

1. Telephone handset (R37)
2. Telephone-navigation speaker (R39) behind left B-pillar lower
trim (Bose® system)

7~ 4
3.
4.
Radio (R)
Front speakers behind front door panels
5. Telephone transceiver (R36)
-1998: Under rear parcel shelf
-1999 - 2004: in trunk or luggage compartment left side storage
compartment
6. Antenna
-Sedan: In rear window
@ -- s -Avant: On roof
7. Telephone microphone (R38)
-1998 - 1999: In left A-pillar
-2000 - 2004: In front interior light module

A9 1·0665

Digital cellular telephone components

1. Telephone handset docking station (R54)
2. Spiral cord
3. Radio (R)
4. Front speakers behind front door panels
5. Telephone antenna (R65) in rear bumper
6. Telematics-telephone control module (J526) in right front
footwell
7. Telephone microphone (R38)
3
C>
Q[==:::J

6 4

5 A9 1·0776
 Radio and Communication 91-11
Navigation

NAVIGATION
<iiiii{ Vehicle navigation systems utilize the signal from 24 global
position ing system (G PS) satellites.

The navigation system is available as an option in Audi A6 vehicles .

Two ve rsions of the system are used ;
• Navigation Ill , 1998 - 2001 :
-Displ ay in instrument cluster driver information screen
-Data entries via multifunction switch on center console
-Control module with CD reader in trunk or luggage compartment
-Navigation antenna on roof
• Navigation IV, 2002 - 2004, has similar components but offers the
A6049 1006 following additional functions and features:
-Dynamic route guidance
-Integration with Audi Telematics
-Compass
-Help functi on

The navigation system is integrated with the vehicle CAN-bus

network. The dynamic route guidance feature in Navigation IV
2 3 4 enables local traffic report information to be accessed from either
the radio or the telephone .

The navigation system is self-diagnosing . DTCs are stored in the

navigation control module.

Navigation system components

1. Radio (R) in center dashboard
2. Function selector switch (E272) in center console
3. Instrument cluster driver information display
4. Navigation antenna (R50)
Radio-telephone-navigation antenna (R52)
1998 - 2001: On trunk lid
2002 - 2004: On roof
5. Navigation control module with CD reader (J401) in trunk or
8 7 6 5 luggage compartment left side storage compartment
6. Telephone-navigation speaker (R39) in B-pillar trim (vehi cle
with Bose® sound system)
A91-07 13 7. Bass speaker in front door lowe r trim
8. Tweeter I midrange speaker in front door upper trim

Navigation display
<iiiii{ The driver information display at center of instrument cluster serves
as navigation display.
91-12 Radio and Communicati n
Telematics

Navigation function selector

~ The function selector switch (arrow) is on center console , to right of
parking brake handle.

Navigation control module

~ Navigation control module with CD reader (arrow) is in storage
compartment at left side of trunk or luggage compartment.

TELEMATICS
Telematics is an optional system that uses cellular, internet and
global positioning system (GPS) technologies to provide the driver
with safety, security and convenience services.

The Telematics-telephone control module receives GPS data,

decodes it, and transmits vehicle location to the service provider
On Star® call center via cellular network. On Star® service plans may
provide route directions, concierge services or emergency veh icle
repair services.

If the airbag control module detects a crash , vehicle emergency

flashers are activated and doors are unlocked via door control
modules. In addition , the Telematics system automatically places an
emergency call to the OnStar® call center.

An emergency (back-up) battery for the Telematics control module is

used in case the vehicle battery goes dead or becomes
disconnected .
 Radio and Communication 91-13
Multifunction Steering Wheel

Telematics components
1. Emergency battery (A 16) on Telematics-telephone control
module in right front footwell
5 6 7 2. Telematics-telephone control module (J526 ) in right front

i
footwell
3. Multifunction steering wheel
4. Front interior light module with Telematics control head (E264)
A. OnStar® button
B. System status LED
C. Emergency button
D. Communication button
E. Telephone microphone (R38)
5. Telematics speaker (R91) behind right 8-pillar lower trim
6. Navigation-Telematics antenna (R50, R90) on roof
7. Antenna splitter (R87) in trunk or luggage compartment left
storage compartment
8. Telephone antenna (R65) in rear bumper
15 14 13 12 11 10 9 8 9. Navigation control module with CD reader (J401 ) in trunk or
luggage compartment left side storage compartment
10. Cellular telephone (R54) in center console (optional with
A91-0779 Telematics)
11. Front bass speakers (R21 , R23) behind front door lower trim
12. Front midrange speakers (R26 , R27) behind front door upper
trim
13. Multifunction steering wheel control module (J453)
14. Instrument cluster
15. Radio

MULTIFUNCTION STEERING WHEEL

-4iiiiii{ Switches and buttons integrated into the optional multifunction
steering wheel allow the driver to operate the rad io, telephone and
Tiptronic controls without taking hands off the steering wheel. In
addition , the steering wheel is electrically heated .

Integrated electronics in the steering wheel regulate steering wheel

heating and transmit switch operations to the multifunction steering
wheel control module via vehicle CAN-bus network. The control
module controls radio, navigation , telephone , instrument cluster,
steering wheel heating and Tiptronic functions .

WARNING-
• The steering wheel houses the driver airbag. An airbag is an
explosive device and part of the vehicle safety system. Prior to
working on the steering wheel or its components, read the
airbag precautions in 69 Seat Belts, Airbags .
91-14 Radio and Communica ion
Multifunction Steering Wheel

Multifunction steering wheel, 1998 - 2001

1. Instrument cluster
2. Radio (R)
3. CD changer (R41) in trunk or luggage compartment left
storage compartment
4. Telephone transceiver (R36)
5. Multifunction steering wheel control module (J453) in 13-fold
5 C> Oc::::J ~--·- 2 relay panel , underneath left side dashboard
6. Multifunction steering wheel

4 ~--- 3

I A9 1-0778

Multifunction steering wheel, 2002 - 2004

1. CAN-bus (infotainment)
2. Radio (R)
3. Multifunction steering wheel control module (J453) in 13-fold
2 3 5 relay panel, underneath left side dashboard
4. Multifunction steering wheel
5. Telematics-telephone control module (J526) in right front
OC:=J footwell
6. Navigation control module with CD reader (J401) in trunk or
luggage compartment left side storage compartment
7. Instrument cluster

7 6
A91-0721

Multifunction steering wheel control module

(J453)
~ The multifunction steering wheel control module is a double-relay in
positions 7 and 8 of the 13-fold relay panel under left side
dashboard.

A60491008
 92-1

92 Wipers and Washers

GENERAL .. . .. .. . .. . .. . ...... .. .. . .... . 92-1 Windshield wiper motor,

Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-1 removing and installing 92-6

WIPER AND WASHER CONTROLS . ......... 92-2 REAR WIPER AND WASHER ASSEMBLY .. . . 92-7

Wiper and washer switch .. . .. .... .. .. ... . . 92-2 Rear wiper . . . .. . .... . . .. . . . . . ... . . . . . .. 92-7
Wiper and washer system fuses ...... .. .. . . 92-2 Rear wiper assembly ...... .. ... ... ... . ... 92-7
Wiper and washer system relay .. . . .. .. .. . .. 92-2 WASHERS . . .... . . . .. . . ...... . . ... .. . . .. 92-7
WIPER ARMS AND BLADES . . ... .. ........ 92-3 Washer fluid reservoir and motor,
removing and installing . . . .... . . ..... ... . 92-8
Wiper blade cleaning problems . . ... . .. ... .. 92-3
W indshield washer nozzle ,
Wiper blade , replacing . . . . . .... . .. . . . .. . . . 92-3
removing and installing .. . . ... .. . . . . . . . .. 92-9
Wiper arm , removing and installing . .... .. . .. 92-3
Windshield washer nozzles , aiming . . . . . . . .. . 92-9
Wiper blade contact angle, adjusting . .... . . .. 92-4
Rear window washer nozzle ,
WINDSHIELD WIPER ASSEMBLY REPAIRS .. 92-5 removing and installing . . .. . . ... . . .. . .. . . 92-9
Windshield wiper assembly . .. .... .. ....... 92-5 Rear window washer nozzle, aiming . .... .. . 92-1 O
Windshield wiper assembly, Headlight washer system . . .. .... ... . .... . 92-10
removing and installing . .. .. . ... . . . . . .. .. 92-5 Headlight washer nozzles aim . . . . . . . . . .. . . 92-1 O

GENERAL
This rep air group covers wiper blade service and wiper assembly
repairs . Also covered are the windshield , rear window and headlight
washer assemblies .

Also see :
• 48 Steering for steering column stalk switch (wiper and washer
switch) replacement
• 97 Fuses, Relays, Component Locations
• EWD Electrical Wiring Diagrams

Cautions

CAUTION-
•Switch the ignition OFF and disconnect the negative(-) battery
cable before removing any electrical components.
• Prio r to disconnecting the battery, read the battery
disconnection precautions in 00 Warnings and Cautions.
• Prior to disconnecting the battery:
-Obtain radio code.
-Record radio presets.
• Only use a digital multimeter for electrical tests.
• Do not operate the windshield wipers with the engine
compartment lid open. The wiper arms may scrape.
92-2 Wipers and Washers
Wiper and Was her Controls

WIPER AND WASHER CONTROLS

Wiper and washer switch

~ Switch positions are as follows :
1. Wipers parked
2. Intermittent wipe
3. Slow wipe
4. Fast wipe
5. One-tap wipe
6. Intermittent wiper speed adjuster
7. Pull back: Automatic windshield wiper and washer function
Push forward: Automatic rear window wiper and wash er

Wiper and washer stalk switch replacement is covered in

48 Steering.

Wiper and washer system fuses

~ In main fuse panel , left end of dashboard.

Wiper and washer fuses

Protected circuit Fuse# Amperage
Washer nozzle heater 1 5
Front wiper I washer 24 25
Rear wiper I washer 27 15

Wiper and washer system relay

~ In micro central electric panel , underneath left side dash board.

NOTE-
• To gain access to relays, see 97 Fuses, Relays , Component
Locations.

Wiper and washer system relay

Intermittent wiper I washer relay I Relay positions 5 and 6, micro

(J31) central electric panel
 Wipers and W ashers 92-3
Wiper Arms a nd Blades

WIPE R ARMS AND BLADES

Wiper blade cleaning problems

Common problems with the windshield wipers include streaking or
sheeting , water drops after wiping , and blade chatter.

Streaking is usually caused when wiper blades are coated with road
film or car wash wax .

- Clean bl ades usi ng soapy water. If cleaning does not cure problem ,
rep lace blades.

Drops that remain behind after wiping are usually caused by oil ,
road fi lm, or diesel exhaust residue on the glass.

Use an alcohol or ammonia solution or other non -abrasive cleaner

to clean windshield .

Chatter may be caused by dirty or worn blades , or by wiper arms

that are out of alignment.

- Clean bl ades and windshield as described above.

- Bend wiper arm so that there is even pressure along blade, and so
that blad e is perpendicular to windshield at rest.

- If problems persist, rep lace blades and wiper arms.

Wiper blade, replacing

- Fold wiper arm away from windshield .

~ Remove wiper blade :

• Rotate blade on arm approximately 1.ki turn .
•Squeeze plastic retainer and slide blade off arm.

CAUTION-
• Do not allow wiper arm to snap back against windshield

Installatio n is reverse of removal.

Wiper arm , removing and installing

- Make sure wipers are in PARK position and ignition switch is OFF.
Open eng ine hood .

~ Gently pry off plastic trim plugs (arrows) from base of wiper arm .

- Remove wiper arm mounting nuts .

- On each si de, mark position of wiper arm on shaft to aid installation .

Remove wiper arms.

Installation is reverse of removal. Tighten mounting nuts after

adjusting position of arms.

NOTE -
• The right wiper arm is longer.
92-4 Wipers and Washers
Wiper Arms and Blades

<liiiiii{ Check that in PARK position wiper blades are at specified distances
from top of water channel at lower edge of windsh ield .

Wiper arm position at PARK

Distance from wiper blade tip to lower
edge of windshield :
• Right wiper (A) approx . 12 mm (% in)
• Left wiper (B) approx. 25 mm (1 in)

- If necessary, loosen wiper arm mounting nut, adjust arm and

retighten mounting nut.

Tightening torque
A60403051
Wiper arm to shaft (M8) 16 Nm (12 ft-l b)

Wiper blade contact angle, adjusting

Possible causes for wiper blades skipping or chattering are as
follows :
•Windshield is scratched .
• Wiper blade rubber has become detached from arm or is spl it.
• Wiper arm or blade is loose or bent.
• Wiper blades are coated with wax or road grime.

If wiper blades are skipping or chattering and none of the causes

listed apply, use the following procedure to adjust angle of wipe r
arms relative to windshield before installing new wiper blades.

- Move wiper arms to PARK position . Remove wiper blades.

<liiiiii{ Insert wiper arm (2) into windshield wiper adjuster tool (Aud i special
tool 3358 B) and secure with locking screw (3). Compare angle with
specifications.

Wiper arm angle specifications

2 Left wiper arm _go

0,
Right wiper arm _50

- If necessary, use 24 mm wrench (1) to adjust angle to specification .

I N02-0300 I,
 Wipers and Washers 92-5
Windshield Wiper Assembly Repairs
WINDSHIELD WIPER ASSEMBLY REPAIRS

Windshield wiper assembly

1. Wiper blade
2. Wiper arm
3. Trim cap
- ---- 3
4. Nut, 16 Nm (12 ft-lb)
----- 4
5. Link
6. M6 bolt
7. Grommet
----- 3 8. Spacer bushing
---- 4
9. Wiper assembly frame
10. Wiper motor
11. MB self-locking nut
12. Crank

6 8 11 12
A60492003

Windshield wiper assembly,

removing and installing
- Make sure wipers are in PARK position and ignition switch is OFF.
Open engine hood.

-"iiii( Pull off rubber molding at engine compartment rear bulkhead . Pull
plenum chamber cover forward and remove.

-"iiii( Remove electronics box (E-box) cover retaining bolts (arrows). Lift
off cover.

- Remove wiper arms . See Wiper arm, removing and installing in

this repair group.
92-6 Wipers and Washers
Windshield Wiper Assembly Repairs

"'iiiii{ Pull out 3 retaining clips and carefully lift out (arrows) plastic cowl
cover at base of windshield.

"'iiiii{ Working inside plenum chamber:

•Remove wiper assembly mounting bolts (1 ).
•Tilt (arrows) wiper assembly (2) forward and slide to right to
remove from plenum chamber.
• Detach electrical connector at wiper motor.

Installation is reverse of removal.

CAUTION-
• Before reinstalling wiper arms, switch ignition ON, make sure
wiper motor is in PARK position, then switch ignition OFF

Tightening torque
Wiper arm to shaft (MS) 16 Nm (12 ft-lb)
Wiper assembly to plenum chamber 8 Nm (6 ft-lb)

- Adjust wiper arms to correct position . See Wiper arm, removing

and installing in this repair group.

Windshield wiper motor,

removing and installing
- Remove wiper assembly. See Windshield wiper assembly,
removing and installing in this repair group.

"'iiiii{ Place wiper assembly on work bench :

•Detach wiper links at wiper crank ball joint (A) .
• Remove wiper motor mounting bolts (arrows) and lift motor off
frame .

A60492005a
 Wipers and Washers 92-7
Rear Wiper and Washer Assembly

<iiiiii{ Installation is reverse of removal. Make sure :

• With motor in PARK, wiper crank is parallel to wiper frame .
• When wiper links are attached to crank , they lie in a straight line
(AB) al igned with wiper crank.

- Reinstall wiper assembly in vehicle . See Windshield wiper

assembly, removing and installing in this repair group.

A60492005a
REAR WIPER AND WASHER ASSEMBLY
4 3 2 On Avant (station wagon) models, the rear window wiper is
controlled by the wiper switch . Washer fluid is supplied from the
same reservoir as the windshield washers. See Washer fluid
reservoir and motor, removing and installing in this repair group.

Rear wiper
1. Wipe r blade
2. Cap
3. MS nut, 16 Nm (12 ft-lb)
4. Sprin g washer
7 6
I A92 ·0010 I 5. Wipe r arm
6. Washer jet

2 3 4 7. Wipe r shaft

Rear wiper assembly

1. Wiper motor
2. Seal
3. Hole in rear window
4. Washer jet
5. Wipe r shaft
6. Wash er fluid hose connector
7. Harness connector
8. M6 mounting nut
9. Wash er fluid hose
10. Wipe r motor cover

8 10 9 8 6 7 8 I A92-00 11

WASH ERS
The wind shield washers , rear window washer (Avant models) and
headlight washers are supplied from a fluid reservoir under the left
front fend er.

When the headlights are ON , the headlight washers operate each

time the windshield washer is operated.
92-8 Wipers and Washers
Washers

In Avant models, a single bidirectional washer motor supplies fluid to

the windshield and headlight washers when activated in one
direction and to the rear window when activated in the opposite
direction .

Washer fluid reservoir and motor,

removing and installing
~ The fluid reservoir is a one piece plastic bottle on the left side of the
engine compartment. It extends into the left wheel housing .

- Prior to removal , siphon out as much fluid as possible.

~ Remove washer reservoir upper mounting bolt (arrow) .

Raise left front of vehicle and support safely.

WARNING-
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove left front wheel housing liner. See 66 Exterior Equipment.

~ Place 2-gallon bucket underneath left fender. Pull off locking clip and
detach fluid hose. Allow fluid to drain into bucket.

~ Working underneath left wheel housing :

• Detach fluid level sensor harness connector.
• Remove reservoir mounting bolts (arrows).

- Lower reservoir carefully. Reach up in front of reservoir and pull

washer fluid pump out of front of reservoir.

CAUTIO~
• Be prepared to catch spilling washer fluid.

Installation is reverse of removal. Be sure to replace washer motor

sealing grommet in reservoir.
 Wipers and Washers 92-9
Washers

A __,_ Windshield washer nozzle,

....--- A removing and installing
I
- Open engine hood .

~ Working at underside of rear of hood :

• Detach fluid hoses (A) from nozzles.
• Detach harness connectors (8) from washer nozzle heaters .

~ Press nozzle forward (A) and tilt (8) out of engine hood .

- Installation is reverse of removal.

A60492008
Windshield washer nozzles, aiming
Washer fluid sprays at a slightly different angle when the car is
stationary. The specifi ed adjustment points take this into account.

~ Mark spots on windshield:

•A = 400 mm (15 .75 in)
• 8= 190 mm (7.5 in) (distance to windshield side molding)
• C = 420 mm (16 .5 in) (distance to top of cowl cover)

- Using special tool VAG 3125 (washer nozzle aiming tool or a safety
pin) , adjust nozzles to correct settings.

- If spray stream is not uniform or cannot be adjusted to specified

,...- A6040305 1a

~
dimensions, replace nozzle .

Rear window washer nozzle,

removing and installing
Working at rear window wiper :
•Lift up washer nozzle cover (1 ).
• Pull out spray nozzlle (2) and insert new.

A92 -0062
92-10 Wipers and Washers
Washers

Rear window washer nozzle, aiming

~ Mark spot on rear window:
•A = 280 mm (11 in) above wiper shaft.

- Using special tool \/AG 3125 (washer nozzle aiming tool or a safety
pin) , adjust nozzle to correct setting.

Headlight washer system

1. Cap
2. Bracket
3. Washer nozzle
4. Washer pump
5. Washer fluid reservoir
6. T-fitti ng
7. Elbow fitting
8. Check valve

A60492009
Headlight washer nozzles aim
~ Headlight washer nozzles, installed in the front bumper, are aimed
correctly by the manufacturer and do not need to be adjusted .

A60492°;;
 94-1

94 Exterior Lights

GENERAL .......... .. ..... ............ . 94-1 FOGLIGHT REPAIRS .. . .. .. ... ........ .. 94-10
Headlights ............................. 94-1 Front foglight, removing and installing ....... 94-1 O
Automatic headlight beam adjustment ........ 94-2 Front foglight bulb , removing and installing ... 94-1 o
Taillights ............ ...... ...... .. ..... 94-2 Front foglight, adjusting .................. 94-11
Exterior bulb applications .. . .. . . . ... ...... . 94-2 Rear foglight bulb , replacing ............ .. 94-12
Parking aid .. .. ............. .. ... ....... 94-3
TAILLIGHT REPAIRS .. . .... . .... ... . .... 94-12
Warnings and Cautions ................... 94-3
Taillight assembly .. . ..... . ... ..... . . .. . . 94-12
LIGHTING CONTROLS .. .. .......... .. . ... 94-4 Taillight bulb, replacing .. .... .. .. . .... .. . 94-12
Lighting fuses ........ . . ........ ..... .... 94-4 Taillight lens, removing and installing . .... .. 94-13
Lighting system relays . ............. ..... .. 94-4
CENTER BRAKE LIGHT REPAIRS 94-13
Headlight controls (xenon) ..... .. . .. .. . . . .. 94-4
Center brake light,
HEADLIGHT REPAIRS ... ......... .. ... .. . 94-5 removing and installing (sedan) . .. . . . .. . . 94-13
Headlight assembly ... . . .. .... . . ......... 94-5 Center brake light,
Xenon (HID) headlight assembly .. ....... . .. 94-5 removing and installing (Avant) .. ...... ... 94-14
Headlight, removing and installing ........... 94-6 LICENSE PLATE LIGHT REPAIRS .... ... .. 94-14
Headlight housing , repairing .. .. ......... . . 94-7 License plate light bulb , replacing 94-14
Headlight bulb , halogen , removing and installing 94-7
TABLE
Xenon (HID) bulb , removing and installing ... .. 94-8
a. A6 exterior bulb applications . ... ... . . ... . . . .... . . 94-2
FRONT TURN SIGNAL REPAIRS . ... ....... 94-9
b. Lighting fuses ....... . ...... ...... ...... . .... . . 94-3
Front turn signal bulb , removing and installing .. 94-9
Side turn signal bulb , removing and installing .. 94-9

GENERAL
This repair group covers exterior lighting repairs and bulb
replacement.

For headlight beam adjustment, see 03 Maintenance.

Also see:
Turn signal - - - -- ------..
• 96 Interior Lights, Switches , Anti-theft
• 97 Fuses, Relays, Component Locations
• EWD Electrical Wiring Diagrams

Headlights
~ The headlights and front turn signals are combined in one unit on
each side. The headlight lens is made of impact-resistant flexible
plastic coated with varnish , which also makes it scratch resistant.

High beam s use a free-space reflector, producing a precisely

formed cone of light. H7 halogen bulbs are used for extra brightness.
94-2 Exterior Lights
General

Automatic headlight beam adjustment

~ A6 models with the optional high-intensity discharge (HID) or xenon
headlights are equipped with the automatic headlight adjustment
system.
1. Headlight adjuster stepper motor in each headlight assembly
2. Headlight adjuster control module
-1998 - 2000: Behind trim in left side trunk or lu ggage
compartment
-2001 - 2004: Behind glove compartment
3. Front suspension level sensor at left front contro l arm
4. Rear suspension level sensor at left rear control arm

Taillights
~ The single rear foglight is on the left. Avant taillights illustrated .
Sedan is similar.

Exterior bulb applications

For convenience , exterior bulb applications for A6 models are li sted
in Table a.

Table a. A6 exterior bulb applications

Function Type Wattage
Back-up light P21W 21
Brake light
•Center (sedan) W5/ 1.2 2.3
• Corners (with parking light) P21 /5W 21 I 5
Fog light
•Front H3 55
•Rear P21W 21
Headlight
•High beam H7 55
•Low beam H1 55
•Xenon D2S 35
License plate light L 5
Parking light
• Front (with turn signal) P25-2-1 (amber) 21 I 5
• Rear (with brake light) P21 /5W 21 I 5
Turn signal
• Front (with parking light) P25-2-1 (amber) 21 I 5
•Rear P21W 21 I5
•Side WY5W 5
 Exterior Lights 94-3
General

Parking aid
2
The optional parking aid system helps the driver during parking
maneuvers by giving audible and visual signals when the vehicle
approaches obstructions in the rear.

~ Parking aid system components are as follows :

1. Parking aid control module (J446) behind left trunk trim
) I
2. Parking aid warning buzzer (H15) on rear parcel shelf
3. Parking aid sensors in rear bumper cover

~ jl
1 1~ A94-0128

Warnings and Cautions

WARNING -
• Xenon (high intensity discharge or HID) bulbs operate at high
voltages. When working on xenon headlight components
(control module, ignition unit, gas discharge bulb, drive motor),
be sure to switch lights OFF
• Some light bulbs, especially headlight bulbs, can become hot
enough to cause injury Allow bulbs to cool before working on
the lighting system.

CAUTION-
• Switch the ignition OFF and disconnect the negative (-) battery
cable before removing any electrical components.
• Prior to disconnecting the battery, read the battery
disconnection precautions in 27 Battery, Alternator, Starter.
• Only use a digital multimeter for electrical tests.
•Do not touch the glass of bulbs with bare skin. If necessary
wipe bulb using a clean cloth dampened with rubbing alcohol.
• Use only original equipment replacement bulbs. Non -original
bulbs may cause false failure readings on the dashboard
display
• Use only specified bulbs. A bulb with higher wattage may cause
damage to bulb housing.
• To avoid marring car paint or trim, work with a plastic prying
tool.

NOTE -
• Xenon (HID) components are often marked with a yellow high
voltage sticker.
94-4 Exterior Lights
Lighting Controls

LIGHTING CONTROL S
In this manual , light switches are covered as follows :
• Brake light switch in 46 Brakes-Mec hanical
• Headlight flasher switch in 48 Steering
•Light switch , emergency flasher switch , back-up light switch in 96
Interior Lights, Switches, Anti-theft.

Lighting fuses
~ In main fuse panel , left end of dashboard .

Table b. Lighting fuses

Protected circuit Fuse# Amperage

Back-up lights 31 15
~ ~ [L]UJ
~~ ~ Brake lights 13 10
~ ~ ~
Emergency flasher 39 15
DI]] CCE:JJ [3C]
~ ~ ~ Fog lights 36 15
~ [[]£]] ~
LOQ:JJ CDI=o ~ Headlights
• Automatic adjustment 10 5
• High beam left 19 10
• High beam right 18 10
• Low beam left 21 15
• Low beam right 20 15

License plate lights 4 5

Taillight, parking light

•Left 23 5
•Right 22 5

Turn signals 2 10

Lighting system relays

~ 13-fold relay panel underneath left side dashboard:
1. Relay positions 9 - 10: Headlight relay (J123)
2. Relay position 6: Foglight relay (JS)

Headlight controls (xenon)

~ Xenon (HID) headlight control module (arrow) at rear of headlight
assembly (static headlight aim adjusting system ).
 Exterior Lights 94-5
Headlight Repairs

~ Xenon (HID) headlight adjustment stepper motor (arrow) at rear of

headlight assem bly (automatic headlight aim adjusting system) .

HEADLIGHT REPAIRS

Headlight assembly
1. Headlight housing rear cover
2. Low beam bulb
3. Turn signal bulb
4. Headlight housing
5. High beam bulb

I A94-011 3 I

Xenon (HID) headlight assembly

1. Headlight housing rear cover
2. Low beam xenon bulb
3. Turn signal bulb
4. Headlight housing
5. High beam bulb
6. Headlight aim adjusting motor (static)
7. Igniter for xenon bulb

I A94-0 123 I
• (l
94-6 Exterior Lights
Headlight Repairs

Headlight, removing and installing

- Remove front bumper. See 63 Bumpers.

- Xenon (HID) headlight: Disconnect negative (-) battery cable and

cover battery terminal to keep cable from accidentally contacting
terminal.

CAUT/O~
• Be sure to have the radio anti-theft code before disconnecting
the battery

~ Working at headlight assembly :

• Remove 3 T30 Torx screws (a rrows). Use 8 inch (200 mm) Torx
driver to remove lower inner screw (insert).
•Use VAG special too 3249 (ball-head Allen wrench) to reach
behind headlight and loosen outer lower screw (A).
• Disconnect headlight electrical connector.

- Swivel headlight assembly toward center of car and remove .

~ Prior to installing new headlight, measure distance A at plastic bolt

on old headlight.

- Adjust plastic bolt on new headlight accordingly.

~ When installing new headlight, first engage lug 1 in guide 2 .

- Remainder of installation is reverse of removal. Position headlight

with even gap to surrounding body panels.

Tightening torque
Headlight to lock carrier (T30 bolts) 6 Nm (53 in-lb)

- Adjust headlight aim. See 03 Maintenance.

 Exterior Lights 94-7
Headlight Repairs

Headlight housing, repairing

A repair kit is available for broken headlight mounting tabs .

Headlight tab repair kits

Left headlight Part no. 480 998 121

Right headlight Part no . 480 998 122

NOTE-
• VAG part numbers given were correct at publication time but may
change over time. Consult an authorized Audi dealer parts
department for current part information.

- Remove headlight with broken mounting tab. See Headlight,

removing and installing in this repair group. Remove pieces of
broken mount from headlight and from lock carrier.

~ Place repair kit mount at edge of headlight housing (arrow). Secure

with 2 screws (1) from behind .

- Reinstall headlight.

Headlight bulb, halogen,

removing and installing
~ Right headlight: Remove air filter housing cover. Then remove air
duct mounting bolts (arrows) at lock carrier (radiator support frame) .
Remove air duct (1 ).

- Remove headlight housing cover.

~Low beam :
•Detach harness connector (1 ).
• Remove wire clip (2) and take bulb out of housing.
94-8 Exterior Lights
Headlight Repairs

"iiiii( High beam :

• Detach harness connector (1 ).
• Remove wire clip (2) and take bulb out of housing .

- Insert new bulb, lining up tabs on bulb with notches in headlight

housing .

Bulb applications

Headlight high beam H7 55 watt

Headlight low beam H1 55 watt

CAUTION-
• Do not touch bulb glass with bare skin.

Reinstall wire clip, reattach harness connector and install cover.

Xenon (HID) bulb, removing and installing

- Disconnect negative (-) battery cable and cover battery terminal to
keep cable from accidentally contacting terminal.

CAUTION-
• Be sure to have the radio anti-theft code before disconnecting
the battery.

"iiiii( Right headlight: Remove air filter housing cover. Then remove air
duct mounting bolts (arrows) at lock carrier (radiator support frame) .
Remove air duct (1 ).

- Remove headlight housing cover.

"iiiii( Working at rear of headli ght:

•Turn low beam harness connector (1) counterclockwise to detach.
• Rotate bulb retainer ring (2) counterclockwise and remove.
• Remove bulb and insert new.

Bulb application

Xenon headlight D2S 35 watt

CAUTION-
• Do not touch bulb glass with bare skin.
 Exterior Lights 94-9
Front Turn Signal Repairs

~ Insert retainer ring (A) on bulb lugs (B) , lining up with notches
(arrows) . Rotate retainer clockwise to secure .

- Reattach harness connector and install cover.

FRONT TURN SIGNAL REPAIRS

Front turn signal bulb, removing and installing

Front turn signal bulb also functions as parking light.

~ Right front turn signal : Remove air filter housing cover. Then remove
air duct mounting bolts (arrows) at lock carrier (radiator support
frame). Remove air duct (1 ).

~ Working at outboard corner of headlight assembly, rotate turn signal

bulb socket (1) counterclockwise to remove.

- Rotate bulb to remove from socket. Replace with new and

reassemble socket.

Bulb application
Front turn signal and parking (amber) I P25-2-1 21 I 5 watt

CAUTION-
• Do not touch bulb glass with bare skin.

Side turn signal bulb, removing and installing

<iiiiii{ Push side turn signal forward (arrow) against spring clip and
remove from front fender.

~
- Detach electrical harness. Remove bulb and replace.

Bulb application

\ Side turn signal (amber)

CAUTION-
• Do not touch bulb glass with bare skin.
WYSW 5 watt

- Installation is reverse of removal.

A94 -011 4
 Exterior Lights 94-9
Front Turn Signal Repairs

~ Insert retainer ring (A) on bulb lugs (B) , lining up with notches
(arrows). Rotate retainer clockwise to secure .

- Reattach harness connector and install cover.

FRONT TURN SIGNAL REPAIRS

Front turn signal bulb, removing and installing

Front turn signal bulb also functions as parking light.

~ Right front turn signal : Remove air filter housing cove r. Then remove
air duct mounting bolts (arrows) at lock carrie r (radiator support
frame). Remove air duct (1 ).

~ Working at outboard corner of headlight assembly, rotate turn signal

bulb socket (1 ) counterclockwise to remove .

Rotate bulb to remove from socket. Replace with new and

reassemble socket.

Bulb application
Front turn signal and parking (amber) j P25-2-1 21 I 5 watt

CAUTION--
• Do not touch bulb glass with bare skin.

Side turn signal bulb, removing and installing

~ Push side turn signal forward (arrow) against sprin g clip and
remove from front fender.

~
Detach electrical harness. Remove bulb and replace .

Bulb application

\ Side turn signal (amber)

CAUTION--
• Do not touch bulb glass with bare skin .
I
WY5W 5 watt

Installation is reverse of removal.

A94-0 114
94-10 Exterior Lights
Foglight Repairs

FOGLIGHT REPAIRS

Front foglight, removing and installing

~ Insert screwdriver in lower grille slot. Pry gently on lock tab (arrow),
then pull grille off.

A60403008

~ Remove foglight mounting screws (arrows).

- Pull foglight assembly forward and detach electrical harness.

- Installation is reverse of removal. Adjust foglight beam . See Front

foglight, adjusting in this repair group.

Front foglight bulb, removing and installing

Foglight with cover screwed on
- Remove foglight. See Front foglight, removing and installing in
this repair group.

~ Remove 2 Phillips screws (A) from foglight assembly cove r. Pull

cover back.

- Disengage wire (8 ) clip and remove bulb.

~ Detach electrical connectors (A ) from bulb holder in housing cover.

Bulb application
Front foglight H3 55 watt
I
CAUTION-
• Do not touch bulb glass with bare skin.

- Installation is reverse of removal.

A
A94-0102
 Exterior Lights 94-11
Foglight Repairs

Foglight with bayonet mounted cover

- Remove foglight. See Front foglight, removing and installing in

this repair group.

~ Rotate cover counterclockwise (arrow) to remove .

A94-0284

~ Disengage wire (1) clip and remove bulb.

Detach electrical connectors (2) from bulb holder in housing cover.

Bulb application

Front foglight H3 55 watt

CAUTIO~
• Do not touch bulb glass with bare skin.

Installation is reverse of removal.

A94-0285

Front foglight, adjusting

~ Insert screwdriver in lower grille slot. Pry gently on lock tab (arrow),
then pull grille off.

A 60403008

~ Use adjustment screw to adjust foglight beam .

•Counterclockwise lowers beam .
•Clockwise raises beam .

It is not possible to adjust foglight beam horizontally.

94-12 Exterior Lights
Taillight Repairs

Rear foglight bulb, replacing

- Open trunk or luggage compartment. Remove trunk lid or rear deck
lid trim.

~ Rotate rear foglight bulb holder (1) clockwise and pull out . Replace
rear foglight bulb.

Bulb applications

Rear foglight P21W 21 watt

I

CAUTION-
• Do not touch bulb glass with bare skin.

- Installation is reverse of removal.

9

TAILLIGHT REPAIRS

~---- 8 Taillight assembly

1. Gasket
2. Turn signal bulb
3. Back-up light bulb
4. Tail lens
• Sedan version illustrated
•Avant (station wagon) version has additional lateral cover
5. Brake light I parking light bulb
6. Bulb carrier
7. Taillight housing
6 8. Spacers
9. Mounting nuts , 4 Nm (35 in-ft)

A94-0093 Taillight bulb, replacing

- Open trunk or luggage compartment. Remove side storage
compartment cover.

~ Working at rear of taillight inside luggage compartment:

• Detach electrical harness (A).
• Press mounting bracket tabs (8) together and remove bulb carrier
(C).
• Replace defective bulbs as necessary.

Taillight bulb applications

Back-up light P21W 21 watt
Brake light I parking light P21 /5W 21 I 5 watt
Turn signal P21W 21 watt

CAUTION-
• Do not touch bulb glass with bare skin.

- Installation is reverse of removal.

 Exterior Lights 94-13
Center Brake Light Repairs

Taillight lens, removing and installing

- Open trunk or luggage compartment. Remove bulb carrier. See
Taillight bulb, replacing in this repair group.

CAUTION-
• Do not touch bulb glass with bare skin.

~ Continuing to work inside luggage compartment , remove taillight

lens mounting nuts (arrows).

Remove taillight lens from body.

A94-0094b Installation is reverse of removal , noting the following :

• Be sure to seat tail lens moisture seal correctly.
•Align tail lens to body contours when tightening mounting nuts .

Tightening torque
Taillight lens to body 4 Nm (35 in-ft)
I

CENTER BRAKE LIGHT REPAIRS

Center brake light, removing and installing

(sedan)
- Disconn ect negative (-) battery cable and cover battery terminal to
keep cable from accidentally contacting terminal.

CAUTION-
• Be sure to have the radio anti-theft code before disconnecting
the battery

~ Loosen center brake light from tabs in trunk and pull out from metal
cut-out toward bottom of trunk.
A94-0095

- Detach electrical connection and remove bulb holder from trunk .

~ Carefully lever off plastic cover from bulb carrier. Replace bulbs as
necessary.

Bulb applications
Center brake light bulbs (qty. 10) W5/ 1.2 2.3 watt

CAUTION-
• Do not touch bulb glass with bare skin.

Installati o n is reverse of removal.

94-14 Exterior Lights
License Plate Uaht Reoairs

96-4 Interior Lights, Switches, Anti-theft

Interior Lights

Rear interior light bulbs, servicing

Rear dome light bulb, replacing

-( Using plastic prying tool or flat screwdriver tip wrapped with masking
tape:
•Careful ly pry off dome light lens (1 ).
• Pry out and replace dome light bulbs (2) as necessary.

Bulb application

Rear dome light K 10 watt

I
I A96-0210 I CAUTIO~
• Do not touch bulb glass with bare skin.

- Installation is reverse of removal .

Rear reading light bulb, replacing

- Disconnect negative (-) battery cable and cover battery terminal to

keep cable from accidentally contacting terminal.

CAUTIO~
• Be sure to have the radio anti-theft code before disconnecting
the battery

-( Using plastic prying tool or flat screwdriver tip wrapped with masking
tape :
• Carefully pry dome light assembly (2) out of head liner.
•Disconnect electrical connector (1 ).

-( Remove reading light bulb (arrow) from back of light assembly and
replace with new.

Bulb application

Rear reading light L 5 watt

I
CAUTIO~
• Do not touch bulb glass with bare skin.

- Reattach electrical connector.

I A96-021 4 I - When installing assembly into head liner, hook in one side and clip
in at opposite side.
 Interior Lights, Switches, Anti-theft 96-5
Interior Lights

Glove compartment light bulb, replacing

~ Using plastic prying tool or flat screwdriver tip wrapped with masking
tape :
•Carefully push in retaining tab (2) and pry out glove compartment
light socket (1 ).
•Detach electrical connectors (3) .

Remove bulb from back of socket and replace with new.

Bulb application

Glove compartment light L 5 watt

I

CAUT/O~
• Do not touch bulb glass with bare skin.

Reattach electrical connectors.

- When installing socket, hook in one side and clip in at opposite side.

Footwell light bulb, replacing

~ Using plastic prying tool or flat screwdriver tip wrapped with masking
tape:
• Carefully push in retaining tab (2) and pry out footwell light socket
(1).
• Detach electrical connectors (3).

Remove bulb from back of socket and replace with new.

Bulb application

Footwell light L 5 watt

I

CAUTIO~
• Do not touch bulb glass with bare skin.

Reattach electrical connectors.

- When installing socket, hook in one side and clip in at opposite side.

Door courtesy light bulb, replacing

~ Using plastic prying tool or flat screwdriver tip wrapped with masking
tape :
• Carefully push in retaining tab and pry out courtesy light socket
(arrow) .
• Detach electrical connectors.

I A96-0269 I
96-6 Interior Lig hts, Switches Anti-theft
Back-up Lights

- Remove bulb from back of socket and replace with new.

Bulb application
Door courtesy light W 5 watt
I
CAUTION-
• Do not touch bulb glass with bare skin.

- Installation is reverse of removal.

Trunk light bulb, replacing

~ Using plastic prying tool or flat screwdriver tip wrapped with masking
tape:
•Carefully push in retaining tab (2) and pry out trunk light socket (1).
• Detach electrical connectors (3).

- Remove bulb from back of socket and replace with new.

IBulb application
Trunk light

CAUTION-
• Do not touch bulb glass with bare skin.

- Reattach electrical connectors.

- When installing socket, hook in one side and clip in at opposite side.

NOTE-
• Avant luggage compartment light bulb replacement is similar.

BACK-UP LIGHTS
Back-up light bulbs are covered in 94 Exterior Lights.

Back-up lights power supply

~ In main fuse panel, left end of dashboard.

Back-up lights fuse rating

Fuse 31 15 A
I
 Interior Lights, Switches, Anti-theft 96-7
Back-up Lights

Back-up lights circuits

D 1. Power supply
I
2,5 ws =white •Terminal 15, switched power in
SW sw = black dashboard wiring harness .

~
1231 ro
br
= red
=brown 2. Fuse 31 , 15 A
E'I S231 gn = green
u 15A bl = blue •In main fuse panel , left end of
23 1a gr = grey dashboard . See Back-up lights
1
2,5
Ii =violet power supply in this repair group.
sw/bl ge =yellow
3. Back-up light switch (F4)
• Manual transmission model.
1,0 0,5 • In transmission case. See Back-up
s w/bl s w/bl
light switch, manual transmission
in this repair group .
tT10015 tfoW15 4. Multifunction transmission range
switch (F125)
1,0 0,5 1,0
sw/bl sw/bl s w/bl • Automatic transmission model.

I,,,,. ~/ 7
• Switch assembly on side of

F.JB m1= -i -~ IJ"'

T9/2
transmission , underneath vehicle .

r D = 5. Park I neutral position (PNP) relay

r
F125
T911T9/8 I T9/6T9/5 (J226)
P/N /B /RF
• Multitronic (CVT) transmission model .
1,0 1,0 0 ,5 • In 13-fold relay panel underneath left
br/ws
side dashboard . See Back-up light

IT;~m
Back-up bll
/ro bll
/ro
switch function , multitronic
lights
transmission (CVT) in this repair

t Tm11s T11w16
group .
6. Transmission control module (J217)
1,0 1,0 1,0 0 ,5 1,0 • Multitronic (CVT) transmission model.
br/ge bl/ro

TT T mJ!,', I • Inside transmission at rear of case ,

underneath end cover .

NOTE -
• Audi identifies electrical components by a letter and/or a number in
the electrical schematics. See EWD Electrical Wiring Diagrams.
These electrical identifiers are listed in parentheses as an aid to
electrical troubleshooting.

Back-up light switch, manual transmission

2
Q- - 3 ~ 5-speed manual transmission :
1. Harness connector above left drive axle flange .
2. Gear position sender at top right of transmission housing .
•Inclu des back-up light switch (F4) .
3. Bolt , 25 Nm (18 ft-lb) .
4. Hold-down bracket.

A60496005
96-8 Interior Lights, Switche , Anti-theft
Dashboard and Center Console Switche

~ 6-speed manual transmission: Backup light switch (F4)(arrow) on

right side of transmission at selector shaft housing .
•Tighten to 20 Nm (15 ft-lb)

A6049600

Back-up light switch function,

automatic transmission
When automatic transmission is placed in REVERSE , multifunction
transmission range switch (F125) switches back-up lights ON .

Back-up light switch function,

multitronic transmission (CVT)
~ When CVT transmission is placed in reverse , transmission control
module (J217) , under cover in rear of transmission , indicates gear
position to park I neutral position (PNP) relay (J226) (arrow) in
13-fold relay panel under left side dashboard .

- PNP relay switches back-up lights ON .

DASHBOARD AND CENTER

CONSOLE SWITCHES

Light switch, removing and installing

~ Working at li ght switch in dashboard:
• Push in switch knob (1) and at same time turn it clockwise (2) .
•Hold in this position and pull switch housing out of dashboard (3).
• Detach electrical connectors from switch .
 Interior Lights, Switches, Anti-theft 96-9
Dashboard and Center Console Switches

- To reinstall , reattach electrical connectors.

~ Push switch knob in direction of arrow (1) and at same time turn it
clockwise (2) to engage retain ing catch (a).

- Wi th switch in this position , push swi tch housing into recess in

dashboard (3 ) until it clicks into place.

I A96-0278 I
Instrument light dimmer switch ,
remov ing and installing
The instrument light dimmer is part of the light switch , but can be
replaced separately.

Remove li ght switch . See Li ght switch , removing and installingi n

this repai r group.

~ Use thin fl at screwdriver to pry off dimmer switch (1 ) and separate

from light switch housing (2 ).

- Installation is reverse of removal

Center dashboard switches,

removing and installing
~ Using plastic prying tool or fl at screwd ri ver tip w rapped with tape,
carefully pry off center dashboard trim (1 ).

Pull out switch (2) all the way and detach electrical conn ecto r.

l \\
Installation is reverse of removal.
I

. ' ~l
10[""'===

1 I A96-0222 I
I

Mirror adjustment switch ,

removing and installing
Using plastic pryi ng too l or flat screwdriver tip wrapped with tape ,
carefully pry off center console insert and shifter boot.

~ Reach under mirror switc h (1 ) with finge rs or screwdrive r to push

switch up and out of console. Detach el ectrical harn ess (2).

- Installation is reverse of removal. Check for mi ss ing cli ps at front

and rear of mirror switch

I A96-0221 I
96-12 Interior Lights, Switch , Anti-theft
Horns

~ Turn switch assembly over and press on retainer tab (2) to detach
harness connector (1 ).

- Installation is reverse of removal.

------
- -1A?0-0172 I
Right door window or rear window switch
assembly, removing and installing
~ Using plastic prying tool or flat screwdriver tip wrapped with masking
tape , gently pry up on front edge of switch assembly (1).

A70-0178 I
~ Turn switch assembly over and press on retainer tab (2) to detach
harness connector (1 ).

- Installation is reverse of removal.

I A70-0179 I

HORNS
One horn is installed behind each end of the front bumper.

Horn, removing and installing

~ Insert screwdriver in lower grille slot. Pry gently on lock tab (arrow),
then pull grille off.

A60403008
 Interior Lights, Switches, Anti-theft 96-13
Anti-theft System

<iii{ Remove horn mounting nut (arrow).

Disconn ect harness connector and lift out horn.

Installation is reverse of removal.

I A96-0223 I
ANTI-THEFT SYSTEM
Electroni c immobilizer system version 3 is standard on models
covered by this manual. Anti-theft alarm is available as an option .

The ultrasonic interior monitor, supplied in conjunction with the

optional anti-theft alarm , triggers the anti-theft alarm it an attempt is
made to break inio the vehicle .

On-board diagnostics
If the on-board diagnostics (OBD 11) system recognizes malfunctions
in the immobilizer, anti-theft or central locking systems , it sets
diagnostic fault codes (DTCs) .

<iii{ Access fault memory with VAG scan tool or equivalent plugged into
DLC plug (inset) under left side dashboard.

Electronic immobilizer
<iii{ Electronic immobilizer components are as follows :
1. Ign ition key with wireless transponder
2. Ignition lock cylinder with immobilizer induction coil
3. Immobilizer control module integrated with 4
4. Instrument cluster
3 ~ .. ." 5. En gi ne control module (ECM)

Electronic immobilization functions as follows :

•With vehicle key inserted into ignition switch , signal from ignition
cylinder induction coil energizes key transponder.
•Key transponder sends unique signal to induction coil.
• Key signal is relayed to immobilizer control module in instrument
cluste r.
• If control module recognizes key as valid , signal is relayed to
engin e control module (ECM) via CAN-bus network and vehicle
can be started.
• If key is not recognized as valid , starter and engine management
system are blocked : Vehicle cannot be started .
~

I
r
I
96-14 Interior Lights, Switches, Anti-theft
Anti-theft System

-( Ignition keys are inscribed with a W indicating that the key is capable
of being coded to electronic immobilizer version 3. Only keys with
this basic code can be adapted to the vehicle .

The immobilizer control module (J362) is integrated with the

instrument cluster control module. In case of anti-theft immobilizer
control module failure , replace the entire instrument cluster. See
90 Instruments.

The immobilizer induction coil (02) is integrated with the ign ition key
cylinder and cannot be replaced separately. In case of induction coil
malfunction, replace the ignition cylinder. See Ignition key
I A96-0280 I cylinder, removing and installing in this repair group.

The key transponder is integrated with the vehicle key. In case of

transponder malfunction , replace the complete key. Once a key is
replaced , adapt all the vehicle keys to the vehicle using the VAG
scan tool or equivalent. If only one key is adapted , the remain ing
keys will not start the vehicle .

The immobilizer warning light illuminates briefly (max . 3 seconds)

and then goes out when an authorized vehicle key is used . If an
unauthorized vehicle key is used or when a system malfunction
occurs, the warning light blinks constantly during ignition ON .

Anti-theft and central locking

components
1. Hood alarm switch (F120)
2. Ultrasound interior motion sensor,
right (G170)
3. Ultrasound interior motion sensor,
left (G171)
4. Fuel tank filler flap lock actuator
(V155)
5. Trunk lid lock actuator (F124, F206,
F218, V53 , V139)
6. Alarm horn (H8)
7. Alarm system and keyless entry
-{
f- antenna (R47)
8. Interior motion sensor control
module (J347)
9. Interior motion sensor disable switch
(E183)
10. Door lock actuator (F2, F131, F241,
F243, V56, V161)
11. Central locking and anti-theft control
module (J429)
12. Central locking master switch (E150)
13. Avant: Glass breakage sensors
(G183, G184) below rear side glass
(not in this illustration)

NOTE -
• 2000 model is illustrated. Other models are similar.
 Interior Lights, Switches, Anti-theft 96-15
Anti-theft System

Hood alarm switch (F120)

<iii{ In hood lock mechanism on front lock carrier (radiator support

frame)

Ultrasound interior motion sensor (G170, G171)

<iii{ At head liner above left and right B-pillar

A96-0408 I
Fuel tank filler flap lock actuator (V155)

<iii{ In luggage compartment behind right rear side panel trim .

Luggage compartment lid lock actuator

(F124, F206, F218, V53, V139)

<iii{ Behind trim (Avant tailgate lock illustrated)

96-16 Interior Lights, Switch s, Anti-theft
Anti-theft System

Alarm horn (HS)

~ Sedan : In trunk behind left storage compartment cover

~ Avant: In luggage compartment behind left storage compartment

cover

Alarm system and keyless entry antenna (R47)

~ Sedan : Left side of rear bumper cover

• Avant: Rig ht side of rear bumper cover

A96-04 16 1-
Interior motion sensor control module (J347)

~ At lower C-pi llar, behind trim

Interior motion sensor control module actuates warning lights next to

door lock buttons.
 Interior Lights, Switches, Anti-theft 96-17
Anti-theft System

Interior motion sensor disable switch (E183)

~ On left lower 8-pillar

When locking up vehicle , deactivate interior monitor manually by

pressing interior monitor switch (arrow) if, for example, a dog is to
remain in vehicle .

Door lock actuator (F2, Pl31 , F241 , F243, V56, V161)

~ In door cavity behind door trim panel

Central locking and anti-theft control module (J429)

~ In protective case underneath driver seat

A96-0405 I
Central locking master switch (E150)
~ Top front of driver door
96-18 Interior Lights, Switch s, Anti-theft
Anti-theft System

Glass breakage sensors (G183, G184)

~ Avant: Below rear side glass, behind trim
 97-1

97 Fuses, Relays, Component Locations

GENERAL .............................. 97-1 TABLES

Warnings and Cautions ................... 97-2 a. Electrical component locations ...... ... ... .. ... 97-3
b. Left A-pillar connector station plugs ..... ..... . . 97-18
ELECTRICAL COMPONENT LOCATIONS . . ... 97-3
c. Right A-pillar connector station plugs ......... . . 97-19
Engine compartment components . . .... .. . . 97-11
d. A6 fuse and relay panels ... . . ......... . ...... 97-24
Components underneath vehicle .. ........ . 97-14
e. 3-fold relay panel fuses and relays .... . . . ..... . 97-24
Interior components . . ..... ........ . .... . 97-18 f. E-box connector station plugs . . . ... .... . . . .. .. 97-25
allroad quattro components ......... . ..... 97-22 g. Main fuse panel . . . ..... . . ............ ..... . 97-26
FUSE AND RELAY PANELS . .... ......... 97-23 h. 13-fold relay panel fuses and relays . ... ..... ... 97-28
i. Micro central electric panel fuses and relays .. . ... 97-28
E-box (electronics box) components .. ...... 97-24
j. 8-fold relay panel relays .. .. .. . ..... ... ... ... . 97-29
Main fuse panel , fuse panel S2 . ... .... . ... 97-25
k. 8-fold relay panel connectors .. ............... 97-29
Under-dash relay panels .. . ..... .... .. .. . 97-27
I. 8-fold relay panel fuses .. .... .... ... ..... .... 97-29
GROUNDS ............................. 97-30 m. Central carrier relay panel fuses and relays ... .. . 97-30

GENERAL
This repair group covers fuses , relays , ground locations and
electrical component locations , primarily via photos or illustrations.

The complex nature of the Audi A6 electrical systems requires a

large number of fuses and electrical components. Locating the
correct component in this array of equipment is an important first
step in electrical diagnosis. Electrical equipment and accessories
installed vary depending on model and model year. Always confirm
that the proper electrical component is correctly identified.

Almost all electrical circuits are protected by fuses. For a full listing
of fuses and fuse locations, see Fuse and Relay Panels in this
repair group.

Investigating and correcting ground problems often solves

mysterious and difficult to trace electrical problems. For ground
information, see Grounds in this repair group.

Also see :
• 27 Battery, Starter, Alternator
• 87 Heating and Air-conditioning for climate control flap motors
and temperature sensors
• 9 Electrical System-General for information on bus systems
• 91 Radio, Communication for sound system , telephone and
navigation component locations
• EWD Electrical Wiring Diagrams
 r

97-2 Fuses , Relays, Compone nt Locations

General
t
i
Warnings and Cautions
Please read the following before doing any work on your electri cal
system .

WARNING -
•Airbags utilize explosive devices. Handle with extreme ca re.
Refer to the warnings and cautions in 69 Seat Belts, Airbags
• The ignition system of the car operates at lethal voltages. If you
have a weak heart or wear a pacemaker, do not expose yourself
to ignition system electric currents. Take extra precautions when
working on the ignition system or when servicing the engine
while it is running or the key is ON. See 28 Ignition System for
additional ignition system warnings and cautions.

CAUT/O~
• Do not disconnect the battery with the engine running.
• Switch the ignition OFF and remove the negative (-) battery
cable before removing any electrical components. Connect and
disconnect electrical connectors and ignition test equipment
leads only while the ignition is switched OFF
• Relay and fuse positions are subject to change and may vary
from car to car. If questions arise, an authorized Audi dealer is
the best source for the most accurate and up-to-date
information.
• Use a digital multimeter for electrical tests. Switch the multimeter
to the appropriate function and range before making test
connections.
• Many control modules are static sensitive. Static discharge
damages them permanently Handle the modules using proper
static prevention equipment and techniques.
• To avoid damaging harness connectors or relay panel sockets,
use jumper wires with flat-blade connectors that are the same
size as the connector or relay terminals.
• Do not try to start the engine of a car which has been heated
above 176°F (B0 °C) (for example, in a paint drying booth). Allow
it to cool to normal temperature.
• Disconnect the battery before doing any electric welding on the
car.
• Do not wash the engine while it is running, or any time the
ignition is ON.
• Choose test equipment carefully Use a digital multimeter with at
least 10 MD. input impedance, or an LED test light. An analog
meter (swing-needle) or a test light with a normal incandescent
bulb may draw enough current to damage sensitive electronic
components.
• Do not use an ohmmeter to measure resistance on solid state
components such as control modules.
•Disconnect the battery before making resistance (ohm)
measurements on a circuit.
I
I

-- II
 I

Fuses, Relays, Component Locations 97-3

Electrical Component Locations

ELECTRICAL COMPONENT LOCATIONS

Table a is a cross-referenced listing of electrical components for
cars covered by this manual.

Audi identifies electrical components by a letter and/or a number in

electrical schematics. These codes, listed in column 2 , are also
used in EWD Electrical Wiring Diagrams.

Figure numbers in column 4 and page numbers in column 5 refer to

photographs and illustrations immediately following the table .

NOTE -
• Every component is not installed in every car.
•Due to changes in production, component locations may vary from
what is illustrated. Consult your Audi dealer for the latest
information.
• For information about bus systems and associated control
modules, see 9 Electrical System-General.

Table a. Electrical component locations

Component Code Location _j__F_ig
_. # Pg. #
- ---- -- ----- -- - --
13-fold relay panel Underneath left side dashboard Fig. 48 97-27
_ _ _ _ __J_Fig. 49 97-28
3-fold relay panel E-box , left side of plenum chamber under plastic Fig. 44 97-24
cover _ _ _ _ _ _ _ ~ ig. 45 97-24
8-fold relay panel Underneath left side dashboard Fig. 48 97-27
Fig. 51 97-29
I- - - - -

A/C and heater blower motor V2 In evaporator housing behind glove compartment Fig. 30 97-20
~ g. 31 97-20
- -
A/C and heater blower motor control module J126 Under right side dashboard , to left of blower motor
on evaporator housing
A/C and heater blower motor resistor N24 On blower motor
A/C and heater control module J255 A/C and heater control panel in center dashboard
J301
-
A/C and heater left side flap motors and temperature Left side of evaporator housing Fig. 29 97-20
sensors see also 87 Heating and Air-condi_ti_o_n_in_g_______,__ ___--+_ _ _1
----
A/C and heater right side flap motors and Right side of evaporator housing Fig. 31 97-20
temperature sensor~ _____ see also 87 Heating and Air-conditioning
-
A/C compressor clutch N25 On A/C compressor, left front engine compartment
----- - ----- - - - ------
A/C compressor clutch relay J44 13-fold relay panel underneath left side dashboard Fig. 49 97-28
- ---- - --- l-- -
A/C compressor regulator valve, 2002 - 2004 N280 On A/C compressor , left front engine compartment
-- ---- l- + - - - - - + - - - -I
A/C high pressure sensor, 2002 - 2004 G65 Right front engine compartment
------ - -- --
A/C pressure switch , 1998 - 2001 F129 Right side of A/C condenser
-- -
ABS see also ESP entries
ABS control module, Bosch 5.3 J104 Right footwell under floor covering
---- ---
ABS control module , Bosch 5.7 J104 Left side of engine compartment Fig. 12 97-14
-- - - - --------+
I ABS hydraulic pump, Bosch 5.3 V156 Under ABS hydraulic unit, left side of engine Fig. 1 97-11
compartment

l• ABS hydraulic unit N55 Left side of engine compartment Fig.1 97-11
Fig. 12 97-14
ABS return flow pump V39 \ Part of ABS hydraulic unit, engine compartment left Fig. 12 97-14
..
~
-
front
ABS return flow pump relay J105 8-fold relay panel underneath left side dashb_o_a_rd_ __.j._
F_ i g. 52 97-29
' --
ABS solenoid valve relay J106 8-fold relay panel underneath left side dashboard Fig. 52 97-29

'

1
97-4 Fuses , Relays, Componen Locations
Electrical Component Locations

Table a. Electrical component locations

Component Code Location Fig.# Pg.#
--- - -
ABS wheel speed sensor G44 - Integral with wheel bearing assembly (front wheel Fig. 22 19 7- 1B
G47 drive)
I
Mounted at back of wheel bearing housing (quattro)
- ------- -- -
Accelerator pedal module Base of accelerator pedal Fig. 29 97-20
---- - - -- -
Accelerator pedal position sensor 2 G185 Base of accelerator pedal Fig. 29 97-20
- - -·- -
Afte r- run coolant pump V51 Under vehicle , behind left side of oil pan Fig. 15 97-15
1----- -

After-run coolant pump relay J151 3-fold relay panel in E-box , left side of plenum Fig. 45 97-24
chamber under plastic cover
- - - - - -·-
Air quality sensor G238 Under plenum cover , attached to dust and pollen Fig. 11 97-1 4
filter housing
-- -·-
Airbag conn ector, left front Under steering column trim covers
- -
Airbag connector, right front Underneath right dashboard , above glove I
compartment
- - - ---
Airbag control module J234 On center tunnel under front of center console _J_ -
Airbag crash sensor, front side airbag G17~ Under front seat and carpet, on rear of floor pan
G18C brace
-- ----- - - -
Airbag crash sensor, rear side airbag G25E On rear door sill
G25~
- ---- -
Ai rbag igniter, ri ght, left N131 Base of B-pillar behind trim Fig. 34 97-21
- - --
Airbag spiral sp ri ng F13E Steering column
-- - -
Airbag , driver Steering wheel
--- -- --~

Airbag , passenger Right side dashboard Fig. 30 97-20

- - - --- - f---- --
Airbag , side Outer seat bolster
- - -- - -
Alarm horn HS Left side luggage compartment , behind trim Fig. 39 97-22
--- - - ---
Alarm system see Central locking
Alternator (generator)
----- - -- -c Right front of engine compartment , on engine Fig. 16 97-15 I
--
----- - - -- ~

Amplifier, audio Right side luggage compartment , behind trim

see 91 Radio and Communication
I
----- -1--

Antenna amp lifie r R82 Behind D-pillar trim

-- - - --
Antenna selection control module J51 ( Under parcel shelf, left side
- --- --- -
Antenna , alarm and central locking R47 Avant: Rear bumper, right side
Sedan : Rear bumper, left side
see also 96 Interior Lights, Switches, Anti-theft
--- --- -
Antenna , navigation I telephone I auxiliary heater R6E Roof
R1/ 2 see also 91 Radio and Comm unication
- - - - - --- - ---
Antenna , rad io and telephone R5 Left rear fender
------
Antenna , sound system R1 Roof (Avant)
R5( Trunk lid (sedan)
I
see also 91 Radio and Communication
- -- -- - - - - - - ---- - - I

Antenna, tire pressure check R5' Behind wheel housing liner, above wheel (allroad ) I
R61
I
R6
I
_,_R6 - _,_____ _ _[_ -
Anti-theft control module see Central locking control module
~
- .___ ~~---

ASR see ABS

-- - .__
see also ESP
- ---- ·--
Aud io components see 91 Radio and Communication
- - - -- -
Automatic headlight vertical aim control system see Headl ight aim control module
modul e
~

Automati c transmission control module, 5-speed

-- .___
J2 7
·- -- -
Inside protective box in floor cavity underneath front
I -

automatic transmission I
passenger seat and carpet , in front of floor pan brace I

I
 I

Fuses, Relays, Component Locations 97-5

Electrical Component Locations

Table a. Electrical component locations

Component Code Location Fig.# Pg.#
Automatic transmission control module, Multitronic® J217 Inside transmission , at rear of case
transmission (CVT)
-----
Automatic transmission gear position switch see Automatic transmission multifunction range
switch
----
Automatic transmission multifunction range switch F125 Left side of transmission housing Fig. 21 97-16
Automatic transmission selector lever switch At shifter
-
Aux iliary coolant pump see After-run coolant pump
Back-up light switch , automatic transmission see Automatic transmission multifunction switch
--- -- ---
Back-up light switch , manual transmission F4 Top of transmission
----
Battery A Rear of engine compartment in plenum chamber Fig. 1 97-11
~--

Blower motor see A/C and heater blower motor

-- --
Blower motor resistor see A/C and heater
- -
blower motor resistor
Brake booster pressure sensor G294 Under plenum cover, directly in front of brake Fig. 5 97-12
booster
~---

Brake booster vacuum pump V192 Engine compartment, left side Fig. 12 97-14
-- - -
Brake booster vacuum pump fuse, allroad 8279 13-fold relay panel underneath left side dashboard Fig. 49 97-28
Brake booster vacuum pump fuse, except allroad 8279 Central carrier relay panel under left side dashboard Fig. 55 97-30
Brake booster vacuum pump relay G569 Central carrier relay panel under left side dashboard Fig. 55 97-30
~---

Brake fluid level warning switch F34 Brake fluid reservoir in plenum chamber Fig. 1 97-11
Brake light switch F On pedal cluster above brake vacuum vent switch
Brake vacuum vent switch F47 On pedal cluster, below brake light switch
Broken window glass sensor, left rear G183 Under left rear window behind trim Fig. 41 97-23
Broken window glass sensor, right rear G184 Under right rear window behind trim
Camshaft adjustment valve 1 N205 Rear of right cylinder head (bank 1)
------
Camshaft adjustment valve 2 N208 Front of left cylinder head (bank 2)
Camshaft sensor, left G163 Rear of left cylinder head (bank 2)
Camsh aft sensor, right G40 Front of right cylinder head (bank 1) Fig. 2 97-11
Fig. 8 97-13
CD changer R41 Left side luggage compartment in storage Fig. 39 97-22
compartment
see also 91 Radio and Communication
Central carrier relay panel Underneath left side dashboard Fig. 55 97-30
Central locking control module J429 In protective box underneath driver seat and carpet ,
in front of floor pan brace
Charge air pressure sensor, biturbo G31 In air intake boot, on intake manifold , front Fig. 8 97-13
Connector station , A-pillar Behind A-pillar trim in kick panels, left and right Fig. 26 97-18
Fig. 27 97-19
Coolant see Engine coolant
Cooling fan see Engine cooling fan
Crankshaft sensor see Engine speed (rpm) sensor
Crash sensor see Airbag crash sensor
Cruise control module J213 Behind glove compartment, near blower motor Fig. 30 97-20
housing
Cruise control stalk switch E45 On steering column, left
- -
Cruise control vacuum pump V18 Underneath ABS control module, left front wheel Fig. 19 97-16
housing
----
Data link connector (DLC) Under left side dashboard Fig. 28 97-19
--
Diagnostic connector see Data link connector (DLC)

I &.
 I
97-6 Fuses , Relays, Compor ent Locations
Electrical Component Locations

Table a. Electrical component locations

Component C Dde Location Fig.# Pg.#
Door contact switch FP Door lock motor Fig. 32 97-20
F1
F 0
F 1
Door courtesy light Door edge Fig. 33 97-21
Door lock motor V ~6 In door lock Fig. 32 97-20
v 7
v 7
v 15
E-box (electroni cs box) Left side plenum chamber, left rear engine Fig. 1 97-11
compartment Fig. 44 97-24
E-box connector stati on In E-box , left side of plenum chamber under plastic Fig. 44 97-24
cover Fig. 46 97-25
ECM see Engine control module (ECM )
Electronic immob ili ze r inducti on coi l Integrated with ignition key cylinde r
Electronic power control (EPC) see Electronic throttle drive
Electronic throttle dri ve G 86 Top rear of engine , behind intake manifold
see Throttle valve control module
see also Throttle angle sensor
see also Throttle position sensor
Electronics box see E-box
Emergency flasher E'.: Center of dashboard
Engine control modu le (ECM ) J2 PO In E-box , left side of plenum chamber under plastic Fig. 6 97-12
cover Fig. 44 97-24
Engine control module (ECM) fuse , 2001 - 2004 SD 2 3-fold relay panel in E-box , left side of plenum Fig. 45 97-24
chamber under plastic cove r
Engine control module (ECM ) power supply relay, J2 1 3-fold relay panel in E-box , left side of plenum Fig. 45 97-24
2001 - 2004 chamber under plastic cover
Engine coolant level warn ing switch F6 > Bottom of coolant reservoir expansion tank Fig. 1 97-11
Engine coolant pu mp relay see After-run coolant pump relay
Engine coolant tem perature (ECT) sensor G::'. In coolant pipe behind intake manifold
GE ~
Engine cooling fan V7 In front of engine at radiator
V1 7
Engine cooling fan co ntrol modul e, 1998 - 200 1 J2!3 Left lower engine compartment on frame rail
Engine cooling fan control module, 2002 - 2004 In front of engine compartment attached to fan
Engine cooling fan relay J2E 8-fold relay panel underneath left side dashboard Fig. 52 97-29
Engine cooling fan re lay, hig h speed j 1( 1 8-fold relay panel underneath left side dashboard Fig. 52 97-29
Engine cooling fan series resisto r N3 Left front , underneath longitudinal chass is member Fig. 18 97-1 5
Engine cooling fan switch F5' On radiator, lower right Fig. 14 97-1 4
F11
~e oil temperature sen sor G8 Left front of cylinder block, above oil filter housing
Engine speed (rpm) sensor G2 Left transmission bellhousing near drive flange
EPC see Electronic throttle drive
ESP see also ABS entries
ESP sensor un it Underneath rear seat Fig. 35 97-2 1
ESP switch E2~ 1 6 Cente r console
EVAP purge valve see Fuel tank evaporative cont rol canister purge
regulator valve
- - -- ----------------!-
Evaporator temperature sensor see 87 Heating and Air-conditioning
Exhaust flap val ve N 3~ . 1 On exhaust system between muffler and tailpipe tips Fig. 25 97-17

I
 Fuses, Relays, Component Locations 97-7
Electrical Component Locations

Table a. Electrical component locations

Component

Exhaust temperature sensor modules

(2.7 lite__i:_ e~ gine) _ __
_
Exhaust temperature sensor 1, 2 (2.7 liter engine)
-
Code
G235
G236
-

-
Location
In turbochargero utlet pjpe, righ_t_, le-ft_ _ _
(2.7- liter- engine)
- - - -- - ------
Center top of engine, right of intake manifold
------
F
I Fig. # Pg . #
Fig. 10 97-13

Fig. 9
_ r_ _
97-13

Flap motor see 87 Heating and J~ir-conditioning

--------- -------
Flasher see Emergency flasher
- - - ----- - -- - - - ---- -
Fog light £ront b~mper u~de~Eift and rig_h_t h_e_a_d_lig_h_t_s _ _ _,_F_i_g_. _1 8 97-15
Foglight relay J5 13-fold relay panel underneath left side dashboard Fig. 49 97-28
Fu ~ injectors __________ _ Top of intake manifold , frontof e-n-g-in-e - 1-
Fuel level sensor, center G23_7_ Topof fuel tank~accessthmughlugg_a_g_e-----+-F-ig-.-31 f97-=22
compartment (quattro)
- - - - - - -+---- - - -
Fuel level sensor, left G169 Top of fuel tank, left Fig. 36 97-21
Fuel level sensor, right G Top of fuel tank, right Fig. 36 97-21
- - - -------+---- - --
_ Fue_l_
pu~ p con_t_ro_l_m
_odule fuse , RS6 __ S81 Central carrier relay panel under left side dashboard Fig. 55 97-30
-- - -- - ---
Fue ~ ump_c_o_
ntrol module , RS6 _ _ _ _ J538 Top right side of cylinder head
Fuel pump relay J17 Micro central electric panel under left side Fig. 50 97-28
dashboard
Fuel pump, all models except RS6 G6 In fuel tank , access under rear seat bench ___ - F ig:3697-21
-- --- - - - - -
Fuel pump, RS6 _ ~nderneath rig~ear ~vehicle , ahead of fuel tan ~ - ---+-- _
- - - - ----------- -
Fuel tank evaporative control canister purge N80 Right side of intake manifold Fig. 9 97-13
regulator valve , 2.7 liter engine
----
Fuel tank evaporative control canister purge NBO - Right side of en[lin8compartmeni -- - IFlg~ 97-11
regulator valve , 2.8 liter engine
Fuel tank filler door lock motor V155 Right side of luggage compartment
---- ------ - - - -------
Fuel tank filler neck ground terminal r-- J:! nderneath right rear wheel housi~iner IFiQ. 24 97-17
- --- - ---
~ e l__!_
an_k~ak_detection pu_m_p_ _ _ _ _ V14~ ~ Back of left re~ whee~-~ousing , behind liner Fig. 23 97-17_
Fuse panel S1 3-fold relay panel in E-box , left side of plenum Fig. 44 97-24
chamber under plastic cover Fig. 45 97-24
---- - - ----
Fuse panel S2 Main fuse panel , left end of dashboard Fig. 47 97-25
Fuses see Fuse and Relay Panels in this repair group
- - - - - - - - -f--

Generator see Altern ator

GPS see 91 Radio and Communication
- ---- - - - - - - - - - - - - - - ---+---·+---<
~ ro_
u_nd_s_ see G_.!:ounds ~n th is repa~ro_u_
p

1----
_ _ _ _____ _ _ _ _ _ Fig. 56 97-30
Headlight aim adjustment motor V48 In headlight housing , below headlight Fig. 7 97-13
V49
-Headlight aim contrOi modul€. 1 998 -2ooo J431 L ett side luggage compartment: behind trim
Headlig ~ aim contro~odule , 2001 - 2004 ~ ~ J431 Beh~d glove compartment onbracket Fig~-9~
Headlight bulb control module J343 In headlight housing , below headlight
J344
-Headlight washer pump -- - V1 1-Wa~her fluid reservoir under left front fender - Fig. 19 97-16
Heater core - --- - --- - In evaporator housing , access from leftSide- - --Flg. 29 9 7-20 -
H igh intensity discharge (HID) headlight - - see Headlight entries - - - --
- -- -- ----+--- - -
Hig ~ r~s_s_
ure_s_
en_
is_
o_r ________ _ see A/C high pressure sensor
- - - -
Hood alarm switch F120 Part of hood latch assembly 97-11
Horn button Steering wheel
Horn relay J4 Micro central electric panel under left side Fig. 50 97-28
dashboard
- -- ---- --- --
~ o ~ , high tone _ _ _ _ H2 Behind front bumper, left side _ _ ___ _ ! ig~ 97-15
Horn , low tone H7 Behind front bumper, right side Fig. 18 97-15
- --- --------
Hydraulic pump relay, 2001 - 2004 J555 Micro central electric panel under left side Fig. 50 97-28
dashboard
 97-8 Fuses, Relays, Compon ant Locations
Electrical Component Locations

Table a. Electrical compo nent locat ion s

Component Cc cte Location Fig.# Pg.#
---
Ignition coil pack , 2.8 liter engine code AHA Front of engine compartment in front of intake Fig. 1 97-11
manifold
- - ------------+- ~ •----+-------------------~-
Ignition coils power output stage, 2.7 liter V6 engine Air filter housing
code APB I
Ign ition coils power output stage , 2.8 liter V6 engine N1 2 Front of engine compartment in front of intake Fig. 1 I 97-11
code AHA manifold I
~ -- ----
Ignition coils power output stage , all except 2.7 liter
engine code APB , 2.8 liter engine code AHA
-----------1-~ r--+--------

Ignition coils , all except 2.8 liter engine code AHA

Integrated with ignition coils

Above each spark plug , top of cylinder head covers

L._
Immobilizer see Electronic immobilizer
see also Central locking
- - - - - - - - - - - - - - - + - - - - 11- 1 - - - - - - - - - - - - - - - - - - - - - - - - - + - · - - - + - - -
Induction coil see Electronic immobilizer induction coil
Instrument cluster combination processor J21 ~ Behind instrument cluster
- - - - - - t - ---tt-- + - - - - - - - - - - - - - - -
1nstrum en t cluster control module J28 ~ Instrument cluster _[ _ _
----
Intake air temperature (IAT) sensor G4~ Mounted on intake ai r ducting , rear of intake
manifold I
l~a~man~~hang ~overvalve , 2.81i~ren ~~ 1_5_6---t-_ L_
~_t_re_a_r_i_
nt_a_k_
e_m_a_n_i_
to_ld_a_
b_ov_e_in_~_k_e_a_
ir _d_u_
c_t _ _~----+----~
Fig. 1 97-11
Intake manifold change-over valve , 3.0 liter engine N26' Front of intake manifold Fig. 13 97-14
-- - - - + ----ti-- + - - - - - - - - - - - - - - - - - - - - - - + - - -
Kickdown switch F8 In engine compartment on bulkhead Fig. 1 97-11
-- ~ --
Knock sensors G61 Near right cylinder head underneath intake manifold
G66 Near left cylinde r head underneath intake manifold_,_____,_____ _,
--------- -
Lamp control module J12~ Fig.
13-fold relay panel underneath left side dashboar_d___,__ _49 97-28
___,__
--
Leak detection pump see Fuel tank leak detection pump
Level control system accumulator valve N31 Under vehicle , rear, center, above stabilizer bar Fig. 42 97-23
(all road)
- - -- - ------- ~ •-+----------------
Level control system co mpressor motor V66 Under vehicle , rear, driver side Fig. 43 97-23
-
Level control system compressor relay J40::: 8-fold relay panel underneath left side das_h_b_o_
a_rd__,_Fig.
__ 52--+--_
97-29
__,
- - -------
Leve I control system control module J197 In luggage compartment, left rear Fig. 41 97-23
- -~

Level control system sensors G76 In front wheel housing Fig. 40 97-22
G77 In left rear wheel housing
G78
G84
Level control system solenoid valve N111 Under vehicle , rear, driver side Fig. 43 97-23
---------- ------+-------t+-+---
Light switch E1 Left of steering wheel on dashboard
ig_hter _
L_ _ _ _ _ _ __ In center console below_ ra_d_io
_ _ _ _ _ _ _ _ - - - - + - - --1
Load reduction relay J59 Micro central electric panel under left side Fig. 50 97-28
dashboard
f--- - ~ - - - - - - - - 1--- - -H-- t - - - - - - - - - - - - - - - - - - - - - - - t - - - - - i i - - - - - -1
Manifold absolute pressure (M AP) sensor G71 Biturbo only
~ - - - - - - - - - - - ----+----!~--!-----------------------+------+-----I
Mass air flow sensor _ __ _ _ ~ ~i ntake air duct near top of air cle_a_ne_r _h_o__ Fig. 1 97-11
u_si_n_g_--+-------+---t
~ ------
Micro central electric panel Underneath left side dashboard Fig. 48 97-27
Fig. 50 97-28
- - - - - - - - - - - - - - - + - - - - - + - - - -!
f--M irror fo ld awa~ontrol module J351 13-fold relay panel underneath left side dashboard Fig. 49 97-28
-~-

Motronic control module see Engine control modu le (ECM)

_!1!1otronic main relay _ __ _ see Engine control module power supply relay
Multifunction steering wheel control module J453 13-fold relay panel underneath left side dashboard Fig. 49 97-28
Navigation control module - - - -\ Lett side luggage compartment in storage Fig . 39 97-22
compartment

_Ne_u_tra_l _sa_fetysw_it_
~B_
D _ll p
_l_ug_ _
ch_ _ _ _ _ _ _ __ _ ~_
]
-:=_
I see also 91 Radio and Communication
_J
_
= Park I neutral position (PNP) relay- - - - - - - + - - - - - + - -
_!!!_e Data link connecto_r _(D_L_C
_) ________- - 1 - -
-
--
- -
Oil level thermal sensor TG266 Under engine on oil pan Fig. 16 97-15

II
 Fuses, Relays, Component Locations 97-9
Electrical Component Locations

Table a. Electrical component locations

--
Component
-- - -- - --- -
Code Location _ _ _ _ ----;_F_i_g_. # _ Pg . ~
Oil pressure sensor F1 On oil filter housir1_9 , underneath left front of engine
----- --- -- - -
Outside air temperature sensor G17 In front of A/C condenser
Outside rear view mirror see Mirror
-- ---- ---- - - -
Oxygen sensor, post-catalyst G130 Behind catalytic converter
G131 - - - - - - - - + -F
- i_g_. 20 / 97-16
Oxygen sensor, precatalyst G39
-
Before catalytic converter in front exhaust pipe Fig. 3 --t 97-12
G108
Park I neutral position (PNP) relay, Multitronic®
~smissi ~CVT) _ _ __
J226 13-fold relay panel underneath- 1-eft side dashbo_a_r_d--+-
F-i g. 4j 97-28-
-
Parking aid control module
--- - -- - --- - -
J446 Left side luggage compartme ~ behi n ____--1-_F_ig_._3~ 97-2 ~
_d_ tr_im
Parking aid sensors G204 In rear bumper
G205
G334
G335
-- - ---- -----
~rking aid warning buzzer, Avant H15 Left side luggage compartment, behind trim
- - - - - - - --+-----+-----
Parking aid warning buzzer, sedan H15 Rear she lf
- - ----+---1--- -
Parkingbrakewarning light switch- F9 At parking brake lever mechanism beneath center
console
-- ----- --- ---
Pressure switch see A/C high pressure switch
-Radiator outlet hose coolant temp8rature sensor see Engine coolant temperature (ECT) sensor
- --- - -----f--

Radio R Center dashboard

see also 91 Radio and Communication
Rear window shade control module J262 Left side luggage compartment, behind trim
-------+--
Rear window shade motor fuse S100 Micro central electric panel under left side Fig. 50 97-28
dashboard
~ -- -- ------ -
Rear window wiper motor V12 Under center of tailgate trim _ Fig. 38 97-22
- - -- ----- - - -
Recirculating pump _____ see After-run coolant pump _ _ ____ - - - + - - - - + - - --1
Relays see Fuse and Relay Panels in this repair group
Remote rear lid unlock motor V151 Under deck lid trim , center
~ationrate sensor (yaw sensor) - G202 Under rear seat bench , center
-
Fig . 35 97-21
---------+----+----
---- - -
Satellite radio R146 In left side of luggage compartment
see also 91 Radio and Communication
- --- --------~--+-----l

Seat adjustment circuit breaker S44 8-fold relay panel Fig. 54 97-29
S80
- - --- - ____,_ _ - + - ---1

Seat belt lock microswitch Seat belt buckle on seat

---- --------- -
Seat belt tensioner igniter N153 Behind lowe r B-pillar trim Fig. 34 97-21
N154
Seat memory control module , left J136 Under driver seat
-
Seatbelt reel microswitch , left F145 Behind left B-pillar lower trim
----- -- ---
Seatbelt reel microswitch , right F146 Behind right B-pillar lower trim Fig. 34 97-21
- -
Secondary air injection pump V101 Underneath right front of engine Fig.16 97-15
_ _ _ _ _.._F_ig.17 97-15
Secondary air injection pump fuse , 1998 S130 13-fold relay panel underneath left side dashboard Fig. 49 97-28
Secondary air injection pump fuse , 1999 - 2004 S130 3-fold relay panel in E-box , left side of plenum Fig. 45 97-24
chamber under plastic cover
Secondary air injection pump relay J299 3-fold relay panel in E-box , left side of plenum Fig. 45 97-24
chamber under plastic cover
-
Secondary air injection valve N112 Back of intake manifold above intake air duct Fig. 1 97-11
--- - --- - - - - - - - - - - - + - - - - 1 - - -1
Selector lever light relay, 1998 13-fold relay panel underneath left side dashboard Fig. 49 97-28
----- - -
Servotronic control module J236 13-fold relay panel underneath left side_ d_
as_h_bo_a_rd_ +-F
_ ig. 49 97-28
- -- ---
Shiftlock solenoid N110 Part of gear selector mechanism underneath center
console
97-10 Fuses , Relays, ComponE nt Locations
Electrical Component Locations

Table a. Electrical component locations

Component Code Location Fig.# Pg.#
------ -
So~r cell_s_
e_pa_ra~onre__
la~
y _ _ _ _ _ _ _ _ _-+_
J_30
_9-----ll+-
13
_-_fo_l_
d _r_
e_la_
y_p_a_n_
e_l _
un_d_e_r_n_
e_at_h_l_
e_ft_s_id_e_d_
as_h_b_o_a_r_
d _~_
F_ig_._4_9-t-9_7_-_2_8-----j
Solar opera
_t_io_n c_
on_tr_o_I mod_u_le_ _ _ _ _ _ _ __j__
J_35_5_ -a-1---
0_n_s_u_n_ro_o_f_i_
nn_e_r_s_u_rf_a_c_e___________-+----+----1
Soundsy~em
_ _ _ _ _ _ _ _ _ _ _ _ _ _---+-----j.i-+-s_e_e_9_1_ R_a_d_io_ a_
nd_ C_o_m
_ m_u_n_i_
ca_t_io
_ n _ _ _ _ _ _t - - - - - ' - - - - - - - '
Speakers see 91 Radio and Communication
----
Speedometer vehicle spe_e_d_ s_
e_ns_o_r_ _ _ _ _ _--1-----G_2_2--11--l--
O_n_l_e_ft_s_id_e_ of_t_ra_n_s_m
_i_s_
si_o_n_n_e_a_r_d_ri_v_
e _a_x_le_f_la_n_g_e_-t---
Starter B Right side of engine compartment connected to
transmission
- - - - - - - - - - - - - - - 1 - -----+l- - + - - - - - - - - - - - - - - - - - - - - - t - - - --~---
Starter interlock relay, manual transmission J207 13-fold relay panel underneath left side dashboard Fig. 49 97-28
Steering angle sensor G85 Steering column
Steeri ng column adjustment motor fuse S27E
Micro central electric panel under left side Fig. 50 97-28
dashboard
- - - - - - - - - - - - - - - · - + - - .Jl.-1- - - - - - - - - - - - - - - - - - - - - 1 - - - - - -
Stop light switch see Brake light switch
Sunlight_s_e_n_s_
o_r - - - - - - - - - - - - - - + -G_1_0-ll----+-
To
_ p_ c_e _
nt_e_r_o_f _d_
as_h_b_o_a_r_
d ___________--t-_ _ _____,__ __
Sunroof solar sensor control module J35!: Above headliner on sunroof panel
Suspension strut valve N14: Under vehicle , center rear, above stabilizer bar Fig. 42 97-23
-N1 E ~
Tailgate lock motor V53 Under center of tailgate trim Fig. 38 97-22
Tailgate rem ote unlock motor V15 Under center of tailgate trim Fig. 38 97-22
----------+--~J--1---------------------1----~-----4
Telephone control module J41: Below center console rear, near parking brake lever
see also 91 Radio and Communication
- ---------------l--~~-+--------------------+-
Telephone transceiver R36 Right front footwell
- -----
Throttle angle sensor G18 !7 Integrated with throttle valve control module (J338) Fig. 4 97-12
G1e3 Fig. 8 97-13
Thro~e position sensor _ _ _ _ _ _ _ _ _ ~ E~~--+-B_a_s_e_o_f_a_c_c_
e_le_ra_t_
o_r_
p_ed_a_I_ _ _ _ _ _ _ _ _~_
Fig. 29 97-20
Throttle valve control module J33 On throttle body at back of intake manifold Fig. 4 97-12
Fig. 8 97-13
Tiptronic gear selector At shift selector housing
T iptronic switch _ _ F1 E ~ Left side of gear selector assembly
Tire pressure monitoring control module J50 t> Left side luggage compartment , behind trim Fig. 39 97-22
Fig. 41 97-23
--
Tire pressure sensor G2 2 On wheel rim near valve stem
-G~ 26
Traction control see ESP
-----
Transfe r fuel pump, RS6 In fuel tank
Transmission control module see Automatic transmission control module
------ ---- - ------!-------+---~

Transverse acceleration sensor G2 DO Under rear seat bench , center Fig. 35 97-21
- - - - + t -- - - - - t - - - - - - - - - - - - - - -
Trunk lid lock motor V5 Under center of trunk lid trim
- -- --- - -
Trunk light In trunk trim
Trunk remote unlock motor V1 11 Under center of trunk lid trim
- - - - ------ --
_1i_urn signal I high be ~m_stalk~witch - - - - - - 1 - -E2 ~~n steering column
Turn signal flasher E3 Emergency flasher
- --------!
Ultra-sound sensor control module J3 7 Below C-pillar on inside left rear door jamb, behind
rear seat side trim
------------- - --
Washer fluid level sensor _,_G: 113
1--+---
W-a-she r f Iu-id_r_e_s_e-rv_o_ir-, _b_e _
h i_n_d_r-ig_h_t _fr__o_n_t _w_h_e_e_I ---+-
Fig. 19 97-16
housing liner
Waste gate bypass regulator valve , 2.7 liter engin~ ~N/ ~ 1--+-C- e-nter of in_t_a_k_e _m_a_n- if-o-ld- ,-r-ig_h_t _o_f _
a_ir-in_t_a-ke_ d_u-ct- - - + --
Fig. 9 -+ ---
97-13
.__
~h eel speed sensor _ see AB~w~el_s_p_e_e_d_s_e_n_s_
o_r --------+-----·--+----!
Window control module J1 95 Integrated with window motor and window regulator Fig. 32 97-20
- ._- 1298 assem ~
Window motor In door Fig. 32 97-20
- - ---------- - - - -----------------!--
Window motor switch In door Fig. 32 97-20

.1

I
 Fuses, Relays, Component Locations 97-11
Electrical Component Locations

Table a. Electrical component locations

Component Code Location Fig.# Pg.#
-
Windshield washer fluid pump vs Washer fluid reservoir, behind left front wheel
housing liner
Windshield washer nozzle, heated Under engine hood
Windshield wiper motor v Under left cowl in plenum chamber
--
Wiper I washer intermittent relay J31 Micro central electric panel under left side Fig. 50 97-28
dashboard
--
Wiper I washer stalk switch On steering column
Wiper motor, rear window (Avant) V12 In tailgate underneath trim panel Fig. 38 97-22
--- ---
Woofer see Speaker
-
Yaw sensor see Rotation rate sensor (yaw sensor)

Engine compartment components

Component locations pictures, unless otherwise noted , are of a
1999 A6 Avant quattro with 2.8 liter engine code AHA. Components
and locations vary depending on year and model.

Fig. 1 1999 2.8 liter engine compartment, upper cover

and plenum chamber cover removed

1. Fuel tank evaporative control canister

purge regulator valve (N80)
2. Dust and pollen filter
3. Mass air flow (MAF) sensor (G70)
4. Oxygen sensor harness connectors
5. Battery (A)
6. Secondary air injection valve (N112)
7. Intake air temperature (IAT) sensor
(G42)
8. Intake manifold change-over (tuning)
valve (N156)
9. Transmission kick-down switch (F8)
10.Brake fluid level warning switch (F34)
11.Fuel pressure regulator
12.Electronics box (E-box)
13.Power output stage (N122)
Ignition coils (N , N128, N158)
14.Hood alarm switch (F120)
15.Engine coolant level switch (F66)
16.Left camshaft adjustment valve
(N208)
17.ABS hydraulic pump (V156))
ABS hydraulic unit (N55)

Fig. 2 Right front of engine

~ Right upper timing belt cover removed

1. Right cams haft sensor (G40)
97-12 Fuses, Relays, Comp nent Locations
Electrical Component Locations

Fig. 3 Right rear of engine

~ Intake air duct and engine cover removed

1. Precatalyst oxygen sensor 1 (G39)

Fig. 4 Rear of engine

~ Intake air duct and upper engine cover removed

1. Throttle valve control module (J338)
Throttle angle sensor (G187 , G188)
Throttle position sensor (G79)

Fig. 5 Plenum chamber, left of battery,

3.0 liter VG, all VB engines

~ Plenum chamber cover removed

1. Brake booster vacuum pressure sensor (G294)

Fig. 6 Plenum chamber, left side

~ Plenum chamber and E-box covers removed

1. Secondary air injection relay (J299)
2. Engine control module (J220)

The electronics box (E-box) in the left rear of the engine

compartment is protected by a plastic cover. It contains 3-fold relay
panel and S1 fuse panel. For fuse ratings and relay applications, see
Fuse and Relay Panels in this repair group.
 Fuses, Relays, Component Locations 97-13
Electrical Component Locations

Fig. 7 Left headlight, xenon (HID)

~ Headlight cover removed

1. Left headlight beam adjusting motor (V48)

Fig. 8 Top of engine, 2.7 liter biturbo V6 engine

~ Upper engine cover removed

1. Throttle valve control module (J338)
Throttle drive (G186)
Throttle valve angle sensors (G187 , G188)
2. Charge air pressure sensor (G31)
3. Right camshaft sensor (G40)

Fig. 9 Top right of engine, 2.7 liter biturbo V6 engine

~ Top of intake manifold , upper engine cover removed

1. Waste gate bypass regulator valve (N75)
2. Right exhaust temperature sensor module (G235)
3. Fuel tank evaporative control canister purge regulator valve
·==-- 2 (N80 )

_,,,,,..~ol~~- 3

Fig. 10 Rear of engine, 2.7 liter biturbo V6 engine

~ Right turbocharger outlet pipe

1. Right exhaust temperature sensor (G235)
97-14 Fuses, Relays, Comp nent Locations
Electrical Component Locations

Fig. 11 Plenum chamber, right of battery,

3.0 liter VG engine

-liiiiiii{ Plenum chamber cover removed

1. Air quality sensor (G238)

Fig. 12 Engine compartment, left side,

3.0 liter VG engine

-liiiiiii{ Left side engine cover removed

1. Brake booster vacuum pump (V192)
2. ABS hydraulic unit (N55)
3. ABS control module (J104)
4. ABS return flow pump (V39)

Fig. 13 Top of engine, 3.0 liter VG engine

-liiiiiii{ Upper engine cover removed

1. Intake manifold change-over (tuning) valve (N261)

Components underneath vehicle

Fig. 14 Underneath right side of engine

-liiiiiii{ Radiator outlet pipe , engine lower cover removed

1. Engine cooling fan switch (F54, F18)
Fuses, Relays, Component Locations 97-15
Electrical Component Locations

Fig. 15 Underneath left side of engine

~ Lower engine cover removed

1. After-run coolant pump (V51 )

Fig. 16 Underneath center of engine

~ Lower sound absorber panel removed , 3.0 lite r engine

1. Alternator (C)
2. Secondary air injection pump motor (V101 )
3. Oil level thermal sensor (G266)

Fig. 17 Underneath right front of vehicle

~ Lower engine cover removed

1. Secondary air injection pump (V101 )
2. Low tone horn (H7)

Fig. 18 Underneath left front of vehicle

~ Lower engine cover removed

1. Eng ine cooling fan series resistance (N39)
2. High tone horn (H2)
3. Left foglight
97-16 Fuses, Relays, Compo ent Locations
Electrical Component Locations

Fig. 19 Left front wheel housing

~ Wheel housing liner removed .

1. Cruise control vacuum pump (V18)
2. Washer fluid level sensor (G33)

Fig. 20 Underneath middle of vehicle

~ Rear of catalytic converter, in exhaust system

1. Post-catalyst oxygen sensor 2 (G1 31)
2. Post-catalyst oxygen sensor 1 (G1 30)

Fig. 21 Underneath automatic transmission

~ Lower sound absorber panel removed

1. Multifunction transmission range switch (F125)

Fig. 22 Underneath right rear of vehicle

~ Right rear wheel hub

1. Right rear ABS wheel speed sensor (G46)
Fuses, Relays, Component Locations 97-17
Electrical Component Locations

Fig. 23 Left rear wheel housing

~ Wh eel housing liner removed

1. Fuel tank leak detection pump (144)

Fig. 24 Right rear wheel housing

~ Wheel housing liner removed

1. Fuel tank filler neck ground

Fig. 25 Above tailpipe, 3.0 liter engine

~ In exhaust pipe
1. Exhaust flap valve (N321)
 11

97-18 Fuses, Relays, Component Locations

Electrical Component Locations

Interior components
Fig. 26 Left A-pillar connector station

~ Behind left kick panel trim

Table b. Left A-·pillar connector station plugs

No. Color From wiring harness To wiring harness
1 Black Dashboard Mirror adjustment
2 Light Central locking , anti-theft Door lock, anti-theft
brown

3 Red Power window Power window in door

4 Black Cruise control Dashboard

5 Blue Speaker Speaker

6 Grey Power window Power window
7 Blue RHar of vehicle Dashboard
8 Brown Rear of vehicle Dashboard
9 Red Xenon headlight, left Dashboard
10 Violet Xenon headlight, left Dashboard
11 Blue Rear of vehicle Dashboard
12 White Seats, seat belt warning Dashboard
13 Brown Power window, sunroof Dashboard
14 Grey Engine cooling fan , A/C Dashboard
compressor
15 Orange ABS Dashboard
16 Violet Dome light Dashboard
17 Black Wiper motor Dashboard
A Black Rear of vehicle Dashboard
B Black Washer Dashboard
c Blue Dashboard Temperature gauge
D Yellow Airbag , driver Dashboard

II
 Fuses, Relays, Component Locations 97-19
Electrical Component Locations

Fig. 27 Right '~-pillar connector station

~ Behind right kick panel trim

Table c. Right A-pillar connector station plugs

c E No. Color From wiring harness To wiring harness

1 Black Dashboard Mirror adjustment

2 Red Power window Power window in door

3 Yellow Central locking , anti-theft Door lock, anti-theft

D
4 White Parking aid Dashboard

5 Blue Headlight aim , xenon bulb Dashboard

I A97-0122 I 6 Green Speaker Speaker

7 Bl ack Central locking , anti-theft Dashboard

8 Violet Xenon headlight, right Dashboard

9 red Xenon headlight, right Dashboard

10 Blue Automatic transmission Dashboard

11 Grey ABS Dashboard

12 Yellow Airbag Dashboard

13 Black Reading lights Dashboard

14 Grey Automatic transmission Dashboard

15 Yellow Daytime running lights Dashboard

16 Brown Leak detection pump, Dashboard

automatic day/night mirror

17 Orange Central locking , anti-theft Dashboard

A Open

B Open

c Open

D White Seat belt tensioner, Dashboard

passenger airbag

E Open

Fig. 28 Under dashboard, left side

~ Lower left dashboard trim panel pulled down (back side shown)
1. Main fuse panel
2. Data link connector (DLC)
3. 13-fold relay panel
Micro central electric panel relay panel
4. Footwell light
97-20 Fuses, Relays, Compon nt Locations
Electrical Component Locations

Fig. 29 Left footwell

~ Lower left dashboard trim panel removed

1. Left temperature regulator flap motor (V158) and sensor
(G220)
2. Heater core
3. Accelerator pedal module:
Throttle position sensor (G79)
Accelerator pedal position sensor 2 (G 185)

Fig. 30 Under dashboard, right side

~ Glove compartment removed

1. Passenger airbag ignitor (N131)
2. Blower motor (V2)

Fig. 31 Under dashboard , right side

~ Components behincl glove compartment

1. Right temperature regulator flap motor (V159) and sensor
(G221)
2. Center air flow flap motor (V70) and sensor (G 112)
3. Defroster flap motor (V107) and sensor (G 135)
4. Cruise control module (J213)
5. Headlight aim control module (J431)
6. Blower motor (\/2)

Fig. 32 Driver's door

~ Door panel removed

1. Door lock motor (V56)
Door contact switch (F3)
2. Door lock
3. Window motor (V14)
Window control module (J295)
4. Outside mirror electrical connector
Fuses, Relays, Component Locations 97-21
Electrical Component Locations

Fig. 33 Driver's door panel

~ Backside of panel removed from door

1. High frequency speaker (tweeter) (R34)
2. Midrange speaker (R21)
3. Door courtesy light
4. Door warning light

Fig. 34 Lower 8-pillar

~ B-pillar trim removed

1. Seat belt reel microswitch (F146)
2. Seat belt tensioner igniter (N153)

Fig. 35 Under rear seat, 2000 - 2004 sedan

~ Rear seat cushion removed

1. ESP sensor :
Transverse acceleration (G200)
Rotation rate (yaw) sensor (G202)

Fig. 36 Under rear seat

~ Rear seat cushion and fuel tank access covers removed

1. Fuel level sensor, left (G169)
2. Fuel level sensor, right (G)
Fuel pump (G6)
97-22 Fuses , Relays, Compo ent Locations
Electrical Component Locations

Fig. 37 Luggage compartment, Avant

~ Behind rear seats, rear seat folded forward , luggage compartment

carpet removed , fuel tank access cover removed
1. Fuel level sensor, center (G237) (quattro only)

Fig. 38 Tailgate, Avant

~ Tailgate trim removed

1. Tailgate remote unlock motor (V151)
2. Tailgate lock motor (V53)
3. Rear window wiper motor (V12)

Fig. 39 Left side luggage compartment, sedan

~ Left storage cover removed

1. Alarm horn (H8)
2. Tire pressure monitoring control module (J502)
3. Parking aid control module (J446)
4. CD changer (R41)
5. Navigation control module

allroad quattro components

Fig. 40 Left front wheel housing

~ Wheel housing liner removed

1. Left front level control system sensor (G78)

NOTE -
• Level control sensors for the other wheels are as follows :
-Right front: G84
-Left rear: G76
-Right rear: G 77
 Fuses, Relays, Component Locations 97-23
Fuse and Relay Panels

Fig. 41 Left side luggage compartment

~ Left storage cover and trim removed

1. Broken window glass sensor (G 183, G 184)
2. Tire pressure monitoring control module (J502)
3. Level control system control module (J 197)

Fig. 42 Rear underside of vehicle

~ Above stabilizer bar

1. Suspension strut valve (N148 , N149 , N150 , N151)
Level control system accumulator valve (N311)

Fig. 43 Left rear underside of vehicle

~ Between exhaust system and spare tire well

1. Level control system compressor motor (V66)
Level control system solenoid valve (N111)

FUSE AND RELAY PANELS

~ The majority of A6 fuses and relays are in the locations shown in the
illustration. See Tabled for names and locations .

6 5
L-----------------~
A6.0497064
97-24 Fuses, Relays, Compo ent Locations
Fuse and Relay Panels

Table d. AG fuse and relay panels

No. Panel Locatio See section in this repair group
3-fold relay panel , fuse panel 81 lenum chamber, rear of engine E-box (electronics box) components
com part ent
2 Main fuse panel , fuse panel 82 Left end f dashboard Main fuse panel , fuse panel 52
3 13-fold relay panel Under le side dashboard Under-dash relay panels
4 Micro central electric panel Under le side dashboard Under-dash relay panels
5 8-fold relay panel Under le side dashboard Under-dash relay panels
6 Central carrier relay panel Under le side dashboard Under-dash relay panels

E-box (electronics box) components

- Open engine hood and remove plenum chamber cover.

~ Remove E-box cover retaining bolts (arrows) . Lift off cover.

Fig. 44 E-box

~ Plenum chamber cover and E-box cover removed

1. 3-fold relay panel
Fuse panel 81
2. Engine control module (ECM)
3. E-box connector station

Fig. 45 3-fold relay panel, fuse panel 51

1a 4a ~ Relay and fuse configuration varies by year and model

Table e. 3-fold relay panel fuses and relays

Fuse Amps Protected circuit
1 Open
1a Open
1b After-run coolant pump relay (J 151)
2 Secondary air injection pump relay (J299)
3 ECM power relay (J271)
4 Open
A60424005 4a Open
 Fuses, Relays, Component Locations 97-25
Fuse and Relay Panels

Table e. 3-fold relay panel fuses and relays

Fuse Amps Protected circuit
1a 4a
5 15 ECM fuse (S102)
6 Open
~- - -

7 40 Secondary air injection pump fuse (S130)

- -
8 Open
9 Open
10 Open

A60424005

Fig. 46 E-box connector station

Table f. E-box connector station plugs

No. Color From wiring harness To wiring harness
1 W hite Dashboard Engine
2 Bl ue Dashboard Engine I transmission
3 Orange Dashboard Engine
4 Red Dashboard Engine
5 Brown Dashboard Engine/ transmiss ion
6 Black Dashboard Eng ine compartment

A60497065

Main fuse panel, fuse panel S2

~ Gently pry open cover at left end of dashboard to gain access to
main fus e panel.

Fig . 47 Dashboard fuse pane\

~ Left end of dashboard , under cover.

1. Fuse panel S2

See Table g for fuse ratings and applications. Be sure to rep lace a
bad fuse with one of equivalent rating.

NOTE -
• Starting with fuse 23, fuses in the main fuse panel are identified
with an additional S2 in the wiring diagrams.
-Example: Fuse 23 = 5 223
97-26 Fuses, Relays, Compor ent Locations
Fuse and Relay Panels

Table g. Main fuse panel Table g. Main fuse panel

I I

CL:EJJ~~ o=EJ]~ll 38 I
[OI=rJ ~ [DD] [[][]] ~ [DD]
IT::]O] [[]DJ [[3Q=rJ ~ [[]DJ [[3Q=rJ
~ [O[JJ lLE:]] I 4 1 I ~ [LIT]] lLE:]] 11 41 I
~[[]D[O[JJ r:oIJJ [[]D [O[JJ
~corJJ~ ~corJJ~
~[[E=r:J~ ~[[E=r:J~

A6049 )62 A60497062

Fuse Amps Protected circuit Fuse Amps Protected circuit

1 I5 Washer nozzle heater 23 __,_5_ _ __,_~
_a_i_
I a
_n_d_ parking l_ig_h_t_, _
le_ft________ _____,
------+
2 -t--
1
1_0_ _ -+-Turn signal _ _ __ _ 24 -+------+-
25 W
_ ip_e_r_a_n_d_w_ashe r system
3 1

5 Illumination (glove compartment, climate 25 30 Blower, climate control

1----+-- - -1-- - - - - - - - - - - - -----1
-+-c_o_ntrol , instrument cluster) 26 30 Rear window defogger
4 5 License plate lights 27 15 Rear window wiper and washer
5 I 10 Instrument cluster _ ___,__ _ --+_H_e_a_te_d_ steeri ng wheel
1
Climate control 28 15 Fuel pump (1998 - 2000)
1- ---+-- - - - - + - -
Outside mirror
l-28---+------+--
20 F_ue I pump (2001 _-_2_0_04_)_ __
Lamp control module
Seat heating
29 20 Engine control module (ECM) (1998 - 2000)
l- - - - 1 - - -- +---

Rear window shade 29 -+------+--

30 E_n_g_in_e_c_o nt ro 1 module (ECM) (2001 - 2004)

6
CJi 5
10
j~~~:~~:king
ABS - - - - - - _ _
1 - -
30
31
20
15
Sunroof
Automatic transmission
Back-up lights
Cruise control
8 5 Telephone
I -
Automatic day I night interior mirror
9 10
--+--- -+ Mirror heating _ _______ Data link connector
~

10 5 Automatic headlight aim control ! -- - + - -- -+ - - -

32 20 Engine control module
- - t----
11 5 Cruise control 1- - - 1 - -- -- + - -
15
-----~ - -- - 33 Cigarette lighter
12 _j_ 10 ----+- Supply voltage diagnostic
- - l-34 15
----+-----t~ E_n_g_in_e_ control module, fuel injectors
13 110 Br a ke lights
- -- - 35 Open
14 10 Interior lights
15
36
1----+------+- Fog Iights
Reading lights
Central locking
37 20 Sound system
t---- - t - - - ---+- -
Vanity mirror light 38 15 Luggage compartment light
I Seat memory _ _,__ _--+-C _e_ n_t_ra_l_locking system (1998 - 2000)
-
------+
15 -10 - ---ii Instrument cluster 38 20 Luggage compartment light
Automatic transmission Central locking system (2001 - 2004)
Climate control 39 15 Emergency flasher
I- - - + - -- - - + - - - - - - - - - ----t
Mirror memory 40 25 Horn
15 ->-5 Steering angle sensor 41 1----+-0_pen
17 10 Level control system 42 25 ABS I ESP
- -- - -- - - - - -----+
18 10 Headlight high beam , right 43 --t-- --+--O_pen
19 10 Headlight high beam , left 44 30 Seat heater
t---- - + - -- -f - ---
20 15 Head Ii g ht low beam , ri ght
,___ Headlight adjusting
- - --+- -
21 15 Headlight low beam , left
Headlight adjusting
- --+---
22 5 Tail and parking light, right
Fuses, Relays, Component Locations 97-27
Fuse and Relay Panels

Under-dash relay panels

<Oiiii{ Tilt steering column down and pull off trim under instrument cluster.
Remove steering column trim panel fasteners (arrows).

<Oiiii{ Remove lower trim fasteners (arrows) and pull down trim panels
under steering column to gain access to fuse and relay panels under
dashboard .

Fig. 48 Underneath left side of dashboard

<Oiiii{ Lower steering column trim panel removed

1. 13-fold relay panel
2. Micro central electric panel
3. 8 fold relay panel
97-28 Fuses, Relays, Compo ent Locations
Fuse and Relay Panels

Fig. 49 13-fold relay panel

<iiiiii{ Underneath left side dashboard , trim panel removed

Table h. 13-fold relay panel fuses and relays

Pos Amps Circuit or component
1 Selector lever light relay (1998)
2 Open
3 Solar cell separation relay (J309)
4 Starter interlock relay (J207) , manual transmission
Park I neutral position (PNP) relay (J226) ,
Multitronic® transmission (CVT)
A97-0024 5 A/C clutch relay (J44)
6 Foglight relay (JS)
7 Multi-function steering wheel control module (J453)
8
9 Lamp control module (J 123)
10
11 Mirror fold away control module (J351)
12
13 Servotronic control module (J236)
14 15 Brake booster vacuum pump fuse (S279) (allroad)
15 Open
16 Open
17 50 Secondary air pump fuse (S130) (1998)
18 Open

Fig. 50 Micro central electric panel

<iiiiii{ Underneath left side dashboard , trim panel removed

Table i. Micro central electric panel fuses and relays

Pos Amps Circuit or component
1 Horn relay (J4)
2 Load reduction relay (J59)
3 Hydraulic pump relay (J555) (2001 - 2004)
4 Fuel pump relay (J 17)
5 Wiper I washer intermittent relay (J31)

I A97-0110 6
A 20 Steering column adjustment motor fuse (S275)
B 10 Rear window shade motor fuse (S100)
c Open

Fig. 51 8-fold relay panel

<iiiiii{ Underneath left side dashboard , trim panel removed

1. 8-fold relay and fuse panel
 Fuses, Relays, Component Locations 97-29
Fuse and Relay Panels

Fig. 52 8-fold relay panel relays

Table j. 8-fold relay panel relays

Relay Circuit
1 ABS solenoid valve relay (J106) (2002 - 2004)
-
2 En gine cooling fan relay, high speed (J 101)
-
3 Engine cooling fan relay (J26)
-
4 ._ABS solenoid valve relay (J106) (2001)
1------

5 Open
~ -~

6 Leve l control system compressor relay (J403)

(2001 - 2004)
1------

7 AB S return flow pump relay (J105) (2001 - 2004)

A97-0026 ~

8 Open

Fig. 53 8-fold relay panel connectors

Table k. 8-fold relay panel connectors

No. Color From wiring harness To wiring harness
9 Open
~

10 Grey Level control system Dashboard

-
11 Bl ack ABS I ESP Dashboard
--
12 Violet Rear of vehicle Central locking ,
anti-theft
-
13 Open

A97-0026

Fig. 54 8-fold relay panel fuses

Table I. 8-fold relay panel fuses

Fuse Amps Protected circuit
14 Driver seat heater circuit breaker 1 (S44)
(1998 - 2001)
-~

14 60 Engine cooling fan (S42) (2002 - 2004 allroad)

15 20 Luggage compartment auxiliary power socket
(S1 84)
-
16 Front window circuit breaker (S37)
17 Rear window circuit breaker (S43)
23 I -

18 50 ABS control module (S 123)

A97-0026 I 1-------~

19 40 Engine coo ling fan (S42) (1998 - 2000)

19 Open
- -
20 40 Engine cooling fan (S42)
1------ I- -
21 5 Engine cooling fan control module fuse (S 142)
22 Dri ver seat heater circuit breaker 1 (S44)
(2002 -2004)
~

23 40 Level control system (S 110)

- --
24 Passenger seat heater circuit breaker (S80)
97-30 Fuses, Relays, Compo ent Locations
Grounds

Fig. 55 Central carrier relay panel

"'iii( Underneath left side dashboard , attached to dashboard center

support, trim panel removed

Table m. Central carrier relay panel fuses and relays

Pos Amps Circuit
1 Brake booster vacuum pump relay (J569)
2 Open
3 Open
A Open
B Open
c 15 Brake booster vacuum pump fuse (S279)
D 15 Fuel pump control module fuse (S81) (RS6)

GROUNDS
Grounds are distributed throughout the vehicle body. Many are
found under the interior carpets or behind trim panels. Several
components grounds are often ganged. Ground positions vary
among models. Lugs and connectors attached to ground are
susceptible to damage and corrosion. Clean or renew as necessary.

Fig. 56 Ground locations

2 3 4 5 6

~~
\
"'iii( Major grounding locations throughout the vehicle body:
1. Right side engine compartment
- 2. Right lower A-pillar
2
~r \ 3. Battery to body ground cable
' . /) ill
-T-11- I
, { ~ Ij <'~dfjJ
~ ~I

(i I I
J , 4.
5.
6.
Right lower B-pillar
Right lower 0-pillar
Near right taillight
jlj l1 j

.[)(~
7. Left side luggage compartment
8. Left lower A-pillar
9. ABS hydraulic unit ground
12 11 10 9 8 7 10. Left side engine compartment
11. Engine to body ground strap
I A97-0204
12. Near ignition coil pack

NOTE-
• In wiring diagrams, ground locations are described following a
circled number.

-Example: @ - Ground connection on left A-pillar lower part

 EWD-1

EWD Electrical Wiring Diagrams

GENERAL ...... ... . . ......... .. ..... . . EWD-1 Engine management, 4.2 liter,
engine code BAS (allroad quattro 2003) .. EWD-19
Warnings and Cautions .. . .. .. ... . . ... . .. EWD-2
Engine management, 4.2 liter,
Terminal (circuit) identification ... . ..... . .. EWD-3
engine code BCY (RS6 2003) . .. . . ... . . EWD-20
How to read wiring diagrams .. . . . . . ....... EWD-3
Headlight washer (1998) . .. .. . ... .. . . ... EWD-21
Symbols used in wiring diagrams . . .. .... . . EWD-5
Headlight washer (2000) ..... .. ... .. ... . EWD-21
ELECTRICAL WIRING DIAGRAM INDEX .. . . EWD-6 Headlights, xenon (HID) (1998) . ... ... . . . EWD-21
Standard equipment (1998) ....... .. .... EWD-15 Headlights, xenon (HID) (2000) .......... EWD-21
Standard equipment (2001) .. ... ..... .. . . EWD-7 Headlights , xenon (HID) (2001) .... .. .... EWD-21
Standard equipment (2002) . .. . . . . .. .. . . . EWD-8 Headlights , xenon (HID) dynamic (2001) .. . EWD-21
Standard equipment (2003) ...... .. . . .. . . EWD-9 Headlights, xenon (HID) static (2001) . . ... . EWD-21
CD changer (2003) . ... . .. ... . .. ... .. ... EWD-9 Headlights, xenon (HID) dynamic (2003) ... EWD-21
Central locking (1999) .. . .. . .. .. . . ..... . EWD-10 Instruments and controls (1998) ........ . . EWD-22
Central locking (2000) . ..... . .. ... . . ... . EWD-10 Instruments and controls (2000) .. .. . ... . . EWD-22
Central locking (2002 ) .. .. ..... . ........ EWD-11 Instruments and controls (2001) . . . .. ... . . EWD-22
Central locking (2003) . ........ . .... . ... EWD-11 Instruments and controls (2004) .... . ..... EWD-22
Daytime running lights (1999) . ........ . .. EWD-12 Level control (2002) .......... . .... . ... EWD-22
Daytime running lights (2000) .... .. ...... EWD-12 Parki ng aid (Parktronic) (2003) . . . ....... . EWD-22
Daytime running lights (2001) . . . . . ..... .. EWD-12 Seats (2001) ... .. .. .. . . ..... . ...... . . EWD-22
Daytime running lights (2004) .. .. . . . .. ... EWD-12 Sound system (1998) ........ . . . . . ... . . EWD-23
Engine management, 2. 7 liter, Sound system (2000) . . . . . . . . . . . . . . . . . . EWD-23
engine code APB (2001) . .. ... . .. ... .. EWD-13 Sound system (2001) ....... ... .. . . .. .. EWD-23
Engine management, 2. 7 liter, Sound system, Bose (1998) .. .. . . . .. . . . . EWD-23
eng ine codes APB, BEL (2003) ... .. . . .. EWD-14 Sound system , Bose (2000) ....... .. .. . . EWD-23
Engine management, 2.8 liter, Sound system , Bose (2001) . . .. . . .. ..... EWD-24
engine code AHA (1998) .. . . . .... .. ... EWD-15 Sound system , Bose (2003) . ... . .. .. . . .. EWD-24
Engine management, 2.8 liter, Sound system , satellite radio , Bose (2003) .. EWD-24
engine code ATQ (2001) . . ... .. ... .. .. EWD-16
Sunroof (2000) . . . . .... . . ..... . ... ... . EWD-24
Engine management, 3.0 liter,
engine code AVK (2002) ... .. . ... . ... . EWD-17 W indows (1998) . ....... . .. . . . . ... .... EWD-24
Windows (2000) .. ..... .. . .. . . ....... . EWD-24
Engine management, 4.2 liter,
engine code ART (2001) . .... .... ... .. EWD-18 Windows (2001) .. . . .. . . . .. . .. . ... . ... EWD-24
Engine management, 4.2 liter, W indows (2002) .. ... .. . ... . .. ... . . . . . EWD-25
engine codes AWN , BSD (2002) .... . . .. EWD-18
ELECTRICAL WIRING DIAGRAMS . ... . ... EWD-26

GENE RAL
This section contains selected wiri ng diagrams for vehicles covered
by this manual. These diagrams are provided by Aud i of America ,
Inc. The publisher of this manual cannot vouch for the accuracy of
these diagrams. Additional wiring diagrams can be found in the
Officia l Factory Repair Manual available on CD-ROM or via web
subscription at www.BentleyPublishers.com .

For a comprehensive list of fuses , relays and electrical component

locations, see 97 Fuses, Relays , Component Locations .
 EWD-2 Electrical Wiring Diagrc ms
General

',. Warnings and Cautions

Please read the following before doing any work on your electrical
system .

' WARNING-
'I
• Airbags and pyrotechnic seat belt tensioners utilize explosive
devices. Handle with extreme care. Refer to the warnings and
I
·I cautions in 69 Seat Belts, Airbags.
I • The ignition system of the car operates at lethal voltages. If you
' have a weak heart or wear a pacemaker, do not expose
yourself to the ignition system electric currents. Take extra
precautions when working on the ignition system or when
servicing the engine while it is running or the key is ON. See 28
Ignition System for additional ignition system warnings and
cautions.
• Keep hands, clothing and other objects clear of the electric
radiator cooling fan when working on a warm engine. The fan
may start at any time, even when the ignition is switched OFF.

CAUT/O~
• Do not disconnect the battery with the engine running.
• Switch the ignition OFF and remove the negative (-) battery
cable before removing any electrical components. Connect and
disconnect electrical connectors and ignition test equipment
leads only while the ignition is switched OFF.
• Relay and fuse positions are subject to change and may vary
from car to car. If questions arise, an authorized Audi dealer is
the best source for the most accurate and up-to-date
information.
• Use a digital multimeter tor electrical tests. Switch the
multimeter to the appropriate function and range before making
test connections.
• Many control modules are static sensitive. Static discharge
damages them permanently Handle the modules using proper
static prevention equipment and techniques.
• To avoid damaging harness connectors or relay panel sockets,
use jumper wires with flat-blade connectors that are the same
size as the connector or relay terminals.
• Do not try to start the engine of a car which has been heated
above 176°F (B0 °C) (for example, in a paint drying booth).
Allow it to cool to normal temperature.
• Disconnect the battery before doing any electric welding on the
car.
• Do not wash the engine while it is running, or any time the
ignition is ON.
• Choose test equipment carefully Use a digital multimeter with
at least 10 MQ input impedance, or an LED test light. An analog
meter (swing-needle) or a test light with a normal incandescent
bulb may draw enough current to damage sensitive electronic
components.
• Do not use an ohmmeter to measure resistance on solid state
components such as control modules.
•Disconnect the battery before making resistance (ohm)
measurements on a circuit.
 I

Electrical Wiring Diagrams EWD-3

General

Wiring diagram organization

Audi wiring diagrams in this manual are organized as fol lows :
• Standard equipment covers
Grounds
Power supply
Alternator (generator) and starter
Exterior lights
ABS
Wipers and washers
Seats and mirrors
•Central locking system
•Daytime running lights including foglights
• Engine management
•Headlights and headlight washers
•Instruments and controls covers switches and instrument panel
on dashboard
• Sound system
•Windows

Terminal (circuit) identification

Several circuits in the vehicle's electrical system are identified with a
number or letter designation . These circuits are universally identified
in many wiring diagrams and may also be used to identify switch
connector terminals .

,. .~~··
_ Relaypanel
Terminal Identification
Ignition coil/distributor low voltage (i .e. RPM signal)

I
Indicated by grey area .

15 Switched battery positive (B+) from ignition switch

e
WIAI NG
COLOR CODE 30 Battery positive (B+) , hot at all times

ro =red 31 Ground(-)
b1 "' blown
Dnoo gn :o-green
,•, bl = blue
qr= grey
31b Switched ground (- )
ge - yollow
50 Starter control ; switched B+ from ignition switch

l _ _ Cons umer circ uit with w ire routing

All switches anrl co n1acs are shown in rhe 'off"
58
S (SU)
Switched parking light, taillight , B+ from light switch

Key in ignition , switched B+ from ignition switch

-
x
,. ,. Wl,,., Switched B+ from load reduction relay

Infrll c ~ " Ve hi c le g round

How to read wiring diagrams
~
Numbers •n circle mU1c.:dtt: loca11on on vcn1cte
(See legend)
This diagram shows how a typical wiring diagram page is laid out.
~- l_J
)
1 4 / ,-
__ Cu rrenttracknumber
M::ikC! 5 11 P.=tsier 10 fin d !he> cor,rie c t1on~
Details of wiring diagrams are explained on the next 3 pages.
f. - Baller\
IJ - S1 ar-. e~
G.::ncra101 GD'.1
C; VoltagPRegulato1(Vi\1
l lgm1,::w'S!arter Sw11ct1
5162- f--:;se 1 <30111iluscornchct ba11cry
S163- f-u~I! 2·13D1irfusebrackcl battery
- .le - 4 Pr.Connector on 1r1nsm1ss1on
~ 1C1 - 10-Ptn :nnnPc-tor on µ 101ect1vc tiousrng lo r
I ~e~t~:~nngdiagrams l hc s.:unc component
des1gna11on1code ) 1s usedlora paniC'ular
-:cn1r01 1r:>oule: 1n engine comoa n men 1 te ll component. tor example . always A for bat1c 1y
Q "°;r ·vK1 sirap nauer, 10 d~,

Q- 1r1l.ncs11arrrc:ms'T11Ss1on1obocty

8 - S1·•e•\ L<.11111ec1 1cn-1 (.301 onrro.aypanpl

Edition 01 /98
USA.5132.01.2 1 Wir ing diagram lay o u t

I I
EWD-4 Electrical Wiring Diagr ms
General

Wiring diagram details

17 - ~ --~--~----..__..
1. Relay location number
• Indicates location on relay panel.

..____ __ 3 2. Arrow
• Indicates wiring circuit is continued on
- - - -- - - 4
1 6 ---------~
the previous and/or next page.
3. Connection designation - relay con-
- - - -- - 5
trol module on relay panel
~---------------- 6
14 - - - ---- - - - - ----- • Shows individual terminals in a mu lti-
.--'------ @)
o.s 0, 5
I
0 ,5
r--- e
0 ,5
point connector.
<O li/'ws
1 m '---IH---- ---- - - - 7 • For example : terminal 24 indicated .
__
l: T45/29 J~7 1 T45/25 ~r/2 1
13
-i.-T4-S/-36-.-r-
. s-11s--t.-T•_S1_1 ,-.--,T-45-/3 - - - , r -T4' 5128
~----------------- 8 4. Diagram of threaded pin on relay
panel
12 - - - ~: ~: b~/~o g~~e b~i:e
•White circle shows detachable

T 10
T2aa1
17
l connection .
5. Fuse designation
• For example : S228 = fuse numbe r
228, 15 amps , in fuse holder.
6. Reference of wire continuation (cur-
rent track number)
NaoS.j GG G • Number in frame indicates current
track where wire is continued on
another wiring diagram page .
1,0
br/sw 7. Wire connection designation in wir-
filJ G 9 ing harness
56
197---0815 2 1
• Location of wire connections are
indicated in legend .
8. Terminal designation
• Designation which appears on actual
component and/or terminal number of
a multi -point connector.
9. Ground connection designation in
wire harness
• Locations of ground connections are
indicated in legend .
10. Component designation
• Use legend to identify component
code.
11. Component symbols
• See Symbols used in wiring
diagrams in this repair group .
12. Wire cross-section size (in mnf) and
wire colors
• Abbreviations are explained in color
chart beside wiring diagram .
13. Component symbol with open draw-
ing side
• Indicated component is continued on
another wiring diagram page .
 Electrical Wiring Diagra ms EWD-5
General

14. Internal connectio ns (thin lines)

•These connection s are not wires .
17 - ~ - - - - - - - - ---,

J11
I.~1
D ,-2 .:.
• Internal connection s are current
carrying and are shown to allow
20 . · 22. M
tracing of current flow inside
.___--+--+--- --. ...___ _ _ 3 component s or wiring harnesses.
B - --531_1_ ___ 4 15. Reference of continuati on of wire to
4 ,0
16 ---------~ bl
componen t
'f" @~!" _______ 5 • For example : Anti-theft immobilize r

14 ------------------~
1.0 : .:.:. ,___ _
'---- --11,.28•_ 6 (J362) control module on 6-pin
connector, terminal 2.
o-.s- ---- @ 0 ,5 1,0
go/SW
0 ,5

'--'0------ __.__ _ _ _ 7
r-- c
0 ,5
16. Relay panel connector s
I T45129 J 257 1T45125 J: T45/21
30
------11---1---I----~ 8 •Shows wiring of multi-point or single
13 - - t,.,,.;,.... oo tT4 5f1 tT45/3 r. I
T45/28
connectors on relay panel.
12 ---~; 0 .5
1,5
br/ ro
0,5
gn/ge
0,5
br/ ge
•For example: 83/3 =multi-poin t
connector 83 , terminal 3 .

T
wsJro
1 J
T,.,
17
l 17. Reference of internal connectio n
continuation
• Letters indicate where connection
continues on previous and/or next
T•1• T•l3 +T•11 page .

Nsoijj Goa.G
10 - - -..___._ -l-- -1---11--__/ - 1 ,. 2
1.0
br/ sw
- 1,0
b•

~ G @ -- - - - - - - 9

56
197-081521
. EWD-6 Electrical Wiring Diagrams
General
Symbols used in wiring diagrams
Various symbols identified below are used in the wiring diagrams.

Solenoi d valve
Diode
S witch
Fuse (manually opera ledl

Zene r diode Magn etic clutch

Switch
Thermo-luse (thermally operated )
(C1, cu1 1Breaker ) Diode
light sen s111v W ire co nnec tor
Push punon sw11ch
Banery (manua lly operated )

Light bulb
T Pin co nnector
Sw11ch

SI
(mechanically ope rated)

Li ght bulb M u1! 1-point con nec tor

Starter
(dual fila ment) al component
Switch
(pressure op era1ed )

In terna l co n nec t1ons

Mulllple switch in co mponenl

Rt
(manually operated ) LED

Generalor (GEN )
Wi re co nnectmn
detachable
Rcs1s1anc e
ln tenor ligh t
,i
(
fl( Ignition Coil
Var iable resistor
(Rheostat)
Wire co nnection
fixed

tnstru men1

1rt~H ~ ®1
(Gauge) Wt re conne ct1on in
D1str1butor (electronic)
Res1s1or wmng harness
tempe ral ure dependent

Elec tro nic co ntrol

Spark plug connec tor m od ule
and ol ug Hea ter elemenl Resistance w1re
tempera ture dependenl

Rea r window defog ge r

heat e le ment
Glow plug
Heater element Relay
Shield wi re

C1garell e l1g hle r

Crankshalt pos1 11 on sensor
Ifv'I r1 11 1cicil J Mulh·lunc110n
iC KP )
~l r1 r11 11il 1nd1cator Airba g spiral spring

Spe eo senso r

\c~_DJI
Co ntro l m otor.
Knocksensor (KSI headlig ht ran ge ad1us tm en t
H orn

~
Wiper m o 10 1
M o 1or Ana lo g clock
2 speed
l@=@ l Ra dio

D 1g1 ta l cloc k
Speaker

Speed sensor An tenna with elect ronic

antenna amph l1er
 I

Electrical Wiring Diagrams EWD-7

Electrical Wiring Diagram Index

ELECTRICAL WIRING DIAGRAM INDEX Fuel pump ..... .. .. . ........ ........ EWD-105
Grounds . . .... .. ......... . . .... . .... EWD-98
Standard equipment (2001) . .......... .. . EWD-97 Headlight beam adjusting ............. . EWD-100
A/C control panel. . . . . . . . . . . . . . . . . . . . . EWD-1 02 Headlight dimmer I flasher switch .. ... .... EWD-99
ABS control module .. .... .. .......... EWD-107 Headlights . . . .... .. .. ...... . ........ EWD-104
Ai rbag control module ... . .. ...... ... .. EWD-100 Horn button . . . . . . . . . . . . . . . . . . . . . . . . . EWD-1 03
Alternator (generator) .. .......... .. .... EWD-99 Horns ..... ... ... . ....... .. .... . ... . EWD-103
Antitheft immobilizer induction coil .. ... .. EWD-108 Ignition switch . ... . .. . . ... .. . .... . .... EWD-98
Automatic transmission control module .... EWD-98 Instrument lights dimmer switch .. .. . . ... EWD-106
Automatic transmission range switch .. .... EWD-98 Level control system sensors . . . . . . . . . . . EWD-100
Back-up light switch .................. EWD-105 Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-99
Back-up lights ....................... EWD-105 Mirrors . .. ........ ............. .. ... EWD-102
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-99 Oil level thermal sensor .. . ... .. ........ EWD-108
Brake flu id level warning switch . ........ EWD-107 Oil pressure switch . . .............. ... EWD-107
Brake light switch .. ... . ..... . . . ... ... EWD-102 Parking brake warning light switch ..... . . EWD-106
Brake lights .. ....... .. . ..... . ....... EWD-105 Parking light switch ............ .. ... ... EWD-99
Brake pad wear indicator . .......... ... EWD-107 Parking lights . ....... . ... ... .. . .. .... EWD-104
Brake vacuum vent valve .. ...... .. .... EWD-102 Radio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-98
Central locking control module ... .. ..... EWD-102 Rear window defogger ...... ... ... ... . EWD-105
Cigarette lighters .. . ..... ... . .. .. ... .. EWD-103 Seat memory . . . . . . . . . . . . . . . . . . . . . . . EWD-1 03
Clock . ......... .. ... . .. . . . . ..... . . . EWD-107 Speedometer ..... .. . . ..... .... ...... EWD-106
Clutch pedal position switch .... . . . ...... EWD-98 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-99
Emergency flasher relay .. . ..... .. .... . EWD-100 Tachometer ... .. . .......... .. ....... EWD-106
Emergency flasher switch ... .. . . ....... EWD-100 Taillight ..... . ..... .... ...... ...... . EWD-105
Engine control module (ECM) ........... EWD-100 Turn signal switch . .. ..... . ... .. ....... EWD-99
Engine coolant temperature (ECT) sensor . EWD-106 Turn signals .. ......... ... ... .. ...... EWD-104
Engine coolant temperature gauge .. . . . .. EWD-106 Turn signals , rear .... ...... . . . .. . ... . EWD-105
Foglight switch . .. . ......... . ... . ..... EWD-99 Vehicle speed sensor . .... .... ... .... . EWD-106
Foglights , front .. ...... ........ . . ... . EWD-101 Voltage regulator . .. .. .. .. ............. EWD-99
Fog lights , rear ................. . ... .. EWD-105 Voltmeter ...... . .... . ......... . .... . EWD-107
Fuel gauge sender ............. .. .... EWD-105 Warning buzzer ......... . .. .. . ....... EWD-107
Fuel gauge .............. . .......... EWD-106 Wipers I washers .. . .. ... .. .. ..... . ... EWD-101

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EWD-8 Electrical Wiring Diagrc: ms
Electrical Wiring Diagram Index

Standard equipment (2002) . .... . . .. ..... EWD-161 Headlight dimmer I flasher switch .. ..... .. EWD-163
12v socket ...... . ..... .. . . .... ..... . EWD-1 69 Headlights , left .. ... . .... . . .. . . .. . . . .. EWD-169
A/C control panel .. ... .... . . ... .. . . .. . EWD-1 06 Headlights, right .... ... ...... .. . . .. ... EWD-168
ABS control module .. . . .. .... . . . .. . ... EWD-164 Hood alarm switch ..... .. ... .. . .. .... . EWD-172
ABS control module ... .. . . .. . . .. . ..... EWD- 1[71 Horns ...... ....... . . ... . ... .... . . .. EWD-168
Airbag control module ...... . .. . . .. . .. . EWD-165 Instrument lights dimmer switch .. .. . . .. . . EWD-171
Alternator (generator) .. .. ... .. . . ... . . . . EWD- 63 Level control system sensors .. .. . .... . . . EWD-164
Antitheft immobilizer induction coil . . . .. . .. EWD- 72 Light switch ..... . .. .. . .... . . . . . . . .... EWD-163
Automatic transmission control module .. .. EWD- 67 Malfunction indicator lamp . . . ... . .... . .. EWD-170
Automatic transmission range switch . .. . .. EWD- 69 Mirrors . . .... . ... ... . .. .. . ..... .. . .. EWD-167
Back-up light switch . . . . .. ... .. . ... .. . . EWD- 69 Multifunction steering wheel
Battery ....... . . . ... .. . ..... ... . ... . EWD- 63 control module . ...... .. ..... . . . ... . . EWD-172
Board computer function selector switch . . . EWD- 72 Oil level thermal switch . ... ..... . . . ... . . EWD-172
Brake fluid level warning switch . .... . . . . . EWD- 72 Oi l pressure switch . ...... ..... . ... . .. . EWD-172
Brake light switch . . .... . . ... . . ........ EWD- 67 Parking light switch .. ..... . .. . . . .... . . . EWD-163
Brake lights , left ............. . . ... ... . EWD- 69 Parking brake warning light switch . . .. ... . EWD-170
Brake pad wear indicator . . . . . ..... . . .. . EWD- 71 Parking light, left. . .. ... . . .. .... . . .. . . . EWD-169
Brake pedal switch . . .. . . .. . .. . . . .... .. EWD- 67 Parking light, right. .. . . .. . . . . ..... . .. . . EWD-168
Central locking control module . .. . .. . . . . . EWD- 71 Rear window defogger ....... .. ....... . EWD-170
Cigarette lighter ....... . . . .. ... ....... EWD- 68 Seat memory program control .. ... . .... . EWD-167
Clock .. . . ... .. . . ...... . . .... . . . .. .. EWD- ~ 71 Shift-lock solenoid . .... . ........ . . . ... EWD-169
Emergency flasher switch . ....... . . .... EWD ~ 65 Speedometer . .. ... .. .. . . .... . ... . ... EWD-171
Engine control module (ECM) ... . ... .. . . EWD H67 Starter ..... .. .. . ... .. ...... . .. .... .. EWD-163
Engine coolant level warning switch . .... .. EWD h72 Tachometer . ... ......... .... . .. ... .. EWD-171
Engine coolant temperature (ECT) sensor .. EWD h71 Tail and brake lights , right ...... .... ... . EWD-170
Engine coolant temperature gauge . ... . .. EWD 171 Turn signal switch . ... .. .. .... .. . . . . ... EWD-163
Foglight switch . . .. .. .. . .. . ...... .... . EWD 163 Turn signals, left .. ... .. ... . . . .. ....... EWD-169
Foglights, front . ..... ...... . . .. . . .. . .. EWD 166 Turn signals , right. . . .. . . ..... ... .. . ... EWD-168
Fogl ights , rear . . .. . .... ... .. .. .. . .... EWD 169 Vehicle speed sensor . . . . . .. ..... .. .... EWD-171
Fuel gauge senders ... . ..... . ..... ... . EWD 170 Voltage regulator .. .. . .. .. .. . .. .. .. .. . EWD-163
Fuel gauge . ..... .. ............ . . .... EWD 171 Voltmeter .. . ... ..... ....... . ... .. ... EWD-1 Tl
Fue l pump relay .. ... .. . ...... .. . ... .. EWD 170 Warning buzzer . . ... . . .. . .. . ....... . . EWD-171
Fue l pump ...... . ......... . ........ . EWD 170 Washer nozzle heaters . ..... ... . .. . . . .. EWD-166
Grounds .. ........... . .. .. ...... . . . . EWD 162 Wipers I washers . .. . .. . . . . . .... .. .... EWD-165
Headl ight beam adjusting ... . .... . .... . EWD 164

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Electrical Wiring Diagrams EWD-9
Electrical Wiring Diagram Index

Standard equipment (2003) . ....... ... .. EWD-208 Headlight dimmer flasher switch ......... EWD-211
12v socket .... .................... .. EWD-216 Headlights ..... . .. .... ..... . . . . . .... EWD-216
A/C control panel. .................... EWD-213 Hood alarm switch. . . . . . . . . . . . . . . . . . . . EWD-220
ABS control module .. .. ...... ... . . ... EWD-211 Horn button ... . ... .. .. .. ....... . .... EWD-215
Airbag control module . . .... . .......... EWD-212 Horn relay . . .. . . .. . ....... ... .. .. .. . EWD-215
Alternator (generator) . . .. .. .......... . EWD-21 O Horns .............................. EWD-215
Antitheft immobilizer induction coil ....... EWD-220 Ignition switch ....................... EWD-21 o
Automatic transmission control module ... EWD-21 O Instrument lights dimmer switch ........ . EWD-218
Automatic transmission range switch ..... EWD-21 O Level control system sensors ........... EWD-211
Back up light switch . ............... . . . EWD-217 Light switch .... .. . .. . .. . .. .. . . ..... . EWD-21 o
Battery .. .... .. ..... . .. . . . . . . .... .. . EWD-210 Mirrors ..... ..... . .... .... . .... . . . .. EWD-214
Board computer function selector switch .. EWD-220 Multifunction steering wheel
Brake fluid level warning switch ...... .. . EWD-219 control module ..................... EWD-220
Brake light switch ....... ........ ..... EWD-214 Oil level thermal sensor ........ ... .... . EWD-220
Brake light, center .. .................. EWD-217 Oil pressure switch . . . . . .. . . ...... . . . . EWD-219
Central locking control module .. . ....... EWD-21 O Oil pressure warning light .............. EWD-219
Central locking control module . . ... . .. . . EWD-214 Parking brake warning light switch ....... EWD-218
Clock ... ... .................. . ..... EWD-219 Parking light switch ................... EWD-211
Clutch pedal position switch ....... . .... EWD-21 O Parking lights . ... .. ... . . . . ...... ... . . EWD-216
Cruise control brake switch ........ . .... EWD-214 Rear window defogger .. . ............. EWD-217
Emergency flasher switch .. ... . .... .... EWD-212 Seat memory program controls .......... EWD-215
Engine control module (ECM) . ....... .. . EWD-214 Speedometer ........................ EWD-218
Engine coolant level I temperature Starter .. . . ..... . ........ ..... . ..... EWD-21 O
warning light . .... ... .... . .......... EWD-219 Tachometer ..... . . ........... . . .. .. . EWD-218
Engine coolant level warning switch ...... EWD-219 Taillights ....... . ......... .. ... . .... EWD-217
Engine coolant temperature (ECT) sensor . EWD-218 Turn signal switch .. .. . . .. ... . . . . ..... EWD-211
Engine coolant temperature gauge ....... EWD-218 Turn signals ............ .... .... . . .. . EWD-216
Foglight relay .. .. .................... EWD-213 Vehicle speed sensor . .. ... ...... .. ... EWD-218
Foglight switch ...................... EWD-211 Voltmeter ........................... EWD-219
Foglights .... . ....... ........... . ... EWD-213 Warning buzzer . . . . .......... .. . .. ... EWD-219
Fuel gauge senders . . . . ....... ... .. .. EWD-217 Wiper I washer intermittent relay ......... EWD-21 o
Fuel gauge . .. ... .. ........ . . .. .... . EWD-218 Wipers I washers . .... ...... .. ........ EWD-213
Fuel pump relay . ..... ............... EWD-217 CD changer (2003) .. .. .. . .. .... . ... . .. EWD-284
Grounds . .... .. ..... .... .... . . . .. . . EWD-209 CD changer ........... . . ....... . .. . EWD-284
Headlight beam adjusting control module .. EWD-211 Radio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-284
Headlight beam adjusting motors .. . ..... EWD-212

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EWD-10 Electrical Wiring Diagrams
Electrical Wiring Diagram Index

Central lockin g (1999) . .................. EW D-54 Central locking (2000) . .... . . . . ....... . .. EWD-64
A/C control panel . . .... .... .. . .... . . ... EW )-58 Airbag control module . ......... . ... .. . . . EWD-65
Alarm horn ... . .. ......... .. . . . ....... EW )-54 Alarm horn .. .. ........ . ..... . ..... .. . EWD-64
Automatic transmi ssion range switch .. ... .. EW D-57 Antenna , central locking , anti-theft ... . ..... EWD-69
Blower ..... . . .. . ..... ..... ... . ...... EWI )-58 Automatic transmission range switch . ..... . EWD-64
Central locking control module .. .......... EWI )-54 Broken glass sensors ............. . ..... EWD-69
Central locking motor, rear ............... EWI ~-56 Central locking control module ... ......... EWD-66
Central locking motor, right rear ..... . .... EW! >-57 Central locking motor, left front. ..... ..... . EWD-65
Central lockin g switch , left front ... . .. .. . . . EW! 1-55 Central locking motor, right front .. . .. . . ... EWD-66
Central locking switch , left rear. .. . . . . .. . .. EW! 1-56 Central locking motor, right rear ..... . .. . .. EWD-67
Door contact switches . ... .. . . ..... . ... . EW! -55 Central locking switch , left front .... . .. . . .. EWD-65
Door lock switch , driver interior . .. . ....... EW[ -55 Central locking switch , right front ..... .. ... EWD-66
Door warning light, right .... . .. .. . ... . .. . EW[ -55 Central locking switches , rear ..... . ... .. . . EWD-67
Emergency flasher switch . ........ . ..... EW[ -55 Clutch pedal position switch . . . . .... . . .. .. EWD-64
Emergency flasher switch .. . ..... .. . . . .. EW[ -57 Data link connector .. .. . . ........... .. . . EWD-68
Hood alarm switch . . . .. .. . ..... . .. ... .. EW[ -54 Door contact switch , left front .. . . .. . ...... EWD-65
Ignition I starter switch .. . ............... EW[ -54 Door contact switch , right front. . .......... EWD-66
Instrument cluster combination processor ... EWC -54 Door contact switches , rear . ............. EWD-67
Interior (ultrasound) monitoring ........... EW[ -58 Emergency flasher switch .. .. .. . .. . . ..... EWD-65
Interior (ultrasound) sensors control module . EW[ 59 Fresh air blower . .. ... .. ............... EWD-69
Level control system module .. . . ..... . . .. EWC 55 Fuel tank lid unlock motor .. . ...... .. .... . EWD-68
Mirror, automatic day I night interior . . ... ... EWC 61 Hood alarm switch . . . . ......... .. . .. ... EWD-64
Rad io . . . . .. ... ........... . . . . . ...... EWC 54 Ignition I starter switch . . ....... ..... . . . . EWD-64
Rea r lid unlock motor ... . .... .. . . . . .. ... EWC 54 Instrument cluster combination processor .. . EWD-64
Rear wind ow defogger . . . . . . . . . . . . . . . . . EWD 58 Interior (ultrasound) monitoring ........... EWD-69
Seat memory control module . ... . .. . ... . . EWD 55 Interior (ultrasound) monitoring sensors .... . EWD-70
Starter . . ... . . .. . . .. . . . . . . . . . . ... . .... EWD 57 Level control system control module ..... . . EWD-65
Sunroof control module ........... . ..... EWD 56 Parking aid control module ......... . .. . . . EWD-68
Trunk alarm I central locking switch . ....... EWD 57 Radio ................. ... . ........ . . EWD-64
Trunk lid locking motor . ........ . .. . . . . .. EWD 57 Seat memory control module ...... . ...... EWD-65
Trunk lid release switch . . . .............. EWD 54 Starter ........................ . . . .... EWD-64
Window motors .. ... .......... . .. . ..... EWD 56 Trunk or luggage compartment lid controls . . EWD-68
Window regulator, left rear .. . .. . .. .. ... .. EWD ~9 Window motors . . . . ...... ... . . . .... . . . . EWD-67
Window switch , left front. ........... . .. . . EWD 55 Window motors, front . .......... . .... . .. EWD-73
Window switch , right front ... ............ EWD 58 Window motors , rear .... . . . . . . . .... . ... EWD-72
Window switch , right front. . . . . .. . .. .. ... . EWD-66
Window switches , front ... . ..... . . ~ . .. . . . EWD-70
 Electrical Wiring Diagrams EWD-11
Electrical Wiring Diagram Index

Central locking (2002) . . ..... .. .. ...... EWD-191 Central locking (2003) . . ............... EWD-240
Airbag control module ................ . EWD-192 Airbag control module ...... .. . .... .. .. EWD-241
Alarm horn . .. ......... .............. EWD-191 Alarm horn . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-240
Antenna , central locking, anti-theft . ... ... EWD-196 Antenna , central locking , anti-theft ....... EWD-245
Automatic transmission range switch . .... EWD-191 Automatic transmission range switch . . . . . EWD-240
Central locking control module . . . .. ... . . EWD-191 Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-245
Central locking motor, left front .... ...... EWD-193 Broken glass sensor . . . . . . . . . . . . . . . . . . EWD-246
Central locking motor, left rear . ... ...... EWD-194 Central locking control module ... .. . .... EWD-240
Central locking switch, right front ........ EWD-193 Central locking switch . .. .... .. . .. .... . EWD-241
Clutch pedal position switch .... . ....... EWD-191 Central locking switch , rear ....... .. ... . EWD-243
Door contact switches. . . . . . . . . . . . . . . . . EWD-192 Central locking system motor . . . . . . . . . . . EWD-241
Door lock switches , interior ...... . ... . .. EWD-192 Central locking system motors, rear ..... . EWD-243
Door warning lights ... ... ....... ..... . EWD-193 Clutch pedal position switch ......... ... EWD-240
Emergency flasher switch . . . . . . . . . . . . . . EWD-192 Door contact switch. . . . . . . . . . . . . . . . . . . EWD-241
Fuel tank lid unlock motor .......... . ... EWD-195 Door contact switches , rear ............. EWD-243
Hood alarm switch ....... . ... . ........ EWD-191 Door lock switches , interior ..... .. ... ... EWD-241
Ignition switch .................. . .... EWD-191 Emergency flasher switch .. . .. . ........ EWD-241
Ignition switch .... . ........ .. . ....... EWD-193 Fuel tank lid unlock motor ... .. .... . . . .. EWD-244
Interior (ultrasound) monitoring sensors ... EWD-197 Hood alarm switch . . . . . . . . . . . . . . . . . . . . EWD-240
Interior (ultrasound) monitoring . ...... . .. EWD-196 Ignition switch . ... .. ......... . ... .. . . EWD-240
Level control system module . . ... ....... EWD-192 Interior (ultrasound) monitoring . ......... EWD-245
Lock cyl inders contact switch . ......... . EWD-193 Level control system control module ...... EWD-241
Radio . . .. . ............. . ...... ..... EWD-191 Rear window defogger ......... . .. ... . EWD-246
Seat memory control module . . . . . . . . . . . EWD-192 Seat memory control module .. ...... ... EWD-241
Seat memory , left front . . . . . . . . . . . . . . . . EWD-193 Seat memory control module ........ ... EWD-24 7
Starter ........... ............. . . ... EWD-191 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-240
Sunroof control module ................ EWD-194 Sunroof control module .... ..... ..... .. EWD-243
Tail light, left .................. .. . ... EWD-200 Taillight , left .. .. ..... ... . . .. .. ... . . .. EWD-249
Telephone I telematic control module ..... EWD-192 Telephone I telematic control module ... .. EWD-241
Trunk or luggage compartment lid controls . EWD-195 Trunk or luggage compartment lid controls. EWD-244
Window motors ........... . .. . ... ... . EWD-194 Window motors ...................... EWD-243
Window motors ....... . . ............. EWD-200 Window motors ......... .. . . . ........ EWD-249
Window switch . .. .... . . . . ...... . ... . EWD-197 Window switch , left .. . .... .. ... . ... .. . EWD-246
Window switches , front ...... . ......... EWD-192 Window switches, front ... . ... ........ EWD-241
I EWD-12 Electrical Wiring Diag'"ams
Electrical Wiring Diagram Index

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Daytime runnin g lights (1999). .... . . .. .. .. EWD 62 Daytime running lights (2001 ). . ...... . .. . EW D-137
Foglight switch .. .. . .. . . . . ... . . . .. ..... EWD 62 Fog lights . .. ........... . ..... ... .. . .. EWD-138
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Foglights ... . . ..... .. ... .. . . ... .. . . ... EWD 63 Headlight dimmer I flasher switch ....... .. EWD-138
Headlight beam adjusting motors .... . . . . . . EWD 63 Headlights , left .. ... .... .. ... . . . . . . .. . EWD- 138
Headlight dimmer I flasher switch .......... EWD 62 Headlights , right .. ... . ..... . .... . ..... EWD-139
Headlight high beam indicator light .... .. .. EWD 63 Ignition switch . . . .... .. .. . .. .......... EWD-137
Headlights ............... .. ..... .. . . . EWC 63 Instrument cluster comb ination processo r .. EWD-137
Ignition I starter switch . . .... . ...... . . . . . EWC 63 Lamp control module . . .... . ........ . .. EWD-138
Instrument cluster combination processo r .. . EWC 62 Light switch .... . ..................... EWD-138
Lamp control module ................... EWC 63 Parking light, left . . . ................... EWD-138
Light switch .... . .... . . .. .. . .. .... . .. . . EWC 62 Parking light, right. .................... EWD-139
Parking lights ......................... EWC 63 Starter .. . ..... ... . . .. .... . ....... . .. EWD-1 37
Starter . .. ...... . ......... . ... . . . . . . .. EW C 63 Taillight, left ... . ... ... .. ..... . . . .. . . . EWD-138
Taillights .. . . ....... . . ... ............ . EW[ .. 53 Taillight , right ........................ EWD-139
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, Voltage regulator ... . ............... . .. EW[ -63 Voltage regulato r ..................... EWD-137
I Daytime running lights (2000). ..... .. ... . . EW[ -84 Daytime running lights (2004). ........... EWD-250
Foglights ............... . .... . .... . . .. EW[ -85 Foglight switch .... . .. . ....... . . . ..... EWD-251
Headlight adjuster . .. ........... . . . .... EW[ -85 Fog lights . . ..... .... .. . . .. ..... . . . ... EWD-254
Headlight dimm er I fl asher switch ......... . EW[ -85 Headlight dimmer I flash er switch . . ...... . EWD-251
Headlights , left . . . . ... ...... ........... EW[ -85 Headlights, left ...... . . ... . .... .. .. ... EWD-254
Headlights , right .......... . . . ..... . .... EW[ -86 Headlights, right . .................. .. . EWD-255
Ignition switch . . .. . .. . ... . ... .. .... . ... EW[ -84 Ignition switch ........................ EWD-250
Instrument cluster comb ination processor .. . EW[ -84 Lamp control mod ule . .............. . .. EWD-254
Lamp control modu le .. . ................ EWI ~ -85 Lamp control module .................. EWD-255
Light switch . ...... ......... . ... .. .... . EWI ~-85 Light switch ... . ............ . ......... EWD-251
Parking light, left .. ..... . ......... . .... . EWI >-85 Parking light, left .. . ........ . ... . . .... . EWD-254
Parking light, right . . ... ..... . ...... . ... . EWI >-86 Parking light, ri ght. .................... EWD-255
Starter ........................ . . . . . .. EWI ~ -84 Starter .............................. EWD-250
Taillight , left .. . ........... . .......... . EWI ~-85 Taillight , left ....... .. . ........ ..... . . EWD-254
Taillight , right ..... . . ... .. ... .. . ... . ... EWI )-86 Taillight, right ...... ... .... . .......... EWD-255
Voltage regulator .. . .. .. ............ ... EW )-84 Voltage regulato r ....... . ............. EWD-250
 Electrical Wiring Diagrams EWD-13
Electrical Wiring Diagram Index

Engine management, 2.7 liter, Engine speed (rpm) sensor ..... ... ..... EWD-113
engine code APB (2001 )................ EWD-110 EVAP canister purge regulator valve . .... EWD-115
A/C control panel. . . . . . . . . . . . . . . . . . . . . EWD-111 Exhaust temperature sensors ...... .. .. . EWD-114
A/C pressure switch ... . .............. EWD-116 Fuel gauge sender ... . . ... ..... ... ... EWD-117
ABS control module ....... . .... .. .... EWD-113 Fuel injectors .. .. .... . .. .. .. .. . ... ... EWD-112
After-run coolant pump ... . . .... .. ..... EWD-116 Fuel pump relay ..... ... ... ..... . .. .. EWD-114
Airbag control module .......... .. ..... EWD-113 Fuel pump ....... . ........ .. .... . ... EWD-117
Alternator (g enerator) ....... .. ..... .. . EWD-111 Ign ition coil power output stage .......... EWD-112
Automatic transmission control module ... EWD-116 Ignition coils ... .. ......... .. ... ..... EWD-112
Automatic transmission range switch . . .. . EWD-111 Ignition switch .... . .................. EWD-111
Batte ry ................... . ....... . . EWD-111 Intake air temperature sensor ...... ..... EWD-113
Brake booster vacuum pump .. . . . . . . . .. EWD-114 Knock sensors ......... . .. ... ... ..... EWD-113
Brake light switch ... ..... ..... .. . ... . EWD-1 15 Leak detection pump. . . . . . . . . . . . . . . . . . EWD-116
Camshaft adjustment valve . ... ......... EWD-115 Low range control module . ....... ...... EWD-111
Camshaft position sensors .......... ... EWD-113 Mass air flow sensor ... . ............ .. EWD-114
Central idle air control cut-off valve . .... . . EWD-115 Oil level thermal sensor . . . ........... . . EWD-117
Charge air pressure sensor . . . . ... . .. .. . EWD-113 Oil pressure switch ... .. .............. EWD-117
Clutch pedal position switch . . . ......... EWD-111 Oxygen sensors . . . . . . . . . . . . . . . . . . . . . EWD-114
Coolant fan switch ....... .. .. .. .. ... .. EWD-116 Secondary air injection .. ... ..... . .. . .. EWD-115
Cruise control switch ........ . ..... ... . EWD-116 Spark plugs .. .. .. .. . . . ..... ........ . EWD-112
Cruise control vacuum switches .. .. .... . EWD-115 Speedometer ...... ... .. .... ... ... ... EWD-117
Emergency flasher switch ... .. ......... EWD-113 Starter ........ .... .. ... . .... . ... ... EWD-111
Engine control module (ECM) ........... EWD-111 Tachometer ... ..... .. ........ . ...... EWD-117
Engine coolant level warning switch ...... EWD-117 Throttle control ............ .. ... ... .. EWD-115
Engine coolant temperature sensor .... . . EWD-113 Voltage regulator ...... . . . .. . ........ . EWD-111
Engine cooling fan . .... ....... .... .... EWD-116 Wastegate bypass regulator valve .. . . . .. EWD-115
EWD-14 Electrical Wiring Diagrams
Electrical Wiring Diagram Index

Engine management, 2.7 liter, EVAP canister purge regulator valve ...... EWD-228
engine codes APB, BEL (2003) . ........ . . EWD 222 Exhaust temperature sensors .. .... ... ... EWD-227
A/C control panel .... .......... ....... EWD 224 Fuel gauge ..... . ... ..... .... . . . .. ... EWD-230
After-run coolant pump ........ . . . ...... EWD 229 Fuel injectors .. ............. . ........ EWD-225
Airbag control module ...... . ..... ... .. EWD 226 Fuel pump relay ......... ... .. . ....... EWD-227
Alte rnator (generator) ...... . . . ... .. . ... EWD 224 Fuel pump . . .. ................. ...... EWD-230
Automatic transmi ssion range switch . ..... EWD 224 High pressure sensor . .. ......... . .... . EWD-229
Automatic tran smission control module . .. . EWD ~29 Ignition coils .. .. .. .. ..... ... .... .. . .. EWD-225
Battery ........ ... ... . ... ........... EWD 1224 Ignition switch ........ . .. . . ....... .... EWD-224
Brake booster vacuum pump ..... . .. .... EWD 1227 Intake air temperature sensor ....... ..... EWD-226
Brake light switch ....... . . . . .. . ... .... EWD 228 Knock sensors ............. . . ........ EWD-226
Camshaft adjustment valve ...... . .. ... . EWD t226 Leak detection pump ... .... . . . .. .. ... . EWD-229
Camshaft position sensor ..... .. . .. . .... EWD ~26 Low range control module . .... ...... . .. EWD-224
Cent ral idle air control cut-off valve . .. . ... EWD 228 Mass air flow sensor . . .. . .... . ..... .... EWD-227
Charge air pressure sensor . . .... . . ..... EWD 226 Oil level thermal sensor . ... .... .. . ..... EWD-230
Clutch pedal starter interlock switch . . ..... EWD ~24 Oil pressure switch . ............ . . . .. .. EWD-230
Clutch pedal switch .. . ... . ............ EWD- ~28 Oxygen sensors ...... . .. ... ..... . ... . EWD-227
Cruise control switch ........ ..... .. ... EWD- ~29 Secondary air injection . .... ... .... ..... EWD-228
Emergency flasher switch .. ........... . EWD- ~26 Spark plugs .. ... .... .. . ... . .... ...... EWD-225
Engine control module (ECM) ...... ... .. EWD- >24 Speedometer . ...... ... . .. . .......... EWD-230
Engine coolant fan switch .. . . ........ . . . EWD- >29 Starter . . ..... .... . ..... . ... . ........ EWD-224
Engine coolant level warning switch ...... . EWD- 1>30 Tachometer .. ...... . ..... . ..... . . ... EWD-230
Eng ine coolant temperature gauge ....... EWD- b30 Throttle control ... . ...... ...... ... ... . EWD-228
Engine coolant tem perature senso r ... ... . EWD- ~26 Voltage regulator .. ... . ... .... . ....... EWD-224
Engine cooling fans .. .. ........... . .. . EWD- ~29 Wastegate bypass regulator valve . .. .. ... EWD-228
Engine speed (rpm) sensor . ... .. . . ..... EWD- ~ 26
 I

Electrical Wiring Diagrams EWD-15

Electrical Wiring Diagram Index

En gine management, 2.8 liter, Ignition I starter switch ............ . .. . .. EWD-33

engine code AHA (1998) Instrument cluster . .. . .. .. . . ...... . ..... EWD-31
(includes standard equipment) . ... .. .. .. .. EWD-26 Instrument lights dimmer switch .. .... .. ... EWD-34
Alternator (generator) . .. . . .. ........ .. . EWD-27 Knock sensors ..... . . ... . .... .... . . . .. EWD-28
Auto check system .... .. ............... EWD-37 Lamp control module . . . . . . . . . . . . . . . . . . EWD-36
Battery .. . ... . ... . .. .. ..... . .... . .. . . EWD-27 Leak detection pump ........ .. .... . .. .. EWD-28
Blower . . . ... . ... .. ................ . . EWD-35 License plate light. . . ....... . ..... . . . . . . EWD-35
Brake fluid level warning switch . .......... EWD-31 Light switch .. . . . . . . . .. .. ... . ........ .. EWD-33
Brake light switch . .. .. ............ . .... EWD-36 Mass air flow sensor ... . ..... . ........ . . EWD-30
Brake lights ...... .. ... . . . ... . ....... .. EWD-37 Outside air temperature display . . ...... ... EWD-38
Camshaft position sensors ..... . ....... . . EWD-29 Oxygen sensors .. . .. ....... . ...... .... EWD-29
Central locking control module . .. ......... EWD-38 Oxygen sensors .. . ... ...... . . ... ... . . . EWD-30
Cigarette lighter .. ... .. . ... .. ...... . ... EWD-37 Parking brake warning light switch ...... ... EWD-31
Data link connector ....... . ............. EWD-32 Parking light ..... .. ...... . . . ........ .. EWD-36
Emergency flasher . . . . . . . . . . . . . . . . . . . . EWD-34 Power output stage . ... . . . . . .... .. ..... . EWD-28
Engine control module (ECM) ...... .. ... . EWD-28 Rear foglight . . . . .............. . .... .. EWD-37
Engine coolant temperature (ECT) sensor ... EWD-28 Rear window defogger .... . . .. ........ .. EWD-38
Engine cooling fan . .... ..... . ........ . . EWD-30 Secondary air injection pump motor .. .. .. .. EWD-30
Foglights .... .. ... . .......... . ... . .. . . EWD-34 Signal light . .... . . . ..... . ..... . .. . . ... EWD-36
Fuel gauge ... . ................... . ... EWD-31 Speedometer .... . . . ... . .. . .. .. ... . . . . EWD-31
Fuel injectors .. .. . . . .... . ............. EWD-28 Starter .............. .. .... . ....... . .. EWD-27
Fuel pump relay . ... . . . .. .. ............ EWD-29 Tachometer .. . .................. . .. . . EWD-31
Fuel pump . .... . . ... ... . ............. EWD-31 Taillights .. . .. . . .. .. . .. . . .. .... .. . . . .. EWD-37
Glove compartment light .. .. ............ EWD-35 Throttle valve control module ........ .. ... EWD-28
Ground connections .. . .. . .... . ...... . . EWD-27 Turn signal switch ... .. .. .. ... . .. .. ... .. EWD-33
Headlight dimmer. . . . . . . . . . . . . . . . . . . . . EWD-33 Vehicle speed signal. . ..... .... . ...... . . EWD-38
Headlights . .. . .. . . ... .. . ..... . ..... . . EWD-36 Washer nozzle heater .. . . ... ..... . .... .. EWD-35
Horn .... .. . ..... . . .. .. .. .......... . . EWD-37 Windshield wiper I washer .. . . ........ .. . EWD-35

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 EWD-16 Electrical Wiring Diagr :tms
Electrical Wiring Diagram Index

Engine management, 2.8 liter, Fuel gauge ................. . ...... .. EWD-1 24

engine code ATQ (2001) ..... ... . . ... ... EWD-1 8 Fuel injectors . ... ..... .. . ... .. ...... .EWD-119
A/C control panel .. ... . ........ . ... . .. EWD-1 . O Fuel pump relay .. ... .. .. . .. ...... .. .. EWD-121
A/C pressure switch .. . .. . .... .. .... ... EWD-1 ~3 Fuel pump ... .. . . ... .. .. .. ........ . . . EWD-124
ABS control module .. .. . . .. . . . ..... . . . EWD-1 12 Ignition capacitor .. .. ..... .... ...... .. EWD-119
Accelerator position sensors ...... ...... EWD-1 13 Ignition coil .......... . .. ..... . .. ..... EWD-119
After-run coolant pump .... .. . . ..... . ... EWD-1 )3 Ignition switch .. ...... ... . ........ .. .. EWD-119
Airbag control module . . .. ............. EWD-1 t>3 Instrument cluster combination processor .. EWD-124
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Alternator (generator) .. . . . ...... .... . . . EWD-1 9 Intake air temperature sensor ......... . .. EWD-120
! Battery ........ .......... . ...... . ... EWD-1 ~ 9 Intake manifold change-over valve .... .. .. EWD-122
Brake booster pressure sensor ... ..... .. EWD-1 ~2 Knock sensors .... . ......... . .. . ..... EWD-120
I Leak detection pump . .... . ...... . .. . .. EWD-121
I Brake booster vacuum pump relay ..... .. . EWD-1 t22
Brake light switch ............... . .... . EWD-1 t25 Mass air flow sensor .. ..... . .. . ...... . . EWD-121
Brake lights ..................... . .... EWD-125 Oil level thermal sensor .. .............. EWD-122
Brake pedal vacuum vent valve .. .. .... .. EWD-1 ~5 Oil pressure switch .. .. .... .. .. . . ...... EWD-124
Camshaft adjustment valve ............. EWD- • 22 Oxygen sensors . .. .. . .......... .. .... EWD-121
Camshaft position sensors .. .. . ... .... . . EWD- 20 Power output stage .............. ...... EWD-119
Clutch pedal position sensor . . . .... . . . .. EWD- 19 Secondary air injection .. .. .......... . . . EWD-123
Clutch pedal switch .. .. . . .... ......... EWD- 22 Spark plugs . .. ... .................... EWD-119
Cruise control switch ..... ...... . . .. . . . EWD- 22 Speedometer ........ .... .... .. ... ... EWD-124
Emergency flasher .. . . ........ . . ...... EWD- 23 Starter .. . . ...... ...... ..... .. .. . .. .. EWD-119
Engine control module (ECM) . . . . . . . . . . EWD- 19 Tachometer .. . .... .. . ....... ..... . .. EWD-124
Engine coolant temperature (ECT) sensor .. EWD- 20 Throttle control . ... ................... EWD-120
Engine coolant temperature gauge ...... . EWD- 24 Throttle position sensor .. . ......... .. .. EWD-123
Engine cooling fan .. . .. ..... . ......... EWD- 23 Transmission control module ....... ..... EWD-120
Engine speed (rpm ) sensor . . ... . ..... . . EWD- 20 Voltage regulator ....... . . . ..... ...... EWD-119
EVAP canister purge regulator valve ...... EWD- 22

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 Electrical Wiring Diagrams EWD-17
Electrical Wiring Diagram Index

Engine management, 3.0 liter, Engine cooling fan . . .. . . . . ... ...... ... EWD-181
engine code AVK (2002) . .. . . .. .. . . . .. . . EWD-17 4 Engine speed (rpm) sensor . . . . .. ... . .. . EWD-176
NC compressor regulator valve .. . .. .. ... EWD-179 EVAP canister purge regulator valve . . . ... EWD-178
NC control panel .. . . . .. . . . ..... . . . . .. EWD-179 Exhaust valve flap . . . ... .. .. .. .... .. .. EWD-179
NC pressure senso r . . . .. . . .. .... . ... .. EWD-181 Fuel gauge ..... . . . .. . .... . ... .. . .... EWD-181
Accelerator pedal position sensor . . ... .. . EWD-179 Fuel injectors .. . . . ...... ... . . . .... .. . EWD-175
After- run coolant pump . . .. .. .... . ...... EWD-181 Fuel pump relay . . . .... .... . .. . .. ..... EWD-177
Airbag control module .... . ...... .. . .. . EWD-179 Fuel pump . . ... . ... . .. . .... .. ... . . ... EWD-181
Alternator (generator) ... . .. . . . ... . .. . .. EWD-175 Ignition coils with power output stage . . . . . . EWD-175
Automatic transmission control module . ... EWD-176 Ignition switch ......... ... .. .. . ...... . EWD-175
Automatic transmission range switch .. ... . EWD-175 Instrument cluster warning lights . .... . . . . EWD-182
Battery ... . ........... . . ....... .. .. . EWD-175 Intake manifold change-over valve .... .... EWD-178
Brake booster pressure sensor .......... EWD-180 Knock sensors ... .. . .. . . .. . .. .. .. .. . . EWD-176
Brake booster vacuum pump relay .. .. . ... EWD-180 Leak detection pump . ... ..... .. .. . . ... EWD-179
Brake light switch ....... ..... .. .. .. .. . EWD-180 Mass air flow sensor ....... . .. .. ... . . .. EWD-178
Brake lights . . .... ....... . ..... . .. . ... EWD-180 Oil level thermal sensor .. . . .. . ... . . ... . EWD -179
Brake pedal switch . . ... .. . . ...... ... .. EWD-180 Oil pressure switch . .. .. .. . ... .. ... .... EWD-182
Brake system vacuum pump . .... . ... . .. EWD-180 Oxygen sensors ....... . . .. . .. .... .... EWD-177
Camshaft adjustment valve ........... .. EWD-178 Oxygen sensors , precatalytic converter .. . . EWD-178
Camshaft position sensors .... ..... . .. .. EWD-176 Power supply relay .. . . ... . . . . .. . ... . .. EWD-177
Clutch pedal position sensor ... ..... .. .. EWD-175 Secondary air injection . . ... . .. . .. ... . . . EWD-180
Clutch switch ....... . . ... .... .... . ... EWD-178 Spark plugs . ..... .. . . ... . .... . . . .. . .. EWD-175
Cruise control switch . . . . . ............. EWD-179 Speedometer . . . .. . .. ........ .. . . ... . EWD-182
Emergency flasher switch . . .. .. .... . . .. EWD-179 Starter . . .. . . . . . . . . . . .. ......... .. . . . EWD-175
Engine control module (ECM) . . .... . .... EWD-175 Tachometer ...... . .. .. ... .. ..... . . . . EWD-182
Engine coolant level warning switch . ... . .. EWD-182 Throttle control ..... .. ... .... ... . .. . .. EWD-176
Engine coolant temperature (ECT) sensor . . EWD-176 Throttle position switch .. . . .... ... ...... EWD-179
Engine coolant temperature gauge . .... . . EWD-182 Voltage regulator . .. . ..... . . .. .. .. ... . EWD-175
EWD-18 Electrical Wiring Diagrams
Electrical Wiring Diagram Index

Engine management, 4.2 liter, Engine management 4.2 liter,

engine code ART (2001) ... . .. . . . .. . . . . . EWI )-126 engine codes AWN , BBD (2002) . .. . . . . ... EWD-183
A/C pressure switch .... . . . . . . ......... EWI )-132 A/C control panel .... .. ....... .... . ... EWD-189
Ai rbag control module . .. ... .. . . . . . .. .. EWI >-129 A/C high pressu re se nsor . .. ..... ....... EWD-189
Automati c transmission contro l module .. .. EWI ~ -132 ABS control modul e ... .. ... . . . . . .... . . EWD-187
Automatic transmission range switch . .... . EW[ -127 Airbag control module .. ..... . .... . ... .. EWD-186
Battery ........ ... .. ... .. .. . .. . .. . .. EW [ -127 Automatic transmission control modul e . . .. EWD- 189
Brake light switch .......... . .. . ... . . . . EW [ -130 Automatic tra nsmission range switch ...... EWD-1 84
Brake lights . . . . ... .. ... . ..... . .. . . . . . EW[ -1 30 Battery ....... .... ... .. .. . . . . . .... . . EWD-184
Brake vacuum vent valve ..... . ..... . .. . EW[ -130 Brake lights . . .... . .. ..... . . . .... . .... EWD-187
Camshaft adjustment valves ... ..... ... . EW C-128 Brake pedal switches ..... ..... . . . .. . .. EWD-187
Clutch pedal position sensor . . . .. . . . . .. . EW C-127 Camshaft adjustment valves ....... . .... EWD-185
Cl utch switch .. .. .... .... ....... .... . EW C 130 Camshaft position senso rs . .. ....... .... EWD-187
Crui se control switch . .. . ....... .. . . .. . EW C 130 Clutch pedal position sensor . ... ..... ... EWD-184
Emergency flasher . .... ... . .. . .. . . .... EWC 129 Clutch switch . . . .. .. . ..... ..... ... ... EWD-187
Engine control module (ECM ) .. . . . .. . . . . EWD 127 Cruise control switch .... . ..... . .. . .... EWD-187
Engine cool ant temperature (ECT) senso r . . EWD 129 Emergency flasher .. . . .. ... . . . ... . .. . . EWD-186
Engine coolant temperature gauge . . .. ... EWD 133 Engine control modu le (ECM ) . .. .. . . . . .. EWD-184
Engi ne coolant warning switch .. . ........ EWD 133 Engine coolant level warni ng switch .. . . ... EWD-190
Engin e cooling fan . ... . .. . . .. . . . . . .. .. EW D 132 Engine coolant temperatu re (ECT) sensor . . EWD-1 86
Engine mount sol enoid valves .. . .. . . . . .. EW D 130 Engine coolant tempe rature gauge ... .. . . EWD-190
Engine speed (rpm) sensor ... ... .... . . . EW D 129 Engine cooling fan control mod ule . . .... . . EWD-189
EVAP can ister purge regulator ... . .... ... EWD 130 Engine cooling fan . . . .. .. . . ......... .. EWD- 189
Fuel gauge .............. .. ........ . . EWD 133 Engine speed (rpm) sensor .... . . . .. . . . . EWD-186
Fuel injectors .... .. .... . . . ... . . .. . ... EWD 128 EVAP canister purge regulator . .......... EWD-187
Fuel pump relay . . ... .. ..... . .... .. ... EWD ~ 31 Fuel gauge .. . ..... . . . .. . . ....... . .. . EWD-190
Fuel pum p ........... ..... . . . . . . . .. . EW D 133 Fuel injectors . . . .. . . .. .. ....... . ... . . EWD-185
Ign ition capacitor .. .... .. . .. . . .. . .. . .. EWD ~ 28 Fuel pump rel ay ...... . .... ....... .. . . EWD-188
Ignition coils with power output stage . . .. . . EW D- 28 Ignition capacitor .. . .. . . . .. .... .. .. . . . EWD-185
Ignition coils .. .. . ... ... ... ..... . .... . EWD- 28 Ignition switch . . .. . . . ... . . . . .. .. .. .. .. EWD-184
Ignition switch .. ... .... . .. ... ... . ... . . EW D- 27 Ignitions coils . .. ... . ... .. .... .. .. . . . . EWD- 185
Intake man ifold change-over valve .... ... . EW D- 30 Intake manifol d ch ange-ove r valve .. .. . ... EWD-187
Knock sensors ..... . . . . . . . .. .. . . ..... EW D- 29 Knock senso rs . . ..... . ... . .. ... .. . . . . EWD-186
Leak detection pump . ..... .. .. .. . . .. .. EWD- 27 Leak detection pump ........ . . . . . . ... . EWD-184
Mass air flow sensor .. . . .... . . ... . .. . . . EW D- 31 Mass air flow senso r .. . .... .. . . ..... . .. EWD-188
Oil leve l the rmal sensor ... . . . . ... . .... . EW D- 32 Oil pressure switch . ... ..... ... . ...... . EWD-190
Oil pressu re switch .... . ... .... .. . . .... EW D- 33 Oil therm al senso r .... .. ... .. . .. .. .. .. EWD-189
Oxygen sensors ... . .. ... . ... . ........ EWD- 31 Oxygen se nso rs ...... . .. .. . ... . . . .... EWD-188
Secondary air injection . . .. ... . .. . ..... EWD- 30 Secondary air injecti on . . . .. . ..... . .. . .. EWD-187
Spark plugs ..... . .. .... . .... . . . . .. . . EWD- 28 Spark plugs . .. . ... . ... .. .. . . . ...... . . EWD-185
Speedomete r .... ... ... .. . ... ..... ... EWD- 33 Speedometer . ... . . .. ... . ... .. . ... . . . EWD-1 90
Starter . .... . ... . ........ . ... . . . ... . . EW D-"' 27 Starter .. . ..... . . . .... . . .. ..... . ... . . EWD-1 84
Tachometer . .... ... .. . .. .. ..... . . ... EWD -1 B3 Tachometer . .. . . . ..... . . . . .. . .. . .... EWD-190
Th rottle control . ... . . .... . .... . .. . . ... EWD-1 29 Th rottle control . .. ... . .. .... . . ... . .. . . EWD-186
Voltage regulator .. . .. .. . .... ...... ... EWD- 1 27 Voltage regu lator . ... . . . . .... .. . . .. ... EWD-184
Wipe r I washer intermittent relay ... . ... . . EWD-1 ?.7 Wiper I washer intermitte nt relay .. . .. . . .. EWD-184
 Electrical Wiring Diagrams EWD-19
Electrical Wiring Diagram Index

Engine management, 4.2 liter, Engine cooling fan control relay . ..... .... EWD-238
engine code BAS (allroad quattro 2003) . . . EWD-231 Engine cooling fan switch . . ... . . ... ... . . EWD-238
A/C compressor regulator valve .. . ....... EWD-238 Engine cooling fans ........ .. . ........ EWD-237
A/C control panel .. . ... ........... .. .. EWD-237 Eng ine mount solenoid valve . . .. ... .. . .. EWD-235
A/C high pressure sensor . .......... .... EWD-237 Engine speed (rpm) sensor .. . ....... . .. EWD-234
ABS control module ........ .. . ........ EWD-235 Engine coolant circulation pump relay ..... EWD-238
After-run coolant pump ..... . ........... EWD-238 EVAP canister purge regulator valve .. ... . EWD-235
Airbag control module . .. . . .. ... ..... . . EWD-232 Fuel gauge ..... .. ...... .. ...... .. .. . EWD-238
Alternator (generator) . ......... . .... . .. EWD-232 Fuel injectors ........................ EWD-233
Automatic transmission control module .... EWD-237 Fuel pump relay ... .. ...... . ..... .. . .. EWD-236
Automatic transmissi on range switch ... .. . EWD-232 Fuel pump .. .. .. .. ...... . .. . . . ....... EWD-238
Battery ..... . .... .... ............. . . EWD-232 Igniti on coils . ... .. . . .. .. . . .......... . EWD-233
Brake booster pressure sensor .. .. .. .... EWD-235 Ignition switch ... .. .... .. . .. ....... ... EWD-232
Brake booster vacuum pump relay ........ EWD-237 Intake manifold change-over valve . .. ... . . EWD-235
Brake lights .. .... . . .... .. .. ......... . EWD-235 Knock sensors . .. . .. . ..... . .... .. .... EWD-234
Brake pedal switches ............ .. .... EWD-235 Leak detection pump .............. ... . EWD-236
Brake system vacuum pump . .. ......... EWD-237 Mass air flow sensor .. ... ... .. ....... .. EWD-236
Camshaft adjustment valves . . .. .. .. .. .. EWD-234 Oil level thermal sensor .. .. ... . ........ EWD-238
Camshaft position sensors ............ . . EWD-235 Oil pressure switch ...... . .... .. .. .... . EWD-238
Clutch pedal position sensor ... .. .. .. ... EWD-232 Oxygen sensors .. ... ....... ..... .. ... EWD-236
Cruise control switch ... . ... ... .. . ... . . EWD-235 Secondary air injection . . . ....... .. .... EWD-235
ECM power supply relay . . .. ....... ... . EWD-234 Spark plugs ... ... ........ . .. . ... . .. .. EWD-233
Emergency flasher . . .. .. ... .. .... ..... EWD-232 Speedometer ..... . .................. EWD-238
Engine control module (ECM) .. ... . .. . .. EWD-232 Starter .. .. .. .. .. . .. ...... ....... . ... EWD-232
Engine coolant level warning switch . .. . . .. EWD-238 Tachometer ..... .. .. ... .... ....... . . EWD-238
Engine coolant temperature (ECT) sensor . . EWD-234 Throttle control ...... ... . .... . ........ EWD-234
Engine coolant temperature gauge ....... EWD-238 Voltage regulator .. . .. .... . .... . . . . .. . EWD-232
Engine cooling fan control module . ....... EWD-237 Wiper I washer intermittent relay .. .. .. . . . EWD-232
 II

EWD-20 Electrical Wiring Diagrams

Electrical Wiring Diagram Index

Engine management, 4.2 liter, Engine speed (rpm) sensor . . .... ....... EWD-270
engine code BCV (RS6 2003) .... . .... . .. EWD-2 S6 EVAP canister purge regulator valve ...... EWD-271
A/C con trol panel ....... . ... . .... . .... EWD-2 '3 Exhaust temperature sensor .... .. . .. . .. EWD-272
A/C high pressure sensor . ... ... .. . ..... EWD-2 '4 Fuel gauge . . . . .......... . . . . . . .. ... . EWD-27 4
After-run coolant pump . .... ... ... .. .... EWD-2 ~3 Fuel injectors . . ... .... . ..... . . .. . . .. . EWD-269
Airbag control module . . . .. .. ... . .. . . .. EWD-2 7 0 Fuel pump relay ... .... . .............. EWD-272
Alternator (generator) .. . ... . ..... .. . .. . EWD-2 38 Fuel pumps . .. . . ... ........ . . . .. ... .. EWD-27 4
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I Automatic transmission control module . ... EWD-~ 173 Ignition capacitor ...... . .. . .. .. . . . .. . . EWD-269
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I Automati c transmission range switch . ..... EWD-~ 08 Ignition coils with power output stage .. . . .. EWD-269
Battery . . .......... . . . ..... . ...... . . EWD-~ 68 Ignition switch ..... . . . . . . .... ....... .. EWD-268
Brake booste r pressure sensor . . .. . . . .. . EWD-~ 171 Intake air temperature (IAT) sensor ....... EWD-270
Brake booster vacuum pump ... . .. . . . .. . EWD-~ 172 Knock sensors . . . . . .. .. .. .. .... . ... . . EWD-270
Brake booster vacuum pump relay ........ EWD-~ 72 Leak detection pump .. .. . .. . . .. . . . . .. . EWD-272
Brake lights ..... .. ......... . ...... . .. EWD-m 3 Mass air flow sensors . .. . ..... .. .. . ... . EWD-271
Brake pedal switches . .. . ..... .. . . . . .. . EWD-~ r?3 Oil level thermal sensor .. . . .. . .. .... ... EWD-273
Camshaft adjustment valves . . . ......... EWD-~ 69 Oil pressure switch . . ..... ... .. .. ... . . . EWD-275
Camshaft position sensors .. .... .. . .. . .. EWD - ~ 71 Oil pressure warning light ....... . .. . . ... EWD-275
Ch arge air pressure sensor .... . ..... . . . EWD-: 71 Oxygen sensors ....... . . ... . . .. . .. . . . EWD-272
Coolant circulation valve ........ . . .. . .. EWD-: 7 4 Secondary air injection .. ... .. . ... . ... . EWD-271
Cruise control switch .. ... . ....... . . . .. EWD-' 70 Spark plugs . . .. ... . .. . . . . ....... . .. .. EWD-269
Emergency flasher ..... .. . ...... . . ... EWD- 70 Speedometer .. . . .. ... . . ... ..... . . ... EWD-275
Engine control module (ECM) . ..... . . . .. EWD- 68 Starter . . .. . . . . . .. .. . . ... ..... . .. ... . EWD -268
Engine coolant circulation pump relay . . . . . EWD- 73 Tachometer . . ... . .. .... . .. . ......... EWD-275
Engine coolant level warning switch .. . . .. . EWD- D75 Throttle control . ... . ... ... . . .. . ... . .. . EWD-270
Engin e coolant temperature (ECT) sensor . . EWD- 1>70 Turbochargier recirculator valve .. .. .. . ... EWD-272
Engine cool ing fans ... .. ... . .. . .. .. . . . EWD- >7 4 Turbocharger wastegate regulator valve ... EWD-271
Engine mount solenoids . . ... . .. . .. . . ... EWD- ~ 69 Voltage regulator .. . .. ... . ... . . . . . .... EWD-268

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Electrical Wiring Diag rams EWD-21

Electrical Wiring Diagram Index

Headlight washer (1998) .... . . . .. .. .. . .. EWD-50 HID control module . . . . . . . . . . . . . . . . . . . EWD-14 7

Headlight washer (2000) . . . . . .. . .. . . .. . . EWD-91 Ignition switch . . .. ..... . . .. .. . .. .. ... EWD-146
Instrument cluster combination processor . EWD-146
Headlights, xenon {HID) (1998) . .. ....... . EWD-51
Lam p control module .. . .... . . . ... . .. . . EWD-147
Data link connector (DLC) . . . ... . . .. .. .. . EWD-53 Left high beam ... . .... . . . .... . ... . .. EWD-148
Emergency fl ash er switch . .... .. . . .... . . EWD-52 Left level control system sensor . . . . . . . . . EWD-148
Fog lights ............. . .. . ... .. . . .. . . EWD-52 Left side lights . . . . . . . . . . . . . . . . . . . . . . . EWD-148
Headl ight beam adjusting motors . .... . . .. EWD-53 Light switch . . . .. . .......... . .. ... ... EWD-147
Headlight dimme r I flasher switch ....... . . EWD-52 Parki ng light switch . ..... . . .. .... . .... EWD-147
HID bulbs . ...... ... ...... .. . .... .... EWD-52 Rig ht side lights .... .. . . . .. ...... . .. . . EWD-14 7
HID contro l module .. . . .. . . . .. . .. . . .. . . EWD-52 Tu rn signal switch .... . . . . . .. .... . .... EWD-147
High beam s .. .... . . . .. ..... .. .. ... ... EWD-52
Headlights, xenon {HID), static (2001) .... EWD-157
Instrument cluster combination processor .. EWD-51
Alte rn ator (generator) . . . . . . . . . . . . . . . . . EWD-157
Lamp control module .... . ......... ..... EWD-52
Data link connector . .. .. . ...... ....... EWD-159
Level control system sensors ....... . . .. . EWD-53
Emergency flasher . . . . . . . . . . . . . . . . . . . EWD-158
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-52
Headlight beam adjusting control module .. EWD-159
Parking light switch . . .. . . . .. ... . .. ..... EWD-52
Headlight beam adjusting motors .... . ... EWD-160
Parking lights .. ........ . . .. . ... . .. . . .. EWD-52
Headlight dimmer I flasher switch .... . . . . EWD-158
Taillights . . . ....... . . . ..... . . .... . ... EWD-53
HID control module . . . . ... . .... . ... . .. EWD-158
Turn signals .. . . .. .... ... . . . . .. . . . . .. . EWD-52
Ign ition switch .. . ..... . ... .. ... . ... . . EWD-157
Headlights, xenon {HID) (2000) . ..... . .... EWD-87
Instrument cluster combination processor . EWD-157
Alternator (generator) . . .. . .... . .. .. . ... EWD-87 Lamp control module ... .. . .... .. . ... .. EWD-158
Emergency flasher . .... ...... . .. . . .... EWD-88 Left level control system sensors . . . . . . . . EWD-159
Foglight switch ..... . ..... .... . ... .... EWD-88 Left side lights .... .. .. . ... . .. . ... . ... EWD-159
Headlight beam adjusting control module . .. EWD-89 Light switch ...... . ..... . . .. ...... .. . EWD-158
Headlight beam adjusting motors . . . .. . . .. EWD-90 Parking light switch . . .. ... .. . .. . . .. .. . EWD-158
Headlight dimmer I flasher switch . ..... . .. EWD-88 Right side lights .... . .. . . . .. . ... . . . . . . EWD-158
HID control module . . . . . . . . . . . . . . . . . . . . EWD-88
Headlights, xenon {HID), dynamic (2003) . . EWD-257
Ignition switch .. .. ... .... ... ... .. . .. .. EW0-87
Instrument cluster combination proce ssor .. EWD-87 ABS control module . ... .. . . . ..... . .. . EWD-259
Lamp control module ... . . ... .. . ... .... . EWD-88 Alternator (generator) . . . .......... . ... EWD -257
Left side lights . .. ..... ..... ........... EWD-89 Emergency flasher .... .. ....... . ..... EWD-258
Level control system sensors . . .... . ... .. EWD-89 Foglight switch . . ... . . ...... . ... . .... EWD-258
Light switch . . ... . .... . . .... . .. . .. .... EWD-88 Headlight beam adjusting control module . . EWD-259
Parking light switch .. .. . ... .. . . ... .. ... EWD-88 Headlight beam adjusting motors ... . . . .. EWD-259
Right side lights .. .. .. . . . . ...... . .... . . EWD-88 Headlight dimmer I flasher switch .. ...... EWD-258
Turn signal switch .... . . ...... .. ... . . .. EWD-88 Ignition switch ... . .... . ....... . .. . .. . EWD-257
Lamp control module . .. . . ........ . .... EWD-258
Headli ghts, xenon {HID), dynamic (2001) . . EWD-146
Left level control system sensors . . . . . . . . EWD-259
ABS control module . . . ....... .... .... EWD-148 Left side lights ....... . ............. . . EWD-259
Alternator (generator) ........ .. .. . . . . . EWD-146 Li ght switch . . . . . . . . . . . . . . . . . . . . . . . . . EWD -258
Emergency flasher ... ..... .. . . .. .. .. . EWD-14 7 Parking light switch . .. .. .... . . .. .. . ... EWD-258
Foglight switch .... .... . ........ . ... . EWD-147 Rear foglights ....... ... .. ... . . ... . .. EWD-258
Headlight beam adjusting control module .. EWD-148 Right side lights . .... . . . . ... .......... EWD-258
Headlight beam adjusting motors . ... .. .. EWD-149 Turn signal switch .. .. ..... ... .. . ..... EWD-258
Headl ight dimmer I flasher switch .. .... . . EWD-147
HID bulbs .... . ...... ..... . . .. . . . ... EWD-148

I
EWD-22 Electrical Wiring DL 1grams
Electrical Wiring Diagram Index

Instruments and controls (1998} ... .. .. . .. EV 1D-39 Instruments and controls (2004} . . ..... .. EWD-2S3
Automatic tran smission control module .... . EV ~D-40 A/C control panel . .. . ......... ... . .... EWD-2S4
Board computer .... . . .... ... . . ..... .. . EV D-39 Auto check system .. ........ .. .... .... EWD-2S4
Brake lights ....... ............... . . ... EV D-41 Board computer .................... .. EWD-2S4
Ignition I starter switch ............ . .. . . . EV D-40 Brake lights ......... . ..... . .......... EWD-2SS
Lamp control module .. .......... ....... EV D-40 Ignition switch ................. . .... . . EWD-2S4
Light switch ............. .... . ..... .... EV\ D-40 Lamp control module . ........ .. . ...... EWD-2S4
Low beam headlights . . ...... .. . .... . .. . EV\ D-40 Left parking light .. .. . ... .......... .. .. EWD-2SS
Outside air temperature sensor .... . ...... EV\ D-40 Light switch .. ....... . .. . ..... . ....... EWD-2SS
Parking lights ..... .... ... . .... ... . .... EV\ D-40 Low beam headlights . .. . . ... .. ... ..... EWD-2SS
Radio .. . .......... . . . . . . ... .... . . .. . EV\ D-39 Outside temperature display ... . . . .. .... . EWD-2S4
Taillights . .. ... .. .... . . . . ...... . . . . ... EV\J D-41 Outside temperature sensor ... .. ... .. .. . EWD-2S6
Washer fluid level warning switch .......... EV\J D-39 Taillights . ... . ... .. .... . . .. . .. ....... EWD-2SS
Instruments and controls (2000} .. . ....... EW J-81 Washer fluid level warning switch .. ....... EWD-2S4
A/C control panel .... . .. . ........ .... .. EW D-83 Level control (2002) . . . ... .. . ........... EWD-20S
Auto check system ...... . ...... ... ..... EW D-81 ABS control module ....... . ..... .. . . .. EWD-206
Automatic transmission control module .... . EW D-82 Alternator (generator) . ... . ..... .. .. .... EWD-206
Automatic trans mission range display .. . .. . EW ~-82 Capacitor .. .. . ...... . . .. . .. . ... .... . EWD-20S
Board computer .. . . ... . ... ........... . EW )-81 Central locking control module ...... ..... EWD-20S
Brake lights .... .. ..... . .. ......... . ... EWD-83 Headlight beam adjusting control module .. EWD-206
Engine control module (ECM) . ... ... .. ... EWI 1-81 Headlight beam adjusting motor .. .. . ..... EWD-207
Headlight beam adjusting motors .... . . .... EWI 1-82 Ignition switch ...... .. .............. .. EWD-20S
Ignition switch ... ...... .. ...... .. . . .... EWI -82 Left level control sensors .... . .. ........ EWD-206
Lamp control module .. .. ..... .. .. .... . . EW[ -82 Level control compressor motor .. . ..... .. EWD-206
Light switch ........... . . .. .... . . .... .. EW[ -82 Level control module ..... .. . . ........ . EWD-20S
Low beam headlights .. .. . ......... . .... EW[ -82 Level control sensor ... . ...... ... . ..... EWD-206
Outside air temperature display ... .. . .. ... EWC -82 Level control solenoid .............. . ... EWD-206
Outside temperature sensor . . ..... . . . . ... EWC 83 Light switch . .. .. ... .. ...... . . . .. . .... EWD-207
Parking lights . .... ... ............ . .... EWC 82 Rear suspension strut valves . ... . .. ..... EWD-206
Radio ... . ......... .................. EWC 81 Starter ............ . ..... .. ... .. ..... EWD-206
Taill ights ... ......... .... . ....... . . ... EWC 83 Parking aid (Parktronic) (2003) . . . . .. .. ... EWD-276
Washer fluid level warning switch .......... EWD 81
Automatic transmission range switch . ..... EWD-277
Instruments and controls (2001} ....... .. EWD- 34 Back-up light switch .......... . ....... . EWD-277
A/C control panel . ....... .. . . ..... .... EWD- 3S Foglight shut-off contact switch .. . .... ... EWD-277
Auto check system ......... . . ... .. .. .. EWD- 34 Ignition switch ..... ... .. . .. ..... . ... . . EWD-276
Automatic transmission control module .... EWD- 3S Parking aid control module ........ ... . .. EWD-276
Automatic transmission range display ..... EWD- BS Warning buzzer ..... .... .. . .... .. . ... EWD-276
Board computer . . ... . ................ EWD-1 34 Seats (2001) . ......................... EWD-144
Brake lights ........ . ..... ... . . ..... . . EWD-1 BS
Driver's seat adjuster .. . .. . ......... ... EWD-144
Engine control module (ECM) . . ...... .. . EWD-134
Driver's seat heating elements .. . ....... . EWD-144
Ignition switch .... . . . . . .. ..... ....... . EWD-1 34
Instrument cluster combination processor . .EWD-144
Lamp control module . . .. .. . . .. . .. . . ... EWD-1 35
Passenger seat adjuster ...... . ....... . . EWD-14S
Light switch . ..... . . .................. EWD-1 BS
Passenger seat heating elements ... .. .. . EWD-145
Low beam headlights .. ... . .. . . . ..... . . EWD-1 3S
Rear seat heated elements . .. ........ . . EWD-14S
Outside air temperature sensor .... .. .... EWD-1 B6
Rear seat heating regulation switch . .. .. . . EWD-145
Parking lights .... . ... ... . .. .. ... . . ... EWD-1 ,s
Rear seat temperature sensors ....... ... EWD-145
Radio .. .. .... . . . ... .......... .... .. EWD-1 4
Seat temperature sensors .... ...... . . . . EWD-144
Taillights .. ..... ............ .... .. . . . EWD-1 : 5
Washer fluid level warning switch .. . . . .... EWD-1: 4
 Electrical Wiring Diagrams EWD-23
Electrical Wiring Diagram Index

Sound system (1998) . . . . . . . . . . . . . . . . . . . EWD-48 Sound system, Bose (1998). . . . . . . . . . . . . . EWD-43

Auto check system . . . . . . . . . . . . . . . . . . . . EWD-49 Antenna amplifier .... . .... ..... . ...... EWD-42
CD changer . . .......... . . .. ......... EWD-49 Auto ch eck system . . . . . . . . . . . . . . . . . . . . EWD-4 7
Central locking control module ........... EWD-49 Central locking control module . .......... EWD-43
Data link connector (DLC) ... . ........... EWD-48 Data link connector (DLC) . .. . . .... ... . . . EWD-47
Ignition I starter switch ............ . .... EWD-48 Ignition I starter switch ................. EWD-47
Instrument cluster combinati on processor .. EWD-48 Instrument cluster combination processor .. EWD-43
Power antenna . . ............. .... .... EWD-48 Power antenna . . . . . . . . . . . . . . . . . . . . . . . EWD-42
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-48 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-43
Rear window defogger switch ....... .... . EWD-48 Rear window defogger switch . . . . . . . . . . . . EWD-42
Rear window defogger with antenna ... .... EWD-48 Rear window defogger with antenna .. . ... . EWD-42
Speakers ..... .. .. . ......... ...... . .. EWD-49 Right rear woofer I amplifier ......... . ... EWD-47
Telephone I radio antenna amplifier ...... . EWD-48 Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-46
Telephone transceiver . . ....... ... ... . .. EWD-49 Telephone I radio antenna amplifier .. . .... EWD-42
Sound system (2000) . . .. .. . . . ......... EWD-201 Telephone speaker . . . . . . . . . . . . . . . . . . . . EWD-42
Telephone transceiver ......... . ... . . . .. EWD-47
CD changer . . . ..................... EWD-202
Central locking control module ....... .. . EWD-203 Sound system, Bose (2000) . . . .. . .... . ... EWD-77
Ignition switch ... ... . .... ....... .. ... EWD-201 Aerial selection control unit ....... . ...... EWD-80
Instrument cluster combination processor . EWD-202 Antenna amplifier .... . . ... ... .... . .... EWD-78
Interior lock switch .. .. . ..... . .... .. . .. EWD-203 CD changer . . ................ . . ... .. . EWD-78
Multifunction steering wheel Central locking control module . . . . . . . . . . . EWD-79
control module .. ..... ..... . ...... .. EWD-203 Ignition switch . ... ... .... . ........... . EWD-78
Power antenna ......... . .......... . . EWD-201 Instrument cluster combination processo r .. EWD-77
Radio . .. . . ...... .. .......... .... ... EWD-201 Multifunction steering wheel
Rear window defogger switch ....... . ... EWD-201 control module . .. ... ... ........ .. ... EWD-79
Rear window defogger with antenna .... .. EWD-201 Navigation control unit with CD-drive .. . ... EWD-78
Right rear woofer I amplifier ............ EWD-202 Power antenna . . . . . . . . . . . . . . . . . . . . . . . EWD-78
Speakers. . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-203 Radio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-77
Telephone I radio antenna amplifier ... .. . EWD-201 Rear window defogger I heat element . ... . EWD-80
Telephone transceiver. . ...... . . ....... EWD-202 Rear window defogger switch . . .. .... . . . . EWD-78
Sound system (2001) . ...... ...... ..... EWD-150 Rear window defogger switch .. .. .. . ..... EWD-80
CD changer .................. . .. ... EWD-151 Rear window defogger with antenna . . ... . . EWD-78
Central locking control module . . .. . . ... . EWD-152 Right rear woofer I amplifier . .. . ...... . . . EWD-79
Data link connector ... .... . ..... ..... . EWD-151 Speaker (telephone, navigation) . .... . . ... EWD-78
Ignition switch ............. .... .. .... EWD-150 Speakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-79
Instrument cluster combination processor . EWD-151 Telephone transceiver ................ . . EWD-79
Multifunction steering wheel TV antenna amplifier .. ... ... . ..... .. .. . EWD-80
control module ..................... EWD-152
Power antenna ... . .. . . .... . ... .. .... EWD-150
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EWD-150
Rear window defogger switch ..... ... .. . EWD-150
Rear window defogger with antenna . ..... EWD-150
Right rear woofer amplifier ............. EWD-151
Speakers .... . .. . ... ...... ....... .. . EWD-152
Telephone I radio antenna amplifier . .... . EWD-150
Telepho ne transceiver ..... . .. ......... EWD-151
EWD-24 Electrical Wiring Diagrams
Electrical Wiring Diagram Index

Sound system, Bose (2001) .... ... ...... EV\ D-153 Radio, satellite radio, Bose (2003) . . . . . . . . EWD-278
Aerial selection control unit .. ... .... .... E\A. D-155 Antenna for navigation system (GPS) . .. .. EWD-280
Antenna amplifier ..... . ...... . ........ E\A. J-154 Antenna for radio I telephone I navigation .. EWD-280
Antenna ... . . .... . ......... . .. . ..... EW ~-154 Antenna selection control module .. .... . . EWD-283
CD changer .. ........... .. . . .. . ..... EW )-154 CD changer unit ... .. ....... . .... ..... EWD-279
Central locking control module . . . ... ..... EW D-155 Central locking control module ....... .. . . EWD-281
Data link connector ... . .. . . . .... . . . .. . . EW )-153 GPS antenna splitter .. . . . ....... . . . . . . EWD-280
Ignition switch .... . . .. . ..... . .... . .. . . EW )-154 Heated rear window .. .. . ........ . . .... EWD-282
Instrument cluster combination processor .. EW ~-153 Navigation control unit with CD ... . .. .. . . EWD-280
Multifunction steering wheel Radio ....................... . .... . . EWD-278
control module .. . . .. .... . .. . ...... . . EWI ~-155 Rear window defogger switch ........ .... EWD-282
Navigation control unit with CD drive . .. . .. EWI -154 Rear window defogger with antenna ... .. . EWD-283
Power antenna ... . . .. ... . . . . .. .. . . . .. EW[ -154 Right rear woofer I amplifier .... . . . .. .. . . EWD-281
Radio ... ... . ...... . ... . ..... .. ..... EW[ -153 Satellite radio .. .. ... . .......... ...... EWD-279
Rear window defogger I heat element ..... EW[ -155 Speakers ..................... . .... . EWD-282
Rear window defogger switch . .. . . ...... EW[ -154 Telephone I telematic control module ... .. . EWD-280
Rear window defogger with antenna ...... EWC 155 TV antenna amplifiers . . .. . .... . .... ... . EWD-282
Rear window defogger Windshield antenna suppression filter . . . .. EWD-282
with window antenna .. . .. ... . .. . . .... EWC 154
Sunroof (2000) ... . ......... . .... . . . . ... EWD-96
Right rear woofer/amplifier .. . .. . . .... . .. EWD 155
Speaker (Telephone , navigation) . . . . . . . . EWD 154 Windows (1998) . ... .. .. ... . .. . .. .. .... . EWD-42
Speakers .. .... ... .. . . .. .... . . . . . .. . EWD 155 Front windows .. . ... . .. .. .. . .... . . . .. . EWD-42
Telephone radio antenna amplifie r ........ EWD 154 Ignition I starter switch .... . .. . .... . . . ... EWD-43
Telephone transceiver .. .. . . . . . .... . .. . EWD 155 Instrument cluster combination processor . . . EWD-44
TV antenna amplifiers . ......... . ...... EWD ~ 55 Rear windows ....... . . . ....... . ..... .. EWD-43
Sound system, Bose (2003) . . . . .... . . . .. EWD 261 Sunroof control module . . ............. .. EWD-42
Switch for interior lock, left front ....... . . .. EWD-44
Antenna for radio , telephone, navigation ... EWD-t262
Window lock-out switch .. .. ... . .. .. .. .. . EWD-44
Antenna selection control module .... . ... EWD- g54
Antenna .. .. .... ......... . ...... . ... EWD- )65 Windows (2000) . . . . ..... .. . . ..... .. ... . EWD-77
CD changer . .. . . ... ... . .. . ...... . .. . EWD- ~62 Central locking control module ... . . . .. . . . . EWD-78
Central locking control module .... . .. . ... EWD- >63 Ignition switch ...... . ........ . ..... . ... EWD-79
Multifunction steering wheel Interior lock switch .. . .... . ... . .. . . . .. .. EWD-79
control module . .... .. ... .... . .. . . . .. EWD-: 63 Left front windows .. .. .... . ... .. .. . . . . . . EWD-77
Navigation control unit with CD ........ . . EWD-. 62 Left rear windows ... . ... .. .... . .. .. . ... EWD-78
Radio .... .. . . ... .... .. .. . ... . .. . ... EWD-~ 61 Right front windows .. .. ... . .. . . . .. .. . .. EWD-78
Rear window defogger switch .. ..... . .. . EWD-~ 62 Right rear windows . .. . . .......... . .... . EWD-79
Rear window defogger switch .. ... . .... . EWD-~ 64 Sunroof control module . . . .... .. . . .. .. .. EWD-78
Rear window defogger with antenna .... .. EWD-~ 62 Window circuit breakers .. . .... . ...... . .. EWD-77
Rear window defogger . .. .... . .. .. . . .. . EWD-~ 34 Window lockout switch .. . ......... ... . .. EWD-79
Right rear woofer I amplifier ...... .. . . .. . EWD-2 63 Windows (2001) ....... . .. ...... ...... . EWD-140
Speakers ... ................. . . . ... . EWD-2 34
Central locking control module . . . ... . .. .. EWD-141
Telephone I radio amplifier . . ..... . . . . . .. EWD-2 D2
Ignition switch .... .. . . . . .. . .......... . EWD-142
Telephone I telematic control module . . ... EWD-2 )2
Instrument cluster combination processor . . EWD-142
Telephone I telematic control module . . ... EWD-2 ,>3
Left front windows ... . .. . . . ............ EWD-140
TV antenna amplifier ... . . . .. . .... .... . EWD-2 A
Left rear windows .... .. . .. ............ EWD-141
Windshield antenna suppression filter . .... EWD-2 4
Power sunroof control module ......... . . EWD-141
Rear window switches ..... . . . ... . . .. .. EWD-141
Right front windows .. . . .. . . ......... . . EWD-141
Right rear windows .. . ... . ........ . . .. . EWD-142
Window lockout switch .. ... . . ..... . .. . . EWD-142
 Electrical Wiring Diagrams EWD-25
Electrical Wiring Diagram Index

Windows (2002) . .... ... . .... . .. .... .. EWD-201

Central locking control module . . . . ...... EWD-202
Front window switches . . .. . . . ..... . ... EWD-201
Ignition switch . .... . .. . .... . .... . ... . EWD-203
Left rear window switches ... .... ...... . EWD-202
Power sunroof control module ... . ... .. . EWD-202
Rear window control module ...... . ... .. EWD-202
Rear window motor regulator . . .... .. .. . EWD-202
Right front window module . .......... . . EWD-202
Right front window motor . . .......... . . EWD-202
Right rear door window motor ........ . .. EWD-203
Right rear window switches .... .. .. . .. . . EWD-203
Window lockout switch ....... . . ...... . EWD-203
Window motors .. ....... . . ... .. . ..... EWD-201
Window regulator switches .... . .... . . .. EWD-202
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Audi AG Wiring diagram No. 1/2 No. 1/3 Wiring diagram Audi AG
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t,O 1,0 0,5 0,35 0,35 0 ,35 0,35

!_ ~ 73 ~ 80 ~ 58 ! s5 ___ h br br/ gr br/11 ro/li gr/ ws 11/ro h/ge ws/ge gn/li

--'~'59 ~ '~2
_J 54 J220
~~53 , 74 , 69 l. 75

11
0,35
gelro
6

r
0,35
ws / ge
ITT
I
2,5
s':'
r
2,5
sw/bl
I
2,5
sw/bl
110
I
0,35
I
0 ,35
I
0 ,35
gr~ge
J 220 /

0,35
167
gr~ws
220
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' se ' so

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I / to I 84

~~~ ·. =~~!i 6
' 232
J T5f/3 I T5f/t I I II I I I I I o)

l H ·x·
0 ,35 0 ,35 0 .35 0 ,35 0 ,35 0,5 0 ,5 0 ,35 0 ,35 0,35 0 ,35 0 ,35 0 ,35 2.5
0,5 0,5
ge/ro ws /ge
reiI gn '----=-
,I 232a ~
i "' . _._
gr/ ws gr/ws

~
gr/ ws

s\-
br
3
·~'Ts111
I - --- en
29

t6 -- ---
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T
I
0,5

ws,u
/~
I
0 ,5 0,5 2,5 2,5
--- N 15e N t2e N
ws=wh1te
sw =black
ro =red
WS=Whl te
sw =black

r·:::r
J J J J J JI-
ro =red
ro/gn gn =green
br=brown
bl =blue
gn =green
br =brown
0,35
.-
43

I
bl =bl ue br
gr =gray
I 7 T T T T Ii =viole t
gr =gray
=VIOiet ..
J,;T ton/5
__._
'3
V 144
~ ... ... ... ge=yellow ge =yellow 0,35
Q Q Q Q Q br

29 30 31 32 33 34 35 36 37 38 39 40
. 41
.
42
_ 1 ~~-
43 45 46 47 48 49 50 5t
G et

52 53 54
G ee

55
85

56

97-19658 97-t9t86

G 42 lnta'e Air Tempera ture (IATI Sensor T 6 I Connector 6 oin. re el conrenor sta tion elecuornc ~ox G 2 - Engine Coolant Te1-iperature iECTl Sensor - Ground connect ion - 1 . in engine compartment w1r 1r.g
j 220 l\l otron ·c Eng ine Contr ol Module IECMI plenum chamber G 28 - Engine Speed (RPM) Sensor harness
\J - 'gn1t 1on Coil T 1O n - Connector I 0 pin. yello" connec tor stat •On electror c G 61 - Knock Sensor IKSI 1 -Ground connection (sensor ground) 1n engine compart-
' J 3C - Cyl.ndor 1 °uel ln1ector box plenum cha-nber G 62 - Eno ne Ccolan1 eripera:ure iECT! Sensor ment w1rmg harness
\J 31 - Cy' nder 2 Fuel ln1ecwr T 10 o - Connector 10 pin, brown. ccnr1ector station e .ec:ron1c G 66 - Kn~ck Sensor 1KSI 2 - Ground connector !sensor ground) - 1 . 1n instrument panel
\J 32 Cyl1ncer 3 Fue l ln1ec1oc box plenum c'lamber J 220 - Mo1ron1c Engine Control Module IEC M I wiring harness
\J 33 Cylinder 4 Fue l ln1ec1or T 10 o-Connector 10 pm. biad.. cor,ne.cior station eler trcnic box J 338 - Throttle Valve Control Module
\J 63 Cylinder 5 Fuel lniector plenum chamber T 3 w - Connec tor 3 p;n, grey on engine speed sensor
I'. 84 - Cy'1nder 6 Fue l ln1ec tor V 144 - Leak Detection Pumo ILDPI T 3 x - Cor.nector 3 pin. blue, on knock sensor 1
N 122 - Powe r Ou tpu t Sta ge T 3 y - Connector 3 pin. blue. on knock sensor 2
I'. 128 lg"111on Coil 2 T l Q n - Connector 10 pin, ye llow. connec tor station electronic
158 - 1001110" Coil 3 Gr oun d connect on 1- m engine compartment w1r1ng box plenum ct-amber
P - Soark Plug Connectors harness
0 - Spark ?lugs -Wire connection (inJectorsl. in engine co mpartment wiring
S 232 - Fuse harness
T 5 f • Connector 5 pm, 1gn .11on coil unit -Wtre connect1cn (15!, above c:rc un Break£'1 1n engine
T 6 I - Co:inector 6 ptn. dar~br c wn . connector stat ion/\ p1! ar ccrrpartrT'ent Wtflrig harn~ss
r gh1
Fuel Injectors, Motronic Engine Control Module , Motronic Engine Control Module , Throttle Valve Control Edition 02/98
Editi o n 02 / 98
Power Output Stage, Leak Detection Pump Module , Engine Coolant Temperature Sensor, Knock Sensors W42 USA.5602 .03.21
W42.USA.5602 03 21
Audi AG No. 1/6
No. 1/7 Wiring diagram AudiA6
Wiring diagram

30 ~~~~~~~~~~~~~~---~~~~~~~~~~~~~~~ 30

~ IB
31 ~
1 21131 ~17/30 ,, t9/86

. £.- -£.- ~---·~

- ~
a
J 17

n=
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S3/ LA , S3/ 87i
a7F/DTI
i
30
~ ;]) ( 2,5 1,5
~ J 104 gn/sw gn
E a1
JI~ i21 113 Ela~
·135
r15 133
~
T
0,35
~
, 234
1 1.5~ s
' 228
0,5 0 ,5
1,0 0 ,35 0,35 0,35 0,35 0,35 J te9 ws/bl 2341T
I gn \ =-;n2:BI
ro sw/gr ge gn/sw gn/br gn/ bl gn/bl T 2011 -~ __L ~
l 234a ~
l 6H- ~ ~ f rse12 fT1okl3 B f I ~
8
T
100/9 1 22aa 130
T

r
iT 0,35 2,5 2,5 0.35
0.35 0,35 0,5 0,5 0,5 0,35 0,5 0,35 0,35 0,35 ws/bl swi gs gn/ ge sw/l i
__L __L
sw/ gr sw/bl gn/sw gn/ sw gn/br gn/bl gn/bl gn/bl ge ge/br
~ .m. ,21
~T1001e ~On/9!T1onn
'1 20
!T100/6 k ok/7 k Ow/ 3h Op/ 2k Oo/3!T10on
0,35 0,5 ~ ~ - ~· ~ ~ ~ ~ ~ ©
sw/ge gn/sw gn/br gn/bl gn/bl gn/bl ge ge/ br

, ,o ' s Ls J ,~;o J~40 , 6 ' ta L 58

T
0 ,35
88
T
0 ,35

7 r r '77"'
TT

J
t ,5
32
0,5
gi
r rh r
'-;-~~~--;~~,--~~~~~..,-~~~-,-~~~-,-~-,-~~~~' J 220

I
I 29
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ro/gn
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--.-
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229
:5'
T or/br or/sw gn/sw
05
· \ - S 2291 CD m
I
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0.35 0,35 0 ,35 0,35 0.35 0,35 0,5
ro/ sw gn/br gr/ws

t. 'vs L
gn/ sw ro/sw
ws/sw
_L ! rise1t4
T
!Tis. !T10n12
T /15 T 3 CD
Jfil.
L. L/S LI- 0,35 r".
or/br A122.
0,35
or /sw
0,35
gn/ re
WS =W ne WS = Whlte
t,5
tl:>
::J
(")
+
sw =black
J_
sw = black
----13 · -87 ,.....+
-t- '-' ~ · o = red ro=red 'Z:z: ro/ gn tl:>
r-,
·~
~I
j§i gi =Q r e e ~ Nao .!::____
<Q :::! .
G 40 G tsa
0,35
or/br
.._/ 0,35
or/sw b·=brown
gn = green
br = brown Z 19 G 39 G 10e 1 t i T511•T
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3 tu
b l =olue bl =blue 1.0 1.5 1,0
!T10w1s ! rtOw/ 4 gr =g ray ro/ gn ro/ gn ro/gn
gr = gray
T
T
0,35
or/br
0,35
or/sw
II =violet
ge = yellow
or = orange
li = VIOle t
ge = yellow I
0,5
I
0,5
I
0 ,5 0,5 0.5
I I I
1,0 t,O t,0
CD
::J
~- ~
• 85 • 86 ro/gn ro/gn ro/gn rei gn ro/ gn rei gn rol gn reign
J 217 J 217
__L
J.Q1!
__L
~
__L
_LL
..L
IL
__L
..fill.
__L
.Jll..
__L
~
__L
~
!\) :::! .

t: 87
57 58

- AJC Control Head

59 so 6t 62 63 64 65

T 15
66 67 68 69 70
97-t9659
e - Cor.roector 15 cir whi te. con11ecto .. srntion e!ectron 1c
G 39
71

- Heated Oxygen Sensor IH02SI

72 73 7~ 75 76 n

Z 28
78 79 80

· Oxygen Sensor 102SI 2 He ater

81 82 83 84
--·
():) ::::J
....... (.Q
CD
0
G 40 - Camshait Position !CMPI Sensor
G · 63 · Camshait Position !CMD) Sensor 2 T 20
box o enurn cha11ber
- Connecto~ 20 pin ·ed/wti .t e on ms:ru,......en cli..:ster G 108 - Hea ed Oxygen Sensor (H02S) 2 """
CD
J 1O~ - ABS Control Moaule !w/EDLI
J 17
J 220
- Fuel Pumo (FPI Re lay
- Matron c ~ n g 1ne Control Module !ECM I @ ::J tu
J ; 89 · A~ t o Check Syst em
J 217 · T·ansm1ss1on Cont•ol Modcle !TCMI
J 220 · Motronic Engine Control Module IECtv')
G -Wire con:iect1on IR PM-sig nal). 1n instrumen t panel w1r1ng
N 80 - Evapora 1ve Emission !EVAPI Canister Purge Regula tor
Valve @
-Ground connect ion (sh1e lo1ngl. 1n engine compa rt ment
wmn g h a~n e ss
- Connect or (over iuse 2291. in wiring harness front . right
(Q
:5' tu
(.Q
T 6 e ·Connector 6 pin. grey, connector station A p:llar. righ t
~
'-0
narness
-Con"ec;or IC15. NCI 1n instrument pane wiring harness S 228 ·Fuse
~CD '
- 6 I - Connector 6 pin. red. connector sta tion e;e::troncc box
plenum chamber e- Connection !h·gh busl 1n instr Jment panel ·..v 1ring 'iarness
S
S
T
229
234
4
·Fuse
·Fuse
u · C"nnector 4 oin, black. Heated Oxyger. Sensor (') 3
- 10 k ·Connector 10 01n, cranoe. connec:or sta11or A p1lla-, leit
T 1O ., . Conne::tor 1O pin, yello~. connec tor s~atton e1ecuon1c 8 -Connec11on Cow bus) 1n mstrumem pa1el wiring harness
-
-
4
6
v · Connector 4 oin. black. Heated Oxygen Sensor 2
I - Connec tor 6 pin red. connector station electronic box
a en
~
box plenur-i chamber
- 1J o · Cc1nector 1O pin . brown. connector station electronic ple"um c1amber
box p enum ct-amber T 10 n - Connector 10 pin. ye llow. connec tor siat1on e iewonic
box plMum chamber
~
T · O p Co1nector 1O pin. black. conn ector station e ect·onic box
olenulT chamber
·CAN -Bus
- Ve"l1cle s wit~ front wh ee l drive T 1O o - Connector 1O pin. brown, connector station electronic
m
~
T 1O w - Co.,necior 1O pin. olue. con1ector s~auo-- A piliar. ng.,t cox plenum chamber

---.. ~
Z 19 - Oxygen Sensor 102Sl Hea ter
Edition 10/98 Motronic Engine Control Module,
Camshaft Position Sensors Motronic Engine Control Module, Heated Oxygen Edition 10/98
W42 USA5602 04 1
Sensors, Fuel Pump Relay W42 .USA 5602 .04 .21 --4. 0I
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AudiA6 Wiring diagram No. 1/8 CD 0

No. 1/9 Wiring diagram AudiA6 I
3
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0
.
30 ---~---~- - - 30
15 15 ::J
x
31 ---~------------
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30
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sw/bl

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0 ,35 1
br
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/ gr
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97 "'2/ 67
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r2,5 0 ,5 0 ,5
brn 4 ,0
ro/sw
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ro / gn
0 ,5
rei gn

l!:-'
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ro/ gn
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~ 3
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~ ~ --= ~ B
IT10c12 r.T 10c14

1 2/30
- · J 299
·t 4/ 65
4~0
0 ,35
br/ sw
---<o<o
~
U>

.
ws=wh1te WS=Whlte
4 ,0 0 ,5
I 012
sw =black

:r~
sw =black
~
SW ro / gn 87
ro=red ro =red
I
gn =g reen gn =green
-~ ll 2/Sn E I 4/ 512
br =brown
bl = blue
br=brown
bl =blue ~ V 101 V7
e_ fi . --- -- -
-~
f 54
gr =gray gr =gray
11 =VIOiet 12
12 1 1131 F 18 1 3131
il=v1o let
ge=yellow ge =yellow 4,0
br
4~
~
40
~
0 ,5
~
0 ,5
~
G 13o

h 18 ~ 1 @ 1 ~3
10s t07
I@
toe 109 t1o ttt tt2
99 100 101 t02 103 104 105
65 B6 67 68 89 90 91 92 93 94 95 96 97 98
97-19662
1 97-19661
E 87 · A/C Control Head Ground co nnection. on left A·p1l!ar. lower part
G 70 - Mass Air Flow tMAFI Sensor
18 Coolani Fan Co"trol !FCl Therrial Switch
G 130 - Oxygen Sensor (02SI Behind Three Way Catalytic · Grou:id connect ion 1 , 1n engine compartment wiring
54 Cooia" t Fan Con tr ol IFCl Ther'nal Switch
Convener (TWCI harness
F 129 -A/C Pressjre Switch
G 131 · Oxygen Sensor 102Si 2 Behind Three Way Ca talyti c
J 26 Coolan t 0 a" control IFCl Relay · Ground connection -1 . in coola nt fa n w1n ng harness
Conve er (TWCI
J 101 -Second Speed Coolant Fan Con tro l tFCl Relay
J 220 · M otron1c Engine Control M odu le IECMI J 299 - Secondary Air ln1ect1on tAIRI Pump Re:ay ·Plus conrect on 1301. in instrument oanel w 1nng harness
t 12 - Secondary Air ln1ect 1on (AI R) Solenoid Valve \I 3 - Coolant Fan Control tFCI Senes Resistance
156 - Intake Man ifold Change-Over Valve S 42 ·Coolant Fan Fuse
N 205 · Valve -1- for ca mshaft ad1ustment S 130 · Fuse ior secondary air pump
N 208 - Valve -2- for camsha ft ad1ustmen t S 142 · Con trol module fuse for coolant fan
T 4 s ·Connector 4 prn. green. ear oxygen sensor. behind T 6 a Connecor 6 p;n, blue. connector station A pillar. et
Three Way Cata lyt ic Convener JTWC! T l0 c Connector la pin, grey connector station A p 11ar le't
T 4 t - Connector 4 pin. brown. near oxygen sensor 2. beh ind T 10 n Connector · 0 pir yellow, connector sta11cn electronic
Three Way Ca talyti c Convener tTWCl box plenum chamber
T 10 o · Connec tor 10 pin. brown. connector stat ion electronic V 7 Coolan t Fan
box plenum chamber V 101 ·Secondary Air ln1ec t1on IAIRI Pump Motor
z 29 - Heater for Lambda-probe 1
z 30 - Heater for Lambda-probe 2
Coolant Fan, Edition 10/97
Edition 10/97 Motronic Engine Control Module, Mass Air Flow Sensor, Secondary Air Injection Pump Motor W42 USA 5602 01 21
W42.USA.5602 .0 1 2 1 Oxygen Sensor Behind Three Way Catalytic Converter
Audi AG Wiring diagram No. 1/10 No. 1/11 Wiring diagram Audi AG

30 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 30 - - - 30
ts - - - - - - - - - - -- -- - - - 15
m m x
x x - - -- - - - - - - -- - - - x31
~ ~ 3t - - - -

~
0 ,3S
~
0 ,35
wst ga
252
-r
0 ,35
gr
-.-
2i2
0 ,35
sw/ws
~
0 ,35
SW/gn
ro
-.-
0,35
gel br
1'.Q1
-._./ O,S
gnlge
0 ,35
gn/ge
279
I ~ ;lf a2
I -.-
68 "
I~ ,---,- 3fa
-r
SW 0 ,35 0 ,3S 0 ,35 0 ,35 0 ,35 0 ,35
0 ,35 0 ,35
fss lsL lsR
I _._
re/bl gn/h gr/bl sw/11 gn/bl ws/bl wslbl ws/ gn
l 1s ) s ea

J~/3
I T3211 ,. T32/17 T32a/E IT32118 T32/2 I ' T32116 j 4:9/S.1 ' T32/21
fl_
1
I T32a
S8de 1 58s
30 T32
I T32123 I 129 I /20 l. T32a11_0 _ _ ' T32/11 ' T32a /30 - - -

I
I
T32/12
61
T32a /13
I
T32/ 24
31
I T32113 I T32132 I T32/31 I ~32/9
----r-
0,35 0,3S
I
T32/ E I T32a/21
I

r 3218:;a
I

r 32/ S
1I - ,-
T32128 T32n
_._
bl br/ro
I
SBd

~
-.-
151
h
T 110
1oy 0,35 0 ,35 0 ,35 2,S 0 ,35 0 ,35
gi

~l
bl /ws bllbr gn1ge Htsw b'fo
0,35
gr/ ge
.1
0 ,35
brlro

~Tso12
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O,S 0,35 2,S O,S O,S O,S

~ gn'~ hi~:
0 ,35 O,S 0 ,35 bllws
br/ ro r;--i , ' :3
~-.---.~
br/ ws gr/ ge li/f : ' 1 br/ ro
2
--~1 --~1 _h WS = W I e WS = W ~lte
0 .35 J ·G tl) CD
gr/ge ""T 2a112 (')

'
sw =b l a c~ S'.'. =C laC( L .:"G s .7- G•.z• / ,;! ,21G ::::i
F9 c~~ ::~ F3• E 24 ~ ro =reo ro =red ~ - tl)
......+
::::!.
N-- j2
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gn =green
i2 br=brown
gn =green
br =brown
-~
4 l~ -
oi.s~.~ --G
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0 ,S 0 ,S O,S 0 ,35 0 ,35 0 ,35 _::. G a
m
I
b l =blue bl =blue
G 22 1
' 3131
br br br br br br
gr = gray gr =gray
o .s
~r
:3
~ 12 !Tso11
Ir = v iolet li = v1o let CD
~
ge =yellow
l ge=yellow
~5 . ::::i
G 23a
0 ,35
br
2,S
br ~
O,S
~
0 ,35
~
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~

8 § I® I §_ ------ - 1@I§ ~ ::::!.

~ 2l
TI3 TI4 TIS

· _ett Seat 3e lt Swrtcn

TI6 TI7 na n9 120 121

T •0
122 123 124 12s 126
97-19663
y Connector 10 01n . green. connec:or station P. pd. a#. '1ght G
m

- Fuel Level Sensor

w ~ m ~ m

T 32
m ~ m ~ m ~

- Conrector 32 p1n, blue on 1nsuumen: cluster

m ~

97-t966 4
--.
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" Q . ?arking Bra e Warning 1ght Sw1tcn T 32 - ConneciOr 32 orn. olue. on instrument cluster G 1 · Fuel Gauoe T 32 a - Co ector 32 p1r. greer :in ins n.:mem cluster
= 34 . Brake Fluid Level Warring Swncr T 32 a - Connecto' 32 Pin. greer.. or 1ns:n. . ment c li...1s er G 3 - EnG "e Coolant Tempera1ure i:OCTJ Gauge y ·Analog Clock
G 238
J 218
-Arr Quality Sensor
• 1nstrume n Cluster Combination Processor
G
G
5
6
·Tachometer
- Fuel 0 ur-io IFPJ m
::::i
J 429 - Control mod !e for central locking G 8 ·Engine Or Temperature Sensor - Ground ccnnecuon-1-. n engine cor-1partment w .nng (Q co
K 1 - Headlight High Beam Indica tor Light
- Ground connect ion . on left A-pillar .ewer part
G
G
9
14
·Engine 011 Temperature Gauge
- Voltme te r
harness
s· ......
K
K
K 14
2
4
·Generator IG ENl Warn1rg L1gh:
- Park Light lnd1ca:or Light
. Parking Brake lnd1cato• Lrght
-Ground connection -2-. 1n 1ns:rument panel wnng harness
G
G
21
22
·Speedometer
. Speedome ter Venicle Speed Sensor IVSSJ
-Ground con nect:on -1-. in rear winng ha~ness

- Ground connec tor (sensor ground} -1 . 1n instrument panel

~CD m
K 19 - Seat Belt Warning Lrght ·Wire :onnect·on (dnve~·s door contact switch). 1n instru-
G 169 · "uel Level Sensor 2
G 237 · Fue l Level Sensor 3
wiring harness (') 3
K 29
I( 65
- Glow Plug Indicator L1gnt
· Leit Turn S.gnal \nj1cator Lrght
ment oane l wmng harness h 3 - Warning 8'Jzzer
" 218 -lns:rvnen Cluster Comb nation Processor
- Plus connect ron (58d) . 1n instrument panel wu ·ng harness
IDrsolay llum1natronl 0 en
~
I( 72 - Warning light tor catalyst monitoring - Wire con necuon (vehic le soeed signal) in 1nstrumerit
T 2 a1· Connector 2 p1 ~. black. o.I sensor
K 86 - -ract1on Con trol Indicator Light panel wiring harness
T 6 a - Coon ector 6 pin, blue, connecto r stat ion A pillar. lert
K 94 . ~ ght Turn Srg al lnarcator Light
T 10 · -Co-~ecto· 10 prn , bcown, connector station A pillar . left
)::i.
T 6
T 10
p ·Connector 6 pin. red. be low driver's seat
e - Connector 1O pin. violet. connector s ta t101 A p11:ar left
T 10 o-Connecto· 10 pin, blac• connector s:at1on elecirorrc box
••
- Vehicles w it h fron -wheel anve
- Vehicles wrth all-wh ee drive m
~
::>lenJ.,, chamber

-.... 0~
Edition 10/98 Instrument Cluste r, Parking Brake Warning Light Instrument Cluster, Speedometer, Edition 10/98
W42 USA.5602.04.21 Switch, Brake Fluid Level Warning Switch Tachometer, Fuel Gauge, Fuel Pump W112.USA 5602.04 .21
--4.
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Audi AG Wiring diagram No. 1/12 Cb
No. 1/13 Wiring diagram Audi AG I
:3 VJ
30 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 30
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x x 30 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~- Jo

~ ~ m
x
m
x ~
~ ~
~ m
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Cb
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~- ,.....+

Ea1 !\) ~-
r
0,35
bl/li
JJt!1.
0 ,35
gn/ro
lfj~
0,35
gn/sw
3i1l
0 ,35
ro
n ~
0 ,35
gn
0,35
I
0 ,35 --·
(X)

.-;..
Cb
(')
Ol
IT32a Jass
HLS 112
1
( PR
1
JPL
T32/26 T32/27 T32/30
1 1
1
w
T32a/ 5
I 10
J 104
""'\
Cb ~
-·
::J ~
(Q
I
® J21a tg,'! K 32 @' K 47 @J210 s· co :::J
I
~Cb
I C) 0
I I
I I I
I I I I
0 -·
1
r 32/10 r 32/22 T32a/7 T32/29 T32/19 ~32/25
Ol
ws/gr bilge
"......
br/gn
n .,.c:.
gr/ge
n
getro
.,.c; K 68
-;;l i6a/7T
E01 ~ co
I C4 ')..._ -;
1
JT1opt3
0,5
tT1op1s
0 ,35
~
--
--- 11
N12
fr&,i
0 ,5 116
r

0 ,35
10k/6
~ 3
~

ws/gr

lr2av1
bl/ge

~.h tr
~2ak rak l .,~I 2al
ge/ ro

121 ---c.oc.o
--4.
CJ)

l
12 /1 /1 /2 ws =wnite
J 104
WS = Wh1 te sw =black
0 ,5
SW
sw =b lac k ro = red ~

r
ro=red gn =gree n
gn =green br=brown

:~ F66 br=brown
bl =blue
bl =blue
gr =gray

r
ws/ge
gr =g ray 11 = VIOiet
ge = ye llow I i116a/4~T16ai5
11 = VIOiet
ge= y ellow F210 0,35 0 ,35
0 ,5 0,5 br br
br

I@ le
br
I@Is
155 156 157 t58 159 t6 0 161 162 163 164 165 t66 t67 t6B
141 142 143 144 145 146 147 148 149 EO El E2 153 154
~
/ 97-19665 I 87 - 15 d - Connector 15 pin. black, conoec or station A pillar, ng"t
AJC Con re l Head - t 6 a - Connector 16 pin, data i1 nk conn ector
57 - NC Con ro l rlead T 1O p- Connec or 1O pin, black. con ector s auon electror1c box F 2t8 - Sw11ch for central toe 1ng. trunk hd T 32 - Connector 32 pin blue. on instrument cluste·
1 - Oil Press~ r e Swnc plenum chamber - 32 a - Connector 32 pin. green . on instrument clus1er
J ~04 - A3S Comrcl Module lw/~D LI
66 - Engine Coolant Leve l IECL) Warn1na Sw1tcn T 32 - Connector 32 pin olue. on 1nstrumert cluster J 217 · Transm1ss1on Comrot Moaute ITCM I
104 -ABS Control Module lw/EDU - T 32 a -Connector 32 p·n. green. on 1nstrume1t c uste· J 218 - lnstrurien; Cluster Comb1oa11on Processor
218 - Instrument Cluster Comb1na11on Proce ssor -A.roag Control Modu le
J 234
3 - Oil Pressure Warning L1gh - Control m odule for central locking -Ground connectton -2-, m instrurient pa.,el wiri ng rarness
J 429
16 - Fue l Reserve Warni ng Light
K 28 - Engine Coolant Leve l{Temperatur e iECUECTI W arn ing
Light
8 -Grouno connection on leh A-pil lar. lower part K
~ 75
- DLC !Da t a Link Connec1orl Rao1d Data Tra1sfer
- Airoag Ma fonc11on Ind icator Lamp IM ILI -Connector (K-d1agnos1s wire ). 1n instrument panel w iring
harness
K
K
32
47
- Brake Pad Wear Indicator Light
-ABS Warning Light
® -Ground connection -1 , 1n engine compartment wiring
narness
R
T 3
T 6
· Radie
a - Connector 3 pin, black , connector stat ion A pil lar right
. Connector 6 pin, red. connector station electroni:::: box
-Wire connect 1on (lmmob 11tzat1or. t ime) . 1j"'I instrument
panel wmng harress
N 12 . R1gh1 Brake Pad Wear Ind icator ISnear Element) pte1um chamber
N 13 - Leh Bra ke Pad Wear Indicator !Shear Elemen I T 8 - Coinector 8 pin, black. connec tor rad:o 11 ,
2 a1· Connector 2 pin, black, 011 sensor T 10 k . Connector 1O pin, orange , connector station A pillar. left
- 2 ak- Connector 2 pin, red. on firewall . left T 10 v - Connect or 1O pin. brown. connector sta ion A pillar. rig ht
T 2 al- Connector 2 pin , red. on firewall, r ght - 10 ' - Connect ~r 1O p1r . pink. connector station A pillar. right
I 6 e - Connector 6 pin, grey, connec or sta ion A pillar, rigr t
Instrument Cluster, Data Link Connector Edition 10/98
T 1O k - Connector 1O p1r. orange. conne ctor s:at1on A. pillar lef:
W42 USA.5602 04 2'
Edition 10/98 Instrument Cluster, Shear Elements
W42 USA. 5602 .04.21
Audi A6 Wiring diagram No. 1/14
No. 1/15 Wiring diagram Audi AG

30 - - - - - - - -- - - - - - - - - - - - - -- - - 30
15 - ----- - - - - - - - - -- - -- - - - - 15
x ----------- x
~~ ---- - - - - - - -- - - - - - - - - --- - ~.

sins 30 15
J 234
15

J Z17
-33
0 ,5

t T3913
-.-
173
2,5
-.
172
2,5
310
I
1,5
194
,- ,- 1195
5' fil
I I ~ ~ ro
ger~
gr/ gn

1,0
ge/sw
2,5 2,5 2,5 6,0 6,0 2,5 2,5 0,35 2,5 0 ,5 0 ,5
' 15130 E 1 E ~ __h_IXR K 13 K 11 L9 L 40

r r ICJ r T T T i/. J i "4:

, - -•
-I=~ ~ - -- --7~~,_-0 - .L
- - - - -· -
--
i"

I
-- -
2,5 ~ 2,5 1,5 0,5 4,0
A 2
"-../

~
SW
_'.L 1

r1w r~.
J_
.J!1_ .fill_
I 7156
1 4156 r NL 19/NSL 17158.- 10/31

D D
270
T
:/';:. '=¥.. 0 .5

r·
1,0
- -Ip 1,0 0.5 1,5 0,5 1,0 2,5 1,5

r r
~
ge ws/ge gr/ ws gr/bl

rb
~L~ ~·S·
gn/sw gn/ sw gr
_J_ _J .L -3.!Q_
L

I gi
249 ~ '307

4,0 0,5
,--,. (Q
2,5 2,5 0,5
ge/sw ro/sw bl
~t
A s1
'-.__./
:5"
1- r
fi
J_ J__
188 ~ iJ .fill_
I
1 221
I
m
-r --.-
Tn CD m
0,35
gn/sw
0,35
gn/ro
1,0
SW / W!.
1,0
sw/ gn
1,0
ge
_L
2.5
ge
2,5 2.5
3tl) CD
~ J~f i
¢,5 = w11 te J_ _L
WS=W Il e 148 .1£ 264 (')
sw =b lack
sw =blac ' ::::i r-+
0 ,35 0,35
ro =rea ' 7156 L o tl)
rc = red - ~.
g, = gree n -- -- '2= (Q

~--{
gn =green _ h-=: . ~f_
br=brcwn
br =bro vv1 T ~ -- - CD (')
bl =blue
fl)
bl = blue
gr = gray
gr =gray
l1=v1o let Er--x;
E 4
i 8/ 56b h 3
0 ,35 ~
11= VIOi et
CD
~
ge =yellow 1,0 •• 1,0 . 1,5 1.5 1,5 0,5 ::::i
Lro ge=yellow
_._
sw/ ws/ gn

2?2.
sw/ws/gn
I_
m
_._
gel gr
31 0
ws
_I
_2_5j!
_L_
ID
br
,.-..
·~
~-
!\)
J 429 ~.

D
169 170 171

- lorn ion/Staner Sw1tc

172 173 174 175 176 ITT 178 179 180 181 182

97-19667 =. l
E 2
E :;
· _1:ih: Swnch
183

- T _;'rn Signal Sw~ch

184 185

.-!eao.1a"'lt Dimmer/Flasher Switch

186 187 188

0
@
189 190 191 192 193 194 195

- GroL;'ld ccnrect1or -• · 1n 1ns1rurien panel w iring 'larress

-\l\llre cor. nect 1on t57L . 1n ·nstrume -t panel wir ng

196

97-19668

~arness
--· c.o0
Co
........
CD
.....
::J

J
J
59 - l-oad Reduction Re lay
217 - Transm1ss1on Control Module (TCMI ® -Plus connection (1 5). in 1 ns~rument pane l w .nng harness :
K
23
3
- =og L1gr: Sw1tcn
- Rea• =og eight Indicator L1gh1 8 -Wire connection !57R}. 1n 1nstrurent oanel wiring narness
CD
::::i fl)
J
J
234 - Airbaa Control Mod ule
429 · Contr-;,I module for central lock ing
® -Wire connection (86s) , 1n instru ment panel wir ing harness K
L 9
17 - Fog L1g.ot Indicator Light
- Headlight Sw1:ch Light G) -Wire connect 1on (56). m instrument panel wmng harness (Q c.o
3 a - Connector 3 pin. black. connector station A 01llar ·1ght
® - Plus con nect ion 1301. 1n instrument panel wring harness L 40 - Front And ~ea r Fog Light Sw11ch L1gh1 5· ~
T 15 d ·Connector 15 pin , black. connecto r stat ion A pillar . right
~CD fl)
()
0
3
CJ)
••
- Cnass1s number upto 5000
- Coass1s oumber from 500 1
§-
:b. m
~
Li ght Switch, Turn Signal Switch. Edition 10/98

.........._ ~
Headlight Dimm er/Flasher Sw itch W42 .USA.5602 04 21
Ignition / Starter Switch,
Edition 10/98
Load Reduction Relay 0
--4.
W 42 .U SA.5602 04 .21
c.o I
c.o w
~ w
 ~ m
s· 0~
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AudiA6 Wiring diagram No. 1/16 Cl)

No. 1/17 Wiring diagram AudiA6 I
3 w
30 - - - - - - - - - - - - - 30
tu ~
x15 -
-
- - - - - - - - __________ ------x
- 15 30 30 ::J
15 15 tu
~~
- 31 x x (Q
75 ~
~1; 1; ~ Cl)
m
3
Cl)
::J
CD
(')
~- .....+
282 240 !\) ~-

-
I •
1,5
I
1,5 Q) (')
ro/ ge sw/gn Q)
;:::;.:
' 10/30 J2ns Cl)

~I.: I.: ""' ~

ru
Cl)
128 19Jli E;
I
0,35
gn~I
0 5
giQ
i i7~R
5.ffll 283
I

I
3/ 49a
::J
(Q
s· cc
:::J
~-

' 1158de ly /88- :\ I ~: :30

0 ,5
gr/gn
1,0
sw/ ws
I
1,0
sw/ gn
I
sw/gn
I ~I swl/gn 2l~ gr/bl
I
1~5. . 1,0 .
rol/ge sw~i:/gn ~Cl)

~
I 214 223 Z\6 311
E 20
'rT5a / 4
! snsa ~ 7/30a
("')
a,.... 0
:::::: ·
1 2/31 1 6/ 85 h
0,5
gr/ gn ,-
l~ '.
Cl)
cc
I I I ~ .......
J.2 i i
E 3••
br 0,5 1,5 1,5 Q)
~3
~ 3
I 1/498

I
ws/ sw ws/ gn ws/ gn 3 / Bl 2/ BR
I
;26_Q I -.1_; I W6 187
I
217
I •
189
I
1,0 ••
213
1
1 0 ••
1.0 •• 1,0 •• 10
--.... CJ)
l.
TT1ob15 JTs113 1,0 0 ,35 1,0
I
r T:_ T· f - I _ _
sw/ gn sw/ ws

T"'w~rn T~ 5
gr/bl

2~3
1,0 1,0 I ~
313
WS/ fTl ws/ gn WS=W h1te
f>:_s <c
'tT2ap11 sw =black
ro =red
WS =Whlt e
sw =black 1,0 0 ,35 1,0 0 ,5 •• 0 ,35
I .. - 1,01
0 ,5 0,35 1,0 1,0 .
<c
~
, 1 , 1

(: L 22 C} L 23
0 ,5
br
gn =green
br =brow n
ro =red
gn =green swr• swr• swrs swr• sw/ gn

I
Ii/bl

I
sw/ gn

I
sw/ gn

2~6
sw / gn
I
119
sw /gn
I
305
sw/ gn
I
21 4
bl =blu e br =brow n 255 118 r~T15di 4

r
295 ,,, T 10113 ' •ff15d r.ff1d
12 t T 5a/3
gr =gray bl =blue
I .. 1 14 I I ..
1,0 1,0
I
0 ,5
11 =violet
ge =yellow
gr =gray
h =VIOiet
0 ,5
sw/ gn sw/gn
0 ,35 . 0 ,35 .
Ii/bl
o .5
sw/ gn
219
I
ge =yellow
l 119 ob~
I
br br

269
--'-
1. ~I I (176,1 _ L81,_ J
1 1/10
429 J
1 1/9
429 J
1 34
23 4
~35
J 429
_T3"s
197 198 199 200 201 202 203 20 4 205 206 207 208 209 210

97-19669 I
97-19670
20
5
22
• nsuJmen t Pariel L1gtit Dimmer $\•11 tcn
·Fog L ght Relay
·Le'; Front Fog L ght
® -G rot.Jnd connect 1on -1 1n instrument panel wiring harness E
J
3
2
·Emergency Flasher Swtch
E'11ergency Flasher Relay
- Ground con nec11on -2-. 1n in strument pane wiring hurness

23 ·Righ t Front Fog Ligh t @ -Ground cori riec t1on. 1n right headligh t wmng harness J 234 · Arbaa Con trol N'ccule Plus connewon (righ t tu rn s1gria 1). 1n mstr ur1rnt panel

T
2ap ·Connector 2 pin. black. beh nd 1nst1ument panel. nght
5
- 6
a· Connector 5 pin b1ack. be 1rd nstrumen: panel. og~t
1 - Connector 6 pin red. conrector stat on A p,llar 11gnt
G -GroJnd connect1on. in le· t headlight vv ring narriess
J
T
T
42

·o
ContrOI moaule Tor cent ·a lochng
1 d ·Single con11ector. brown conl"'\ec tor station A pillar right
t Cornector ~ 0 p,r orange, connec or stat or. A p1 ar ngt'it
wiring harness
Plus connection flelt turn signal\ 1n '1Strument panel
wiring harness
T , O c Ccr~ectar 10 oin. red. conrector stat on A pillar left t;;9\. -G,.ound cornector \serisor rcundl 1- m instrument pare! T 15 d - Connecto r 1 5 pin. btack. connector sta t on A p1 tar right
W6 ·Glove Comoa rtm ent L1gh1 \...J w1r1ng harness

ChaSSIS rumber upto 5000

.. - Chassis number 'rem 500 1

Edition 02/98 Instrument Panel Light Dimmer Switch,

Emergency Flasher Switch Edition 02/98
W42 .USA5602 03 21 Fog Light Relay, Front Fog Light
W42.USA.5 02 03.2 1
~----

Audi A6 Wiring diagram No. 1/18

No. 1/ 19 Wiring diagram Aud i A6
30 - - - - - - - - - - - - - - - - - 30
15 - ----------------------~ 15
30 30
1S is
~1 ~~~~--
- -_-_--::_--::__ ----_:__~--~-=---------------~ ; x x
3i

~
~ J 31 Dl!J
0 -·- ·-1
~~ ~ 7S r. ~

}""~Fr".f1 tf'TT. lro

ge!bl gn/11 swlgr

~ ~ T81/ ~. ~T8il ~ T8il I

bllro bllro grl sw gn/ge wslge
rr
I• I •
,~m.1w·
gn/11 swill sw/li

~
ws/gn

~
; LJ..
E e1
A6t
0 ,3S

I T6acl-
~:Ct____

-
8/53a 3/53e 7/ INT 1 1 1 I
T8i/
4153c 1
T8il
5/HW
1BS
I
i,s
I
1,0
IA~;
I
1.0
gr

0,35
I
'
j~~~~.r.--
./
-:~~ ~ j sw/ ge sw/ge gr gr gr gr

Ii~}~~ ~
roJ12
~2 ~2_
I
1
T6acl
E 38 ,, ~~;3b ~ 1 ~~~ b
' i i 224 (225 r226 I 227 ' 4
116
513i I
S i S 2 S 224 S 22s S 22e · S 221 S 3 S 4
~ - 2SA 30A
i
SA 10A 30A · iSA
1 1,0 1,0
j i
SA SA
O,S
br ~~ g~i~ sw
l lli s£~ ~~ • s~i~n il• ~ 22.i;;- 22Sa 226• i 227a , . . - 1 3• 1 4•

2~5 J15~ ._./

0,S 1,s · 1,s ·· t,0 4,0 4,0 i,s ••• o .s o.s O,S

' rI
2k .h 10el 3 sw/ g, sw / gn sw/ gn b1/ro sw/bl ws /ge sw/ ge gr/ gn gr/ gn

2i7 v r--1' •- I I I
I
- I I

1,5 1.5
~
0,5 i,o
I T20/9
0,35 0,5 0 ,5
236 223 218 229
2,S
L 4 324
I
... T ebt3
209

sw/ gr

·' T 10e
gn/ ge

~Tice
gn/li

lT10012
sw/li bf/ro

lrioa/3'.~Tioa/6
sw/ gn

~T2an tT2ao
sw/gn sw / bl

I J 201 , -
0 T 1m11
gi
i.s· ·· (Q
l 18
I 14
I T" 1 1 11 1 11 +'I_ V 2
,M
sw/ ge O,S o.s
s·
I
i,o 1,0 i,o O,S O,S ~
gr/br gr/ge
sw/ gr gn/ge gn/li
{ !f · 12 TTer/ 4
14 Ct)
m
I.
- '- J J 307
3
'11~.:, tb ct>
1 2153 ' 1/S3b ' 4/S3e ws=wh1 te ws =whi te 2,S 1.s ···

~~~~
sw =b lack sw =black br/ gn sw/r;ie
r ()
ro =red
:::s
V Vs

I I
gn =green
ro =red
gr =g•een I L t0 I.
tb
r+
~-

r
12 br =brown ::lr =bro1Nn 2,S V i2
O,S 0 ,5 bl =blue bl =blue br/gn
(Q
Ct) ()
gr =gray
11 =VIOiet
ge =yellow
gr =gray
11 =VIOiet
ge =yello'N J i2e
12
0,5
3
Ct)
m
:::s
~- ~
239 240 241 242 243 244 24S 246 247 246 249 2SO 2si 2S2 ~ ~-
97-i9672 Q:) ::J
97·1967i
::::::-: C.Q
~ 22 W1ndsh1eld Wiper/Washer Swnch
® E 87 AJC Cort·ol Head

e(§)0
C. 38 W 1ri dsh1eld Wiper !mermntent RegJlator - Ground connect on -1 ·, n 1nstrur--1ent panel w;r '19 ha·ness .. 126 - Ccn~ r o module for •re sh air blov1:er - Ground con1ect101 -2- in rear wmng harness
(!)
F 77 . Windsh ield Washer Fluid Level War"ing Sw1icn
e J 20 · - P~mec t 1on ~10Ce
- Se·ector Lever Light Relay Wire connection !75x). instrumen t panel w1r1:19 harness
0
e
J 31 - Wiper/Washer lntermment Relay -Ground connect ion 2-. In l'lS tr ument panel w1 r1n g harne ss J 307 in

189 ·Au to Check SystefT' S 1 Fuse """'

Ct)
J
-
-
2 an Conn ector 2 pin, washer 1et, le'
2 ao- Connector 2 pin, washer iet . right
8
-Ground corincct1on -3- m ns tr umen pane l w 1•1ng harness S
S
2
3
· Fuse
·Fuse
·Plus connection 158bl, 1n mstrument panel wH1ng harness
:::sm
6 ac Connec tor 6 pin. brown. on windshield wiper · Ground connection, w1r1ng harness heated spray Jet S 4 · Fuse
0 Wire connection (]Sall. 1n NC wirmg harnes s CQ C.Q
s· .....
e
T in

1 n~erm1ttent regu la tor

S 224 ·Fuse
@ W ire connection -2-. NC w iring narness
m
S 225 ·Fuse in
T 8 1 Connector 8 pin. on w1ndsh1eld wiper/washer switch - Ground connector !sensor g round) 1 , 1n 1rs trument pane 1
S 226 -Fuse ~Ct)
T I 0 a· Connector 1 O pin . oi nk. connector s tat io n A oll la r, left
0 wiring harness
S 227 ·Fuse
-
-
-
10 b Connec tor l 0 pin. reo. connector station A pillar left
10 e-C onnec tor 10 p in, vio le t. connector station A p11.ar . eft
20 Connector 20 pin. rea/wh 1te. on instrumen t cluster
-Connect or (53al. :n instrument panel wring harness
T 6
T 6
T 10
b- Connector 6 p n .•vh ·te, corinector station A pillar left
r - Co~nector 6 rin. brown, 1n luggage com panment
f ·Connector 10 pin. brown. connectcr station A pillar. left · Chassis number up to 5000
C') 3
a CJ)
V · W1ndsh1e ld Wiper Motor •• Chassis number from 500 I
V 2 · Fres" Air Blowe r
V
Z
Z
5
20
21
· \/V1rdsh1cld Washer Pump
Left Washer \lozzl c Hea te r
. Right Washer Nozzle Heater
only wagon
· booi h is possible
V 12
X
- Rear W1naow 'v\'tper 'll o!or
· License Plate Lig ht
-only wagon
?5-
Edition 02/98 Windshield Wiper/ Washer,
Fuses, Fresh Ai r Blower, License Plate Light, Edition 02 / 98 :ho m
~ ~
Glove Compartment Light W42 .USA.5602 03.21
W42.USA 5602.03.21 Washer Noz zle Heat er

----
~
(Q
0 I
(Q c.u
~ ()1
 ~ m
s· 0~
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AudiA6 Wiring diagram No. 1/20 No. 1/21 Wiring diagram AudiA6
Ct> I
30 - - - -- - - -- - - - - - --------- -------· - 30 30 - -
15
30 3 w
15 - --
x - -- -- - -
- --
-
- - - - - - -- - - - -
·- --
15
x x - - -- -
15
x nl (j)
31 - - - - - -- - - - -· -- ---- - - 31 31 -
- - - - - - -- - -- - - - - ------
31 :::i
~ 75 75 ~ nl
~ ffi - ffi ~ -
(Q
Ct>
3 m
-
Ct> CD
:::i (")
179
-r
194
-r ~- ......+
2,5 1,5
!\) ......

---·
Q) (")
Q)
-.-
187
1,0
183
.....
1,0
-.
241
1,0
-,-
174
6,0 Ct>
~
gn/sw sw/ ge re """'I

'223 , 9 L ,~3 'j~4 , 15

Ct>
:::i
~-

h '-h,--.---r-
(Q
sw/bl sw/ bl ws/ge ws /sw
1,5
ws/ sw
1,0
ge/ br
1,0
ge/gn IJI m - S 22
~
- s 223 ·- s 9
) ~ 10A
- s ; - - S 13 -=- s 14 .:_ S 15
1 s· :::J
l
sw/ ro SA I 10A 10A 10A - 10A
(Q
2~3 I '
L
-+-l-
l3a _ r
_1_~
1 14
t~ ~ ~(!)
j-123- rl~
328

I '
2• -.
14 / 56bR ' 11/56bl
;,.T 10a - -- - - - - -

r
" T1 ot12 ·" T 6k1 4
T 1 ~
() 0
0 ,35
sw/ bl
1,5
ws/ ge
w~t~w
14

1 15/56bR1
@
I 13/ 56bl1 zo
0 ,5
gr/ ro
0,5
gr/ws
0,5

g:~:w g~~
0,5 1,0

T T
1,0 0,35

r~:w
1,0

r" r
0 ,35

T l
1,0

y1
1,0

re/bl
0
Q. Q)
-·
2 I ~ .. Ct> (Q

rT,,. -~
I I I
1,0 1,0 0,5
4/3 1,0 1,0

F~, r~ r" - A ,
J 429 sw/ ws sw/ gn ge/ ws ge/ sw 255 gr/sw
Q)
___..,
0, 5
~T1oa11 ~T6k12
1,0
f'...-
0,5

I
1,0
267
r
0,5
h
I
1,5

I
ge /ws
6k/3 r
1,5
oa/5 1
1,0
Jr10a12
l
0,5 f'"' 3
-.. en
gef~~:.:wff~.J~~O~n
sw/ ws sw/ gn gr/ ro

l
0,5 1,0 1,0 1,0 0 ,35 0 ,5 0,35 --4.
~
J I
BR 58R 56a 56a 56b WS=Whlte
gr/ ro ro/ bl ro/bl ro/bl
co
T10ae T10ae T10an sw=b lac k
WS=Wh 1t e
sw =black
_l_
~
}r8c11f-@~ co
I /9 I /7 I T10ae/1 1 /1 1 T10a e/5 I /5 I /9

1Sl M 29 0 M 5 C M 1
I /7 ro =red
gn =g reen
ro =red
gn = green
10,5 1,0 0 ,35 0 ,35
~
br =brown ro/ sw ro/ sw ro/ bl ro/ bl

~1-;0ae/8 ; 1 br=brown

~ .8 . 117
1
b l =b lue
1 - - -- ·i
T10ae 1· T10an 1 T1 0an gr =gray
b l =blue
$T1ov/ 5 ill.
/10 /8 /10 gr =g ray E 97 J 429
li=VIOlet
t
0,5
1
0,5 1,5
~
1
1,5
~

1,5
~

1,5
~
ge=yellow
li =vtole t
ge=yel low
0,5
ro/sw

br ~ ~ ~ ~ ~ l tO
-
1§· _~--- __1'i~~ _ ___ 1~~ 1~9 l i si
J 217
253 254 255 256 257 258 259 260 261 262 263 26 4 265 266 267 268 269 270 2n 272 213 274 27s 276 2n 278 279 280
97-19673

J 123 . La-np Control Module S 21 · Fuse

J '129 - Control modu le for central locking S 231 · Fuse
E 97 · McMory Prog ·am Switch z '1 · Heated ou tside mirror, driver side
M I · Le i: Parking Light T G k Connector 6 pin, pin<. con1ector sta tion A p1l'ar. fight
F · Brake Light Switch z5 - Heated OJ ts1de rnirror. passenger side
M 3 R1g'i: Park ng Light T 10 a Connector 10 p1r. pin<. connector s t t1on A pillar. left J 217 ·Transm ission Control Module ITC M l
vi 5 Leh Front Turn Signal L.ght T 1O t . Connector IO p n. orange , conn~c t o r sta:1on A p1ilar riaht
J 429 · Cont•ol Module for cen tral lacking
M I ·Right F1ort Turn Signal L,ght T 1O an ·Connector IO p.n. an head'1ght . le ft
S 9 - Fuse
M 13 . Left. Side Turn Signal L1gh1 T 1O ao - Connector IO pin. on head 1ght. right S 12 -Fuse ·Plus connection 130al, 1n instrum en t panel wiring harness
e/ 19 . Right , Side Turn Signal Light S 13 - Fuse
M 29 . Le't Low Beam headlight S 11\ · Fuse - Wire connect ion 154!. in instrument panel wiring harness
M 30
M 31
· Lei t High Beam headlrght
. Right Low Beam Head light
G -Gr ound conrcct1on . n r ght headhgt-t w nr.g harness S 15
S 22
. Fuse
· Fuse · Plus connection (30d) , 1n power win dow/central locking
1 32 . Righ t High Beam Headl ight 6 -Ground connecti on. in left heaa\ 1gr~ w 11ng rarness S 223
T 6
- Fuse
k Cornector 6 pin , pink. connector station A pillar. rig h
sys1erT' and door contact swi tch wir ing harness
S 5
S 6
S 7
· FJse
·Fuse
· Fuse
8 Plu s connection I 15a I), 1n instrum er·t pare I w 1r ng ham·
ess
T 8
T 1O
c - Cornector 8 pin , black, 1n driver 's door
h - Connector 10 p n. black, conn ector station A pillar, left
S ·8 · FcJse T 1O t - Connector 10 pin, orange . connec tor sta tion A pillar, right
T IO u - Connector 10 pin. black. connector station A pillar. rig ht
S 19 Fuse - Vehicles w ith f1ont w r eel drwe T 1O v · Co rnector 10 pin. brown . connector station A pillar. right
S 20 · Fuse
T 15 a · Co r,nector 15 pin. black. connector station A pillar . left
Edition 02 / 98 Pa rking Light, Si gnal Light, Headli ght,
Fuses, Brake Light Switch Edition 02/98
W42 USA 5602 .03.21 Lamp Con t rol Modul e
W42 .USA5602 03 21
 Audi AG Wiring diagram No . 1/22
No. 1/23 W iring diagram Au d i AG
30 ----- - -- - - - 30
IB E
x - x
31 - - - 31 30 30
t5 15

~75 -~t~~Jfu ~
x x
31 31

~85 1
3/ 30 I ~ ~
--- s1m S1 1s21e1H ----- ----
/30ah 17(!
0 ,35 1,5 2,5 1,5 257
I

I
br/ ws ro/ws sw/ r;JS 0,5

t~
J 1S9 J 189
~ 2h ~ T20 /19 T20/t~
sw/bl

I 238 'i' 2J9"y;;o_ _ _ (24~ \ 242

3
I 268
,- -~·T1ow15
I
29 211 21n6 I
r 8 238 8 239 0 8 240 ~ S 241 ] 8 242 ) I r;i 8 2~\ o~s gr/0~5ge ro/t~Osw r~f~w 0,35
ro
0,35
gr/ Ii
0,5
gr/ws
0,5

T
sw/ ro
1
~ ~~ , i W~A_j
I I
,J 15A · - - 15A 25A
I. 2388 r - ' 1 2398 1 2408 I 2418 I 242a ·~33a
t/t5
. ....!_ - _ 1
t8/ 58L I 5/54
--
I 7/54HE
l
- --- om
3/KB ' 9/KS ' 10/58R

r·:
1,5 . 1,5 .. 1,5
ro/g<i ro/g<i ro/w s F 125 -~
r
- - J 123
~J: 2~ tlh 28§

1,5
ro/bl
-1
,_---'.'._
2,5
sw/ge
,-,
E n2 2t3
-1, 58blt
t7/ II S/54L

308
I"""· , , ,.,. t91
1,0
bl/ ro
· ~ Ttow12
I
·~T10t18 I I I
I t, O 0 ,5 t,0 1,0 t,O t,0 0,5 1,0 t0 1,0

~
T 1,5
sw/ ws gr/ sw ro/ ws bl/ ro ro/ sw ro/ ge gr / ro sw/ gn
1,5 1,5
grr ;6a 1tb1,1ro
ro/ bl sw/ge sw/ge
cg_
III I
! T 10119 ·!Tto111 ·! T6a12·! T 1011s !Tt b ! .T6a /6 '' ·1io112 ·!Tto11to

I O TI ,283
I
lTs 114

r
l T1ob11
T 1,5
3~!!
0 ,5 1,5
I -.-
310
0 ,5
IIl A 81-
~ m
T.
1,5 0 ,35 1,5 1,5 1,0 0,5 t,0 t.0 t,0 t,0 t.0 0 ,5 1,0 t.o t.o
ro/bl gr/bl ro/bl gr/ bl sw / ws gr/ sw ro/ws bl/ ro ro/ sw bl/ ro ro/sw gr/ ro sw/ gn b1/ra
3
TT
ro/bl br/ws
'NS =V.hltC I_
ws=wh 1t e 298 tl)
~ 11/TI ,, T 5ci/3 15 sw=black 5w=black
J 429 if_' 2 -~--1 ,--;__ I ro ~red ' 3/ BL ' 5/ 58L ' 6/54 ' 1/RF ' 1 ' 1/RF ' 6/54 ' 5/58R ' 3/ BR ::::i
I ' 3 L ' 2 ' 3 ro=red
tl)
--1 ~ " ~ "1
gn =green · Ms " M• · M9 ·: M16 -.· M 25 ·:: M11 " M10 -: M2 ::· Ms (Q
'.:::i ~ H 1 ~J-b.: : I H 2
L 28 q; :( ; L 28 '.;

-, 12 -r
1
1
br=brown L •6
~1.: IH ~ -'----" LJ 9 _ __i _ _ _ J
bl =blue
ct> OJ
~
U 1 I

l2
b l =blue

r r
gr-grav 1 4/31
gr =g ray I =v1ole1
1 4/31
3
~ -·
~
'•T 5d12 II =v iole t ge =yellow
r 10
12
0,5 0,5
I t,5 t,O t,0

I
ge= y ellow br br br t99 br br
1,5 1,5 1,5

--~- I~
0,35 1,5
~
_k J ~ bf

L'179 - L~
br

J01 ~ ~ m ~ - =
( ss J
D
i
= =
87 (

304
as

305 306 307

8
7

30S
I\)
OJ :::J
~­
281 282 283 284 285 286 287 288 289 290 291 292 293 294 97-t9675
::::-: co
u 9 - Rear Crga•ette L1gh1e·
97-20354 F 125
J 123
-Mu:1 -~JrCtrcn-ranSrT' l$~1or
- LamD Control rv' o du 'e
Range (TPJ s. .·JtCI
0 Ground co'1ncc t1on 1 1'1 rear v".'rrng hJrness

~ 0
H 2
Bu:tor
Tcne Horn
8 h€l~ness
J 169
L 46
Auto Cncc< Sycte'TI
- Le ' : Rea· Fog Light 0 G·0 .... nd cor.ncct1on 2 1n rear v.1•1ng harrcss
ct> -
H 7 - ~ow Tone !Corr -Ground connection -1 , in 1rstrument panel w 1nno M2 R1gh1 Tai Ligh t
0 G·ound cor;nec11or --2-. 1ri instrument pane w:ring har1ess
::::i OJ
J .J - Dual f-'orn Reay
G- M tl - Le ft Ta I L_rg ht

8 - Grourci cornec11on -3-- nstrume'l t panel w1r1r.g harress (Q co

e-
. J ~29 - Centro '110dule for centra :oc,ng Ground conneC11on -2-. 1n 1nstrumeot panel wring hilrness f\I 6 '_ef · Rear 1 urn Signa l _19".i 111

~· 03
fv1 8 - Right Rear T Jrn S1g ..•n L1gt-t
15 - Ash: ray Light
28 - Cigarette Lig hter L1gh: Grouna connccuon. n right hca'.:ll1gh1 wiring harness M 9 ~cft orJte _19'11
e Lrgt-t
@ Con1ector (m--1. 1n instrument panel wiring harness

233
238
=use
- ruse 8 -Grounu connernon. o lef· headlight wiring harness
M 10
lv1 16
M 1I
- ~1gt-1 Brat
Lef · Sac< Up _19•1
- ~1gt-t Bacl -Up L1gl1t
~ 3
239 - Fuse
2-10 - ruse G -Cornec tor (Horo 87hl. 1n 1ostrJment panel wiring harness
M 75
-; l
rl1gn mcunt Bral e L ght
b - S1rg e ccnnect or black. cornecto: s tC!t .on A pJa· r 1CJht 8 CJ)
/:.'

5
Fus~
24'.' - ruse
d Connec10r 5 pin. behind steering co.Jmn switch cover
8- Plus connec t roo (30al 1n power wir··dOV\/central lodrng
sys tem and door con:act switch wiring 'larness
T
T
T
6
10
u Ccn.1ector 6 p1r blue. corirec:or stJ:1on /\ D•llar lef!
Ccnnec: or 10 n·n. brown. corweC:;Jr Stdt 1c:i A p.l'ar. lelt
1O w Ccnriec ~ or 10 p n, b ue connec tor s:a11on A pdlar. r1gr,1
-booth 1s nossrble §-
6 - Connectar 6 pin, ·ed. connector s1a11cn A pillar. rrght
10 o Corv1ecor 10 pin. red cornec tor stat on A pillar, le't -Chassis nJmber upto 5000
T 20 -- Ccn1ector ~O p1r~. reJ/wh1re. on 1nstrim·ent cluster
~ m
~ ~
Auto Ch eck System, Tai l Light, Bra ke Light, Edition 02/98
10 t Connec:or I 0 p•n orange. conn~c:or s1a t 101· /\ µ lla1 r 1gh: Cl ass s numoer from 5001
U 1 - C1ga· et1e L.gh1e· Rear Fog Ligh t W 42 USA 5602 03 2 1
Fuses, Horn, Cig arette Lighter
Ed it io n 02/98
W 42.USA 5602 03 .21
~o
(,Q I
<o VJ
~ -....J
 rn m
::J
:J" 0~
(Q
No. 1/25 Wiring diagram Audi AG ([)
Audi AG Wiring diagram No. 1/24 I
3 w
tu
30
15
x
30
15
x ::J
CX>
30 - - • 30
E ' E 31 31 tu
x x

~
~ - ~ (Q
([)

~ ~ 3([) m
::J CD
.......
~
()
r-+
1 30- j 217
~
I ~ ~.
1 25

-
1,5 4,0
Q) ()
ge/gr 0,35
Q)
~ 236 sw/br
::::+:
rl~5~;;;
'- S2372a1 1 245
I 126 320 ·~T1ov12 ([)

~
4,0 I I I
'--:- 2~
I 236a I 237a
ws / ge 0,35
gr/ge
0,35
ws / gn
0 ,35
sw / br """
([)
4,0 E B7 E is ::J
'-
1,5 ' F2
grl gn
_._ ro/bl , 4 , 7 (Q
Jfill 16 0 I
2,5 l. 7 _l} :..· p R N o 4' B3
' 5

2
Ye :s- (Q
~([)
:::J
ro/bl
+28 ,8 °C
W 1a I Ill Ill
G loe 0
Wm
I
·;iTiox15
I
1 Fl '1 I 2 I 3 ' 10 rs '9
0,35 1,0 ([)
n r/hl 4,0 (Q
ws /11
):::.
tlT10;1e ·'1Ta111 I I 89 I '
Q)
~
A12 07
r,;~ I 1Tea14
I
0 ,35

rfl r_.~
1i5 2i 0
0,35 0.5 0,5 . 0,5 4,0
0,35
sw/ro
0,35
br/ws
0,35 br/ge
3
I I
..-.,
A~
en
rr -r-rA
brL J
A2~

0,5 0,5 0,35 0,35 0,35 ••

r '"'" lTa11a
0,35 0,35 0,5 0,35 0,35
27
WS=Wh1te
sw=block
ro = red
gn ~ green
WS=Wh1te
sw=black
ro=red
r~ z,
-~
I
1,0
sw/ro

2~;!
0,5
sw/ro
0,35
br/ws
g
0,35
br/ge
~,

A13! """'
(Q
(Q
~
· ~'1iob/2' ~'T 1ob/6
I

1
gr/bl gr/bl gr/bl gr/bl gr/bl gr/bl ws/ gn ws/gn ws/gn ws/gn
gn =green 295
~1 ~ ~ i~ ~ L br=brown
I I I
I I I
bl =blue br=brown
C7 •iTi Ow/8 ••IT1ox/6 ·oiT1sd110
E a1 I I I0,35 gr =gray
11=VIOiet
bl = blue
g r =gray
0,5
br/ws
0,5
br/ge

Li'
0,35 @ 0,35 1,5 ge=ye llow
.
gr/bl gr/bl bf ws/ bl
II =VIOiet 2,5 0,35
ge =yellow

J~
1 I 4115 br br

L 1s J 429 ./ G ,1 1 199
~35~
~ m ~ w m ™ n n w a n = ~ = 1 .
75 1

97-19676 ' 323 324 325 326 327 326 329 330 331 332 333 334 335 336
:. 67 -AJC Comrol head 97-19725
J .123
_
- Co'ltrol rnodu,e for cen t·a l 1oc>'.1ng
19 - .\ ... t:>mat1:: -rans'Tl1ss1on Cor.so'e c.1g,: 0 -Ground connection on le:~ A-pillar. lower oan
E 15 Rear W1ndcw Defogger Sw.:ch
0 Ground connect101. on r g1t rear ptllar
S
S
:36 c:use
F11se B - V\11re cc ..,,..ec~·or t58sl. 1n mst·umer't r:anel w1r11g harness E 87 - A/C :crtrol Head

7
T
237
3
•Cl
:::onnec:.~1r a prn_ blad ccnrec tor r3d10 II
Conncc~.Jr : 0 r··'1. dar'...brn1,vn. cornector stat er A p1'!a~ 8
!Sw tch 11lumna11orl
-'Wire -:o;ir.ec~1on (veh1:1e s::ieed s.ara1J 1ri 1ns:~u,...,em oane
'v\-'1r·ng harness -
G
G
·7
106
· Oc:s1d2 A,r Temperatcre Se1sor
Ous1dc Air Terrperature Display G ~Grourid connect.on -2-. 1n AJC w1r1ng har'iess

-
le·t
· O ·,/\/·Connector 10 p.n. blue. connector s:at1on A. rnlla• 6 Plus conrert10~. 1.30asi, 1n .nst'~.men : ua'1t>I w111ng harness
J
T
217 · Traos-n1ss•on Control Module ITCMI
6 a· Connec:or 6 p n. blue, connec1or s:a t1on A pillar, left G -Ground connec:1ori 2-. 1n 1rstrumerit panel w1r1ng hdr'less

T 1 O x Connector 10 p.1. pink_ co;inectc~ sta:1on A pillar,

- · O ti · Conr~ctor I 0 pin. red. connector st atoon A p'llar. left
8 -Ground connection -3-. 1n 1r.st"ument pane wn'ig harness

e
- , 5 d Connector 15 P·n. blaci.... con1ec:or stat ion A pll:ar T · O v - Con rector IO 011. brown. connec10r station A pd ar righ1
W ·3 - R1gr: Front Map/Readong L•ght v 6 - Transmission Range IT=il Selector _ever Display Wire con'iect1on (15al. 1n instr .imer : panel w1r.ng harress
W -9 - Le'· Front Read1og Light Z 1 - l--fea1ed rear window

G ·Connector (ou tside te mperature 1nd,catorl. 1n 1nst~umerit

panel w1r 1ng harness
-Chass:s number upto 5000
Chassis number from 5001

- booth 's ~oss1ble

Edition 02 /98 Connector Radio, Wire Connection (58s ),
W42.USA5602 03 21 Wire Connection (Vehicle Speed S i gnal )
Outside Air Temperature Display, Edition 02/98
Heated Rear Window W42.USA.5602.03.21
Audi AG Wiring diagram No. 5
No. 5/1 Wiring diagram Audi AG
30 30
Driver's Information System 15
x
15
x
31 31

1998 m . y.

Fuse Panel

Fuse Colors : J 220 \

r
·1 -

i
30 A - Green ·~p

25 A
20 A
15 A
- Wh11e
- Yellow
- Blue
0 .5
ge
i T6x/ B T6x /9 t T6x /10
R

I
10 A - Red 0,35 0 ,35 0 .35
gr f ro ro/ br ro / ge
5 A - Beige
" T 10013 ~T10x/9 JT1 oxn ·~T10x110
I I I I
0 ,35 0.35 0 ,35 0 ,35
ge gr /re ro/br ro/ ge
Sta rt ing with fuse posit ion 23. fuses 1n the fuse holder
are 1dent1' 1ed w th 223 n t he wiring d1ag'a'T1 ' T_20 /1 ' T20/12 ' T20/ 13 ' T20 / 15

£; J 189

13 - Fold Relay Panel

Relay Location :
i f 12o111 120 /141 T20 /18 I T20/9-

IJ -_aMo Control ModJle, J 123 0 ,35

gr
0 .35
bl
0 ,35
gn
0 ,35
br/ ro

m- l m
Lamp Cont ·ol Moaule , Jl 23
\VS =White
sw =black
ro =red
~';
4 ' 2

CC•
, 1

r
I tOa/ 6
, 1

\:
Fn
CD
()

ET
E 91 ,....+
gn =green
br =brov,n
0 ,5
12
0 ,5
--.
b l =blue
gr = gray
br / ro br ()
Ii = v io let
ge =yel low
!,,T10b13
I OJ
0 ,35 0 ,5

I ~~~. ~
br 4r
br0 :l

L§ 1 1~ ~t
-
r·"·
~~
tO 12 13 14 ~.
97-19732
::J :::J
C/)
CQ
E
E
91
92
- Board Computer Funct 10, Selector 5W'tch
·Board Corrputer Reset Button - Grouna connect.on -1·. n instr JrPent panel w iring harness 2
F
J
77
189
- W1ndshre ld Washec Fluid Level Warn ng Switch
-Auto Check System - Ground connection -2-, 1n 1ns:rument oanel w ir ing harness 3 0
([)
::J tu
J 220 - Motron1c Engine Control Modu le IEC M I
R - Radio - Ground connec t1on -3-. :n instrument panel wmng harness
6 x - Connector 6 pin. green, conrector radio I - 2
10 a· Connector 10 prn. prnk. connector station A pilla r. left - Ground connector (sensor ground) -1-, 1n ins tr ument pane l
w1rmg harness
en- CQ
--.
10 "b · Connec or 10 01n. red. connector station A pillar, left
10 o - Connector 10 pin . brown. connector statron elec tronic
0,)
::J
tu
box plenum chamber
10 x - Connector 10 pin. pink. connector station A pillar. rrgh t
20 · Connector 20 pin, red/w'111e. on rnstrument cluster
Q 3
CJ)
• - booth 1s possible (")
0
::J
Auto Check System , Board Computer Funtion Selector Switch, Edition 02/98
..........
C3 m
Edition 02/98
Windshield Washer Fluid Level Warning Switch W42 .USA.5602 03.2 1 Vi"
.-._ ~
W 42 USA. 5602.03 21 --4. 0I
co
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m
AudiA6 Wiring diagram No. 5/2 No. 5/3 W iring diagram AudiA6 2 0~
3 I
CD
30 ---~-----~------- --- - - - 30 30 - - - 30
:::i ~
lS -- - - - 15 -
x31 ---~--------
-
--- - - x
31
15 - - - - - - - -
x
31
-
-
15
x
31
Ci)" 0

~
tl)
I
~ :::i
Q. m
I
CJ -
CD

, u
1S
0
()
rs
J 217

0 ,35
8 -,- ,--,-
2,5 4 ,0 O,S ,-~-
(~
1A s1
\

I
:::i
a"Ci)'
"'"+- .....+
......
()
1,0

-~-~ _ )TS5
ge ge ge
--.. Q)
-
s-
'f"'"
0 ,35
sw/br
I
0 ,35
gr/II
0 ,5
sw/ro
11;~ro 1
swt . . J
10A I

sa
1
.'

1S
E1
1 4/ 56
·
1

.'
__!_
- S 21
21

12;; --
- 10A
-
-
L 2

~
-S20 )
10A
-.l
co
co
~
~
' T~ ~-

.J~
D
+ •_1e____ · -- - -- - l -
, , T20/16
::::J
(Q
1
J1e9
-- _'[JIl! / DEJ
1,0
ge / gn
1,0
ge/ br

I
~-­
® C£J
_____',. J 123 ' 1115sbL J 123 D El ' 14/56bR
0
I 3/ KB 2/ 31
'
·
\ c ).JJ
~
o'3s ~i2) I
r
·--· I 13/ S6bl1 1 1S/S6bR1
(Q
......
r.~ brt•
I
0,35
br/ ws
0,35
br/ ws
0 ,35
'"

-.
38
0 ,5 1,0 1,0 O,S
49
I Q)
A_~:il T
0 ,35
I
~T1ob12
0 ,5
E e1
t 12 'i gr/ sw

·~T10a12
ge/ sw

~T1oa1s
ge / ws

h sk/3
gr/ ro
J
~Tskt1
3
CJ)
br/ ge br/ ws
WS=Wh1 te T T I
I 01 ,1 sw =bl ack WS = Wh 1te
0 ,5
gr / sw
1,5
ge/ sw
1,5
ge/ ws
0 ,5
gr/ ro

E e1
~
ro =red
gn =gree n
sw= black
ro= red I T10ann I T10an/ 5 J56b
T10ao/5 I T10aol7
G 17 ~ c br =brow n 1 SSL 1 58R
I 56b 1
E e1 gn =green

r rs bl =bl ue
gr =gray
br =brown
bl =blue
g M 31
- § M 3

I;~oan I
II =VIOie t

I 4I@
~0 ~~
0 ,5 0 ,35
gr =gray 1 31 I 31 I 31 I 31
br/ ge

~T1ob1s
r
br/ge
br 0br,5fs9J
ge =ye llow
II =VIOie t
ge=yellow
TlOan/ 10
I T10ao
/ 10
T1 0ao/ 8

8~
1,5 1,5 1,5 1,5
_ br br br br

15 16 18 19 20 21 22 23 24 25 26 27 28 __!§ l g J0d @_ -------

97-19733 J 29 30 31 32 33 34 35 36 37

D ·Ignition/Staner Switch -Groun d connection -2- 1n NC wiring harness _!ll-197341

E 87 · AJC Con tr ol Head
Ground corf'lection 2- 1n instrumen t pane: w 1rmg harness E 1 L1gh: switch - Ground connecMn. 1n right headlight wiring harness
G 17 - Outside Alf Temperature Sensor
J 123 ·Lamp Control Module J 123 · LaMp Control Modu le
J 189 ·Auto Check System -Ground con nection -3-, in instrument panel w1rinq harness M 1 · Left Par( .ng Lig ht ·Ground connection , 1n left headlight wiring harness
J 217 - Transm1ss •on Control Module ITCtvll M 3 · Right Parking Light
M 29 - Wife co~nect1on 156). 1n instrument pa ne l w111ng harness
s 5 ·Fuse - Plus connec tion (15). 1n ,nstrument nanel w1rn1g harness ·Le ft Low Beam Headl1gh1
T 10 b - Connector 10 pin. red. connector station A pdlar. lelt 1 31 Right Low Beam Headlight
T 10 v - Connector 10 pin. or own, connector station A pillar. right -Wire connection !l 5a) 1n instrume nt panel w111ng harness S 20 Fcse
T 20 - Connector 20 pm , red/wh ite , on instrument clus ter S 21 · Fuse
-Connector (ou tside tempera:·,;re indicator) 1n 1nsuument T 6 k ·Connector 6 pin. pink, connector stat ion A p•llar r ght 0

oanel w1 r1ng harres s T IO a - Connec tor 1O pin, pink, connec tor station A pillar. left
T IO an- Connector IO pin. on headlight, left
8 ·Ground connection. on lef t A pillar. lower pan
T I0 ao· Coonec tor 10 pin . on headlight. 11ght

G -Ground connection- 1-, 1n instrument pane l w iring harness

-boot h 1s possible

Edit ion 02 / 98 Auto Check Syst e m ,

W42 .USA.5602 03 21 La mp Control Mod ule
La mp Co nt rol Module , P ar king Light, Edition 0 2/ 98
Low Beam Hea dlight W 42 USA 5602 03 21
AudiA6 Wiring diagram No. 5/4

30 - - - - -- - - - --- - - - 30
15 - - - - - - - - - - - - - 15
x x
31 - - --- - - - - - 31

-1 1
CB
-, -- r
(A ~

1,0 0 ,5 0 ,5 1,0
gn/sw gn/sw F gn/ro gn/ro

I 223 I ,3/58LI
2
I
El
t4 /58 R
L2
~ S 223 , E
1
1,0 \=S-;;-'•I

A
"-UlI
- 5A ro/sw , - SA ,

~ 223a
~
/~ I
...._ / 1,0 0,5 0 ,5
0 ,5 0 ,5
1,5 ro/sw
gr/sw gr/ge gr/,ws gr~ro
-• 29
ro/sw
37

' 18/58L I 5/ 54 I 7/54HE J 123 El!iJ !__10/58A

I I 8 /5 4L 17/58b L1
CL·
- , 6/5 4H i i 4/54R 12/5 8bA1
THIS SPACE INTENTIONALLY
1,0
ro /ws
0 ,5
gr/sw
1,0
ro/sw
1,0
ro/ge
0,5
gr/ro LEFT BLANK m
-~T6a/2 ~T10111 h,b -h 6a /6 !.T10112
I I I r I WS=Wh1te CD
,,
1,0 0,5 1,0 1,0 0,5
ro/ws gr/sw ro/sw ro/sw gr /ro
sw =black (")
ro=red ,..-+
gn =green
' 6/5 4A ' 5/58 R
br =brown
:::! .
' 6/ 54 ' 5/58L
bl =blue (")
" M 9 -: M 4 & M 25 ~~'?_} M 2
12 1 4/31
g r =g ray
l1=v1olet
OJ
1 4/31
I ge =yellow

~
1,0 0 ,5 1,0
br br

- -·
br

~ -- 1 86 _1=~6 _ __ ......
38 39 40 42 43 44 45 46 47 48 49 ::J :::J
97-19735
~co
"""I
c: 0
E I - L1aot sw'tch
F
o 123
- B~ake Lig ht Switch
- Lamp Control Module
® Ground conriec t ion -1 . tr rear wiring nrirness

:3 OJ
-
~
-Wire ccnnec11on (54 i. 1n 1nstrurnent pa'"lel wirmg harness
I/ 2 - R•ght Tail L ght
M4 - Left Tail Light (t)

~~
-Wire connection l57LI. in 1nsuJment panel w1nng harness
M 9 - Left Brake L•gh;
M '0 - R gh1 Brake Ligh t
\i 25
S 22
- ....... 91-mount Brake L gh~
. ruse
8 -V\'ire conneci1on (57R) 1n ms : rurien~ panel wiring hl1rness
Q) OJ
S 223
T 1
r 6
- Fuse
b Single connector. t"i!aC><. connector stat on A pd lilr right
c1 -Cor·.nectc:- 6 oin. blue. connector station A ::Hiia• eft
::J
Q
3
CJ)
T 10 f - Ccrnectcr 10 p1ri, brown, connector sta:1on A pl 1ar ·e· t
(')
0
~ m
C3
en- ~
Lamp Control Module, Tail Light.
Edition 02 / 98
Brake Light
W42 USA.5602 .03.21
~o
(.() I
(.() ~
()) ~
'-....::.
Audi A6 Wiring diagram No. 12
No. 12/1 Wiring diagram Audi AG

Power Window 30 - --<I>--- - - - - -- - -- - - - - - -·

15 - - - • - - -
x . -------------------~
- - - 30
- 15
--x
31 - - - - - - - - - - - -- -- - - - - - - - - 31

1998 m. y.

Fuse Panel

Fuse Colors:
30 A - Green ~, E4o ==-==--_,.-
=-===
25A
20A
15A
10A
- Wri te
- Yellow
Blue
- Red
I I
2.5 2 .5
:--===
. I
1
0 1
~'\:
0 1
•y='\: i'
- I b

c
auf
7,5 A - Brown ----·~-----~~
I 14 ' 15
5A - Beige
mf
S J7 - .:.
1 f, m
-=r s 43
re/ gr

;.i· h
Starting wnh fuse ~os1 11 00 23, fuses 1n tr.e Iese nolder
are 1dent1f1ed wit~ 223 1n the wiring diagram .

2,5 2,5 2,5 2,5

i~
0 .5
38
I
0 ,35
,-
54

0 ,35
, ,- , -
41
0 ,35
61
0 ,35 2,5
1

ro/ gn ro/ gn ro/sw ro/sw ro/

J
(Q
Micro Central Electric Panel
lTT~~·r~~·r~~·i r1" l
3n/3l
"'T3n/1 "'T15k
/ 10
/ 11
"'T15kfl

l
.......
Ol
3
2 .5
ro/gn
I .
..lli
2,5
ro/gn

~
2,5
ro/sw
_. _
~
2,5
ro/sw
L
Ji§_
~35

re/gr TrII i •r: L

o~ ~35 ~35 o~ ~35 0 ,35 2 ,5
(J)

~
WS=While
sv; =black
ro =red
gn =green

I I I br =brown
bl =blue
A B C gr =gray
li =viol et
ge=yellow

8 - Fold Relay Panel 10 12 13 14

97-19766
Fuse Location :

m- Power W indow C-rcu1t Breaker Front. 537

E 40
J 295
- Le': =·ant Window Sw:tch
- Lef: =·ant Powe· Window Comrol Module 8 ·Ground connec11on, on left A-p1l 1ar. lower pan

m- Power Window Circuit Breake r Rear . 543

~
S
tOS - Door Opener lllu'111na:1on. Driver's Side
37 - Power Window Circu it Breaker Fron t G -Ground connect1or -1- . rn power w indow w iring harness
S
T
43
3
- Power Window Circu t Breaker Rear
n ·Con nector 3 pin, red, connector s1at1on A pillar, left @ -Ground conn ect ion, 1n or1ve ~·s door w1r 1ng harness
T
T
5 t ·Connector 5 pin. black. 1n drive r' s door
10 ag - Connector 10 pin. re d. connector station A pillar. right G - Pus connec11on 130). in power window wiring narness
T I 0 ah ·Connector 10 pin. re d. .n B pillar, left
T 10 a1· Connector : 0 01n. red. 1n B pillar. rig nt
T 15 k - C~ nnec t o r 15 pin. red. connector station A pilla r. left
V 1l - Left Window Motor

Left Front Power Window, Edition 10/98

Power Window Circuit Breaker W42 USA.5602.04.21
Edition 10/98
W42 USA.5602.04 21
Audi AG Wiring diagram No. 12/2 No. 12/3 Wiring d iagram Audi AG
30 - - - - - - - - - - - - - --- 30 30 30
15 - - - - - - - - - - - \5 t5 t5
x -- - - x x x
31 - - - - - - --- -- 31 3t - 31

~ - ~ J 429 J 245
0 ,35 0 ,35 f 4/19 1 3
sw/gn i' E 41 E 53
I
0 ,35 0,35

·~Tl5k12 ~ ~-=- -=----==-~ ~

r-y · V ~ -~- )~
f,T15k/3 Sf ~ :'-- 0 1 :- -
ro/br ro/br Ii

J¢'' ·~ V-'C ' i1i5dn ~T10113 J

0 ,35
ro/gr

·1
~ -,
0,35
sw/ gn

'~T10
'i eg15
0 ,35
j s

r
·"T 10.g12
0,35
gr~ c

~r"T10ag/9
euf

I' 2
•
zU

'ls
• c
C•i
~ut
' Y ~ ---
., r-- \· 0 ,35
ro/br

Lr
0 ,35
rolbr
r T t5dt8
0 ,35

I
r
" Ttodn
r
0 ,35 0 ,35 0,35 0,35 0,35 0,35 0,35 ·o-T1od11
ro/gr

~tgr T: E 101 t ·-
WS

·cili
sw/ gn

L!J 0 ,35 0 ,35 0,35 0 ,35

i
0 ,35
fl
I
0 ,35
)~
0,35
f
0,35
I
0 ,35

J I 1 6~1
sw/ ge br/ro Qe /sw ro/br rolbr ro/br ro/br
-'--------.-,-------"-- ----'1_ _ _ _ _, "l

24
---.- r:jg
---.-
"" 1-+e
lg
8
"/•

41
I
~
11 J 429

rr
J 245
I
"'T 15k/e
I
0 ,35
sw/ge
I
'i"T 1oa1n
I
0 ,5
br/ro
58
0,5
1
br/ro
I
" 'T 15k/5
I
0 ,35
ge/ sw
II
0 ,35
ro/br
56
I
0 ,35
sw
Q 49
I
0 ,35
ti
0 ,35
Ii
0 ,35
II
0 ,5
ro/gr
0,35
ro/br
0 ,35
rotw
0 ,35
Ii
0,35
ro/gr
0,35
ro/ gr I ,k;::! I I I l ~ s's
·~ T1oag ~li5d1JJ.Tto1110
··' T t0ah12 "'T toah " Tt oah/5 " T 10ah/9
I
I
_A T1oag r•·T 10ag
I i: 87
' •' T toah/6

I I I 6.7 I
14
I I
'--'I t3 1 14 In 6.81 _61- I
I
0 ,35 0 ,35 0 ,5 0 ,35 0 ,35 0 ,35
m
t
0 ,35 0 .35
0 ,5 0 ,35
re/gr
0,35
ro/br ws/sw
0,35
ws/li
0 ,35
Ii
2,5
reign
0,5
ro/gr
0,5
ro/g;
0 ,35
ro/gr
0 ,35
ro/ g;
WS=Whlte
gr/bl
.L t>rl ro qel sw

CD
!8_ l1 k::
Vv'S=wh1te
sw =black ' 8 E 52 ' 2_
T r rr J 297 j 8

u·
()
'1 '2 '3 '4 }
J T toa J T toa l
r 13 1 13 ]
sw=black
ro~ red
gn =green
ro=red
gn =gr en
'7
0' ........ • /1 r~\ (Si ........
.......

r-r
br:::browr I 3

r
0 ,5 0,5 0 ,5 0,5

r r
br=brown V 26
()
I
J 296 ol =blue

'°U~ J~r
bl =blue

.! JT1oag
I 11 ~l 0 10
gr =gray
11=v1ole1
gr =gray
II =VIOie t
ge =yellow 0,35 0,35 2,5
h
I
2,5
oah l
1t
2,5 2,5
ro
ge =yellow ws/sw br br bf ro/sw

~
2,5 2,5 0 ,35 2,5 0,35 0 ,5
bf

I lioJ_8g
bf
'i55 bf

l20e
rolgr
d_
gnr

1~ I§ J reg
3
I

15 16 fl 18 19 20 21 22 23 24 25 26 27 28
29 30 3t 32 33 34 35 36 37 38 3g 40 4t 42 ~-
g1-t9768 ::1
4I R1gh1 Fron\ Window Sw11ch
97-19767

Ground connecti on 1 . m power window wmng harness

J

E 52
E 53
- Left Rear Window Sw1tc>i. lln LR Door!
Left Rear W·noow Switch. {Jn Console)
0 Ground connection 1 1n power w ·ndow w1r1r.g ~1arness
co
· 07 - Swi tch for window regulator, 1n passenger door
2.15 Power Sunroof Centro' Module Grourid connection in passenger's door wiring harness
J 245
J
- Power Sunroof Control Module
297 - Left Rear Power Window Con rol Madu e
@ Ground ccnnect1ori 1n eft rear door wmng harness
0
@
296 ·Right Fron\ Power W.ndow Control Mode le
J 42 - Co. rol module ~or central lockmg Plus connec ion (87\, in power w ndow/central locking
J
T
429 Control nodule ior central locking
10 d Connector 10 pm green. connector sta' 1or A pillar. eft
S
-Conrectcr !open). "'w:r:"'g harness int erior
ro
1
L 0
- 5
10
- Door Opener lllum1nat1on, Pass enger' s Side
c ·Connector 5 p.n. blac•. 1n passenger's door
- Connector 1O pin. reen . connector station A pillar. le ft
systerr and door con act switch w1rmg harness T 10 1 ·Connector 10 p1~ dar~orown. connec~or stat1cn A pillar
left
I O ah· Conn crnr · 0 pin, red. 1n lef t rear door
Ccnnector lclosedl H"l w1r,.,g harness 1r"Jtcr or
co
.......
10 1 - Connector 10 pin. darkbrown. connector s 1 a~1on A p lar
left
l O a1 - Connector 1O pin. red. 1n righ t rear door
15 d - Connec:or 15 pin. black, connec tor sta\lon A pillar nght
15 k - Connector 15 pin. red connector station A pillar. left
ro
T 10 ag- Connec ior l 0 1n. red. in oassenger's door T
V 26 Motor for window regula tor. rear. left 3
s
- 10 ah- Connec or 10 p1ri. rea . in left rea r door
~ 10 a · Connec tor 10 p n. red , 1n right rear door
T 15 a - Connector 15 p.n. black. connector station A. p llar right
(J)
- 15 • - Coroec or 15 pin. red connec:or sta tion A pillar. leh
V 15 Right Window Motor
:::J "
Left Re ar Power Win do w Edit ion 10/97 2- m
~ ~
Edit ion 10/ 97 Right Front Power W indow W42 USA 560/ 01 21
V 42.USA.5602 01 21
--.....
0
--4.
co I
co ~
~ w
AudiA6 No. 12/5 Wiring diagram Audi A6
Wiring diagram No. 12/4
30 30
30 15 t5
- - - - - - - 15 x x
x 31 31
31

D
11s
E ss 4 ,0
• Ic:::.===========--==-:====:::::==~-=:I ·
'i "-
r- grr
b 0 1 - 0 1 - ,;. ;' • I b
•'\:
c • \." ~ z;u ~
_ _ _ _:_---'ff-' ";~ c A2 E 150 L 48 L 49
euf 0 ,5
14 I 8 I 16 L 110 Lm

i"'T 1od14
I
0 ,35
re/gr
I
0 ,35
ro/ gr

I r 19
I
38
I 1T4c/3'~T4d/3
0.35 0 ,35 0 ,5 0 ,35 0 ,35 0 ,35
r-1 f'--1
18_yst
w- T TT 0 ,35
br/ ro
0 ,35
ro/ gn
0 ,35 0 ,35
gr/bl
0 ,5
ro/ gr
0 ,5
ro/ gr
0 ,5
ro/ gr
0 ,5
ro/ gr

'rTISk/8
~ I
I· ·T15kt 4 l
13 I
·~T15k11
1
25
I
36
I
26
I
51

0 ,35
gn{ge "*
0 ,35
ro/br
0 ,35 0 ,35
II
0 ,5

T I 02·,
0 ,35
.......
~. 1 1 br / ro

1
I
.J;T 10ei/6 10e l/2 'i'T 1oa1 ' " T ma l/5 lT10a1 33 OJ
66
1 32
-¥ T 1 I I 3
4 /9
I I 1
0,35 0,35 0,35 0 ,35 0 ,5 0 ,35 0 ,35 0 ,35 2,5 0 ,5 0 ,35 0 ,35 0 ,35
gr/ bl sw br/ ro ge/ sw 11 ro/ sw gr/ bl gr/ bl gr/ bl gr/bl
en
~'1-~' ---~'-6_E5~ J~li .Ihad I I
ws-wh1 te 213
ws=wh1te
sw =black sw=black " ' T 1oah" T 10ai
12
I I
4_
ro=red 110 110
(~
ro =red o .5
~I

r r -~LJ
gn =gre en

I
gn =green gr/bl 0 ,35 0 ,35
3 br=brown gr/ bl gr/bl
br =brown

r
I
V 21 I I
bl =blue bl =blue 'A 19' 29 44
gr =gray gr =gray
h 1oa111I II =VIOi et l1 =v1olet 0 ,35
0,35 0,35 2,5 2,5 2,5 ge =yellow gr/ bl
ge =yellow
I T3~~io
___ 12~
gn/ ge

I ,----
205
J 216
43 45 46 47 48 49 50 51 52 53 54 55 56
57 58 59 60 61 62 63 64 65 66 67 66 69 70
97-19769
97 -19770
D - ign •• on/S1a er Swtch Ground conrect1cn 1· tr fl0\'. er window w11m9 harness
1
E 39 - Window LOC<OL Sw,tch
E 54 A.go: R ar Window Sw tel- !In RR DoorJ ·Grourd connect1or 1n driver's door wiring harr.ess
E 150 S v ten for rnt er.or Ice'. orrver side
E ~5 - '11gh: Rear\\ ndcw 5,.,
en, lln Co"SO el Ground connect i....r ., ngrt rear door wir,nq harness
J 21 a lnst'uriert Clcs:er Com 1nat1on Processor
J 298 - :i ght Rear Powe1 Window Con11ol Module -Wire cornac t1on !58sl. 1n 1rstrumect panel wiring harness
L 48 - Left Rear Ashtray ergo:
: 10 d· Co:-ineci.O~ 10 ptn, green, connec:or sta tion A pillar, !e't Pus connection! 15). 1r instrument panel w ri'~~ harness \Sw tch 1l!um1riat1on)
L 49 Right Rear Ashtray Light
- l 0 a - Connec:or 10 01n, red. 1n B p·lla' rignt P1JS con nee on 158sl. 1n power w'ndow wring harnt?ss
Plus conne::t1or t 15! n po1,.·.. er \"v1'1dow w·• rig hJrness L 110 Dco' Opener Jllum1ra:•or rear ef·
T 15 ' - Connerior 15 pin. red. connector Sl3ton A pillar ef t
\ 27 · \1ctor or window regula tor rear r gh L t 11 - Door Ooerer lllum1na t1 on. rear ngn1
T 4 c Cornec:o• 4 C•n black, 1n left rear door
T 4 - Connector 4 pin blaclc. 1n right re ar door
- l 0 d - Connec1or · 0 pin. green. connector sta tion A pillar. lef t
T JO ah-Connector 10 pin, red . 1n B pillar. left
T 10 a1 - Connec tor l 0 pin, red, 1n B prllar. right
T 15 < Connec:or 15 pin, 'ed cornec tor statron A orllar left
T 32 - Connector 32 pin. blue. on instrument clus:er

Edition 02/98 Right Rear Power Window

42 USA 5602.03.21 Window Lockout Switch Edition 02/98
W42 USA.5602 03 21
Audi A6 Wiring diagram No. 16

No. 16/1 Wiring diagram Audi AG

Radio Concert, Bose with and without CD Changer
3 0 - - -·- - - - - - 30
15 - 15
x -- x
1998 m . y. 31 - - 31

Fuse Panel
~
Fuse Colors:
30A Green i30 ------
•.o
25A
20A
15A
White
Yellow
Blue rf 237 I
J 21s
T32/20
5Bs
lOA Rec ·:-=-s 237· 0,35

n
7,5 ll Brown gr/ bl J 429
+8
. - 20A ,
5A Beige
1 237a ¥ Jf ;- 1 3/9

~.~L rF1ox1~~1/~
r·--
0

~~r11
1 0,35 0,35
gr/ bl br/ gr
S:art1ng with • Jse pos11 1on 23. fuses in tr:e : use nolder 1.o ••
are 1c ent1f 1ec with 223 in tre W!r:ng J1agra m
~

,
1,0
ro/bl
25

rrY_;.~ I r·-'
035

0,5
gr/bl
0,35
br/gr

Micro Central Electric Panel ------''~T_B_1_n ____ R_____.!__r10z110 ! TBl/6 IT1e

1
TBg/20
NF-R
r NF-31
Bg/1Bt NF-L
TBg/19
1

r-:··· l
1 TBgl13 -
~~~~,511 :.~~ I 6~:~ ~~~~1· I TBl/B
m
f
Plus Dataplus
out

V\S = Whi t e
', ' CD

~
. T,
sw =back o.5· o.s • 0 ,5 0.35 o .s · o ,5 · o .5 · o.5 · 1,0 ()
....+-

b~J_;:_i,_~Jf, f: r~ , :~ _·~_T_,.;l
re =red

I I I
gr
br
=~ ·eer
=b ~ovvn
b1 =blu e
'
()
A B C gr =gray Q)
11 =VIOiet
ge =yellow R •C

~
or =orange

10 13
'::::l
(Q
218 - l1strum en: Cluste r Co mb1na11or 0 ·oce ssor
J29 Comrol Todule tor certral :oc1<.1na
-R adie -
G - Ground connecnon. 1n sceaker .vir,ng hamess (J)
0 0
.1 1 - CD Cha'1aer Untt
e - $1!"0 e co7'r1ecwr on ~ad.a
8 - Wi re co:-in ection (58s l. 1n instrument oanel w1rinc harness
(Switch 1Ju ri1nat1onJ - c:
e
2
ar - c:i;n ecwr
f - C::::nn ector
2 pi n, black, behind instrume nt panel, center
8 pin. black. :onnec;or radio I'
8 - ?!u s conn ecuon (30asJ. 1n --:sm.. mem pa"le l 1;vrri ng harn-
ess
:::J Q)
Q. {Q
8 g - Conn ect or
8 pin. blue connector ·ad10 I - 3 () - Plus connec: 1on !30L 1n ·ear spea<e• w · .ng tiamess

~ '
- · 0 pin p1rk. connector stat or A. pi llar right
· 0 x - Conriector
8
1

-\'\lire :onnect1on [sh1e la1ngl in CJ-cha'.lger wiring harress

- i 0 z - Connecto~ 10 pin. rec . conn ect or radio !V
T 15 d - Conn ecto~ · 5 pin. blacr... con1ector sta t ion A pil lar. r1gr t
Q)
(J)
i 32 C:::nnector 32 pm blue. on 1nstn.. men; clus:er

- Veh1c es with CD C"1anger

........
CD 3
-Autorna t1 cAmenna
__3 CJ)

OJ
Radio Concert, Bose with and without
CD Changer
Edition 10/98
\IV42 USA 5602.0.C 21
0
(J)
m
Edition 10/98
CD
--.._
~
W42 USA5602 .04 .21 0
-.l.
co I
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a m
Audi AG
c:
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Wiring diagram No. 16/2 Q 0
No. 16/3 Wiring diagram Audi AG I

~ ~
x ------------------------ --- -- x
~
_ _ _--------- ~50
{50 - - - - - - - - - - - - - - - - - - _ - _ -

~
30
15
x
31
30
15
x
31
-
(/)

CD
~3
(j)

OJ m
a(/) CD
CD ()
D -...
-.t..
......+
~-
f 5
R:iii"' 4 ,0 co ()
co OJ
I
J K
~
216
~ J 218
I~ 2 ~
--- .J 1
T32a/30 ·1T1san
I T3~~;
rf 0 ,35
J 169 J 189 J 189
0.35
ws/gn
0,35
gn
2,5
~
·1·T 2av/1 J JT 2av/2
+:As,
gr/ge
I I I
T20/12 T20/13 T20115

0 ,35
A 27' I
0 ,35
A;& I
0 ,35
l s 110 ,5 ':J
0 ,35 0,35 0 ,35 S 5
0 ,5 0 .5
ro/gr br/ gr
gr/ro ro / br rolge ws/ gn gn/ro " \QA sw/ro
gr/ ge
(Q
_,_____
ha•:5__' T~/~_ T10z/2 1 T10z/ 5 1 T10z/6 1 T10zn ~ T1g~fs ,! liox1) ·lioxn ·! •T 10x110 .!T10x12
I
'[T1ox11 f sa ,!_T10x13
l
'll I I
1
-'------'-----'-----'-------~ , I I I
,,,, 0
·r
0 .35 0,35 0 .35 0 .5 0.35 1.5 0,5
/--~-~-~ . i L - .:.....Lcll'
I I j'.11 I
, 111•1 • '_ ·~ _:_'l.. R ro / br ws/ bl sw / ro

I<';~
. ..
T6 f/5
i=-1 9T:_ I I gr
'f OJ
~
I
'
1.0

r-L 1:-i 4 .0
ws/11
l i F:; OJ

-, -u
i T10z/1- I T6w/1 ·1Tew/ 4 i T6w/5 5
_ L _ ! - IA I
T10z/3 i T10z / 4 T6w/2 i T8w/3
I
3

l"
4 ,0
...
R 24 _ _ _~
l rr' I '.' I 'ha.14 0 ,5 0 ,5 0 .5 0 ,5 0 ,5 0 ,5 0 ,5 0 .5 0 ,5 0 ,5
Tl en

Tl Ll I)
gn SW

I I.
1,0 2,5
. 4I,0 w s=wh1te
sw= black
ws =wh1te
sw =black I I
' •'li Og/ 3'' 'liOg/4
ir0g/6
r -'lw 2.5
fO SW WS ro =red
gn =green
ro =red
gn =green
br=brown
I. 1.
0 ,5 0 .5 0 .5 0,5 I 8
ro/bl
' 13

(~- rit,'
, __·-·'
rr'
·':':'~I
' A/MN
- -
i A/U-.0N
-~ Z 24·
br =brown
bl =blue
gr =gray
bl =blue
gr =gray
LL I' 10 -
@ - '
l1 =vrolet R 43

'i:l
11 =VIOiet R 36 R 36 R 36
131 V 21 12 . 31 ge =yc llow ge =yellow
1.0 ·· 1.0 .. 2,5 br
br ro/bl br
~: I ~~, i4
15 16
J s_o 1
17
-}]
18 19 20 21 22
--- 23 24
I~
25 26 27 28
29 30 31 32 33 34 35 36 37 36 39 40

97-19609
1
97-19808
D - Ignit ion/Start er Swnch
E ,5
" 218
- Rear Window Defogger Switch
· lnst1ument C!usi.er Comtinauon Processor 0 -Ground connection. 1n luggage compartrient. le ft J 189
J 2 18
· Au10 Check System
- lnstrumert Cluster Combination Processor
· Grourid connecttor on ,eft A·p1uar lower pari

-Ground connection. 1n speake r w:ring harness

8
9 - Rad •o -Ground connec :ion. on r;ght re ar pillar K - DLC (Data ur- ._ Connector) Rapid Data Trans fp.r
q - A.r t en'"la Connect ion R - Ra 10
-Plus con'.lect1or (15). 1n inst rument panel wiring harness
R 2J - Anterna Ar1p'1f1er r - D 1us
connect1o'I (58dl. 1n 1r.strument pane' vv1r :ig R 36 · Telephcne Transce ve r
'1 39 - Te•epnone Speal.e 1 harness (01sp1Jy illum1nau onl R 43 ·Right Rear W ooler/A1npl1 ' 1er
Wire connect ion ! 15al. 1n ins trument pane 1w1 r1ng harness
R ~5 - T elephone/Rad10 An:enna Amp•, f1er S 5 ·Fuse
r 2 Connector 2 pin , black. for loudspea ker, B pil'ar left T 6 v. - Connector 6 p ;n, yellow. connector radio I - 1
T 6 x ·Connector 6 p.r, green . connector ra dio I - 2 ·Wire connecuon (vehic le speed signal), ·n instr ument
T 6 a - Connector 6 p n. blue. con'"lector sta tion A pillar. eft panel wiring harness
T 8 e - Connector 8 pin, brown conn ector radio \I
T 8 t ·Connector 8 p1r blad., connector radio lll
T 1O g ·Connector 1O pin, white. connec tor sta t ion A pillar. left -Connector !K-d 1agnos1s wire). 1n instrument panel wrring
T 8 f ·Connector 8 pin. blac'. connector rad io 11 harness
T 1O x - Connector 10 pin. pink. connector station A pil lar righ t
T 10 z Connector l 0 p•n, red . conn ector radio IV
T 1O z ·Connector 1O pin, red. conn ector radio IV
T 32 - Connector 32 pin. blue. on instr ument c,uster -Rear Window Antenna
T 16 a Connector 16 pin. data hnk connector
v 21 - Power Antenna u - Au t orra t1c Antenna T 20 ·Connector 20 pin . red/white. on instrum en t cluster ·Ve hicles wi th Telephone
z 24 - Rear Window Defogger With Window An1enna Wagon T 32 a· Connector 32 pin. green . on instrument cluster
-Vehicles w•th Teleph one

Radio Concert, Bose with and without Edition 02.98

CD Changer W42 USA.5602.03 21
Edition 02/98 Radio Concert, Bose with and without
W42 USA 5602 03 21 CD Changer
AudiA6 Wiring diagram No. 16/4

30 30
15 - - - - - - 15
x x
31 - 31

R 21 R 26 R 23 R 21 R 15 R 34 R 11 R 35

rn n n ;
=rJ ~ I ~~- =rJ dj I c:: c:::
-r THIS SPACE INTENTIONALLY
1,5
gn/ge gn
L
1,5 1,5
gn
1,5
gn/ge
1,0

gr/ge
1,0 1,0
gr/ge
1,0
gr

lh. lh. ~ht T!T

'f ,, I I '2 12
3aff1 lr~,
J T~'" T,, l
tT3ah
11
lT3ahl2
LEFT BLANK m
2,5 1,5 1,5 1,5 1,5 1,0 1,0 1,0 1,0 WS =White CD
gr/ge gr/br sw =black ()

LT.tlI
gr gr/bt
ro = red r+

to
dj
LI l j_23
gn
br
bl
gr
=g reen
=brown
=blue
=g ray
'
()
Q)
) 11 =VIOie t
ge =yel low

~
R 43
4,0
br

8 :::::!.
43 44 45 46 47 48 49 50 51 52 53 54 55 56 ::J
97-19810 (Q
R 15 - Left Rear Woofer 8 -G round connection. on left A pi llar. lower part (/)
R
R
17
21
- R1gh Rear Wooier
- Left Front Woofer
0
c:
0
R
R
23
26
- Right Fron1 Woofer
- Left Fron1 Midrange Speaker ~ Q)
R 27 - R1gh1 Fron1 Midrange Speaker Q. (Q
R 34 - Left Rear Midrange Speaker
R 35 - Right Rear Midrange Speaker
!# Q)'
-3
R 43 - Right Rear Woofer/Amp hf1er
T 3 ae - Connector 3 pin. brown, 1n drivers door U)
T 3 af - Connector 3 pin, brown. 1n front passenger door
T 3 ag - Connector 3 pin, blue. 1n rear left door (1)
CJ)
T 3 ah - Connector 3 pin, blue. 1n rear right door
_:3
OJ
0 m
~
Radio Concert, Bose with and without U)
Edition 10/97
CD Changer (1)
W 42.USA.5602.01 .21
.---. 0
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No. 17/1 Audi AG
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AudiA6 No.17 Wirin g d iagram
Wiring diagram

30 • .
!#
Cl)
~
OJ
15 - -
x
30
15
x
(l)"
Radio-Stereo, Concert 31 31
:3
......___
"""""
(.Q
m
1998 m. y.
(.Q CD
(')
Fus e Panel
i 30 D
~ ,.-+

4 ,0
ro
j 218
I 1 32120
j 218
fT32a /30
K
rli6a /7
. 15
4,0
'
(')
Fuse Colors:
30 A - Green
' 237
0,35
58s
0,35 0,35
Si r'f_~ Ol
'1 - 8 237 gr/bl ws /gn gn
25A - W hite 1 1
2,5
2QA

I ~ii I .'!W I :E
"
20A Ye llow
15A Blue I 237a f\_19)
'--' . ,5
10 A Red 4 ,0 0 ,35 0,35 0 ,35 0 ,5 1 :-s 5 ,,
ro/bl gr/bl ws/gn gn/ro sw/ro
5A Be ige

I
--
Asol ,~T10xt6
I
'~'T1ox12
I
~ T10x111~T 10x13
I I
; -:- 10A )
i 5a
'
::J
2,5 0 ,5 0 ,5 0 ,35 0,5 1,0
ro/bl gr/bl ws/ bl gn/ro ro swl ro , G
(Q
~ TS7~s
5
Starting with f use position 23. fus es 1n t he fuse holder ' TBf/1 ' T8f/3 ~ T8f/4 I ~23
are 1dentif 1ed w it h 223 1n the wiring diagram
0 , _ ____J_.__ _._ _ ______J_
I (R 0
-~ -
Ol
I HF •
'
2,5

r1iv?
1,0 1,0
-I~ . I Ol

r·
Micro Ce ntral Electric Panel ws/li
roltbl I~ I R 4~ 3
~~ ~- !:
(J)
ws =wh 1te
sw = b lack
ro =red
I..
1,0
ro/ bl
1,5
ro/ bl
v

~ '~'A/U~
L I
gn =green 8 36
br =brown

-=- fi
bl =blue
gr =gray
I I I li=v1olet
ge=yellow
i 31
Z 2 4·

A B C 2,5

l@
10 12 13 14

97-19811

D - lgn 1t 1on/Starter Switch

E 15 - Rear Window Defogger Switch -Groun d connec ti on, on rig ht rea r pilla r
J 218 - Inst rumen t Cluste r Comb1nat1on Processor
K - DLC !Data Link Conne ctor) Rap•d Data Transfer - Plus connection (15) , 1n instrument panel wiring ha rness
R Radi o
R 1 - Antenna Connect ion - Wire connection (58s). 1n ins tr ument panel w1r1ng harness
R 45 Telephone/R adio Antenna Amp l1f 1er !Switch illum 1nat1onl
s 5 - Fuse -Wire con nection (1 5a) , 1n instrument panel w 1r1ng harness
s "237 - Fu se
T 6 Connector 6 pin , blue , co nnec tor station A pillar. le ft -W1re connec tion (ve hicle speed signa l). 1n instrument
T 8 - Connector 8 pin . black . connector radio Ill panel w 1r1ng harness
T 10 Connector 10 pin. pink. co nnector srnt1on A ptl la r. right - Plus connection (30asl. in instrument panel w iring harn
T 16 Connector 16 pin, data link connector ess
T 32 - Connector 32 pin, blue. on ins trum ent cluster -Connec tor (K-d1agnos1s wire) , in instrument pan el wiri ng
T 32 a - Connector 32 pin. green . on ins tru men t clus t er harness
v 21 - Power Antenna -Plus connection !30). in rear speaker w 1r1ng harness
z 24 - Rear W indow Dei ogger Wi th Window Antenna
- Rea r W indow Antenna
50 - Ground connection. 1n luggage compartment. left - Automatic Ante nna

Radio Concert, Power Anten na, Edit ion 02/98

Rear Window Defrogger With Window Antenn a W42.USA.5602.03 21

Edition 02/98
W42 USA 5602 03 21
Audi AG Wiring diagram No. 17 /2 No. 17 /3 Wiring diag ram Audi AG
30 - - -- - - 30
15 - -- - - -- - - - - - - - -- - - - - - - - 15 30 - - - - - - - - - - - - -- 30
x - --- - - - - - - -- - -- - - -- - - - - - - - x 15 - - -
x
---------· - - - - - - 15
~ ~ x
31 -----------~ 31

-------~--,---:Z.'·,. ----,--------- R 41·

}~J"'f~J°j~"t°s l ~ ·~ ·~TM" 1
J 218
IT3~~~ J 189 J rn9 J1 69
r 20/12 T20/13 T20/15
0 ,35
gr/ ge
0,35
1
0 ,35
1
0,35

0 ,5 . 0,5 . 0,5 0,35. 0 ,5 . 0,5 . 0,5 0,5 .

l-8
0 ,35
1 gr/ro ro/br

!T1ox19!.if10xn
ro/ge

!I T 1ox110
I 1
i
l1;,hd~fo~
0 ,35 0,35 0,35

t
ro wst olr gr/ ro ro/ br ro/ge

" I
NF-R I NF-31 NF-L
T6g/ 20 I T8g/ 16 .!_T6gi_i:i_ _~
· _
T6_g1_13_ _
CD-B:ata in
gr,/ ge 58d

1
TlOz/ 9 ' T6x/8 ' T6x/9 I. :r~x:io_
- - - - - - - - - -- - - -
R 1 TIOz_12_ __,_1 _n _oz_15_ __,___
I T10z/6
. ~n
.~

I I l
)----

R T8e/5 j TBe/ S- TlOz/10 r Be/3 1 T8e/ 4

--·~

·r Tle I T6f/6
r l T6w/ 3 T6w/2 j jT6w/1 T6w/6+ t nozi1 j TlOz/3 I T10z/ 4

0 ,5 0.5 0,5 0 ,5 0,5 1,5 0 ,5 0 ,5 0 ,5

br/ws br/ ws ge ro/bl gn
0 ,5
bl/gr
0 ,5
Ol/br
0 ,35
Ii
0 ,5
ro/gr
0 ,5
br/gr
0 ,35
br/gr ~8 _ _R43 ! 1
I
"'T 1og1s !T10 913
sl
.,..T tog/ 4

I 1
r,T 3ae "'T 3ae/1
l Jro:T 3at 1
"'T 3a111 1T15d/9
;-. 't l .
0 ,5
r.
0,5
I.
0 ,5
m
R 2s
I I 1
2

1,5
r

0 .35 .
2ar/1

R 21
I l
1,5
1
2

1,5
l
0.35
WS;;:Wnlte 1~\S ;;: White
T0 ,5
~- f3

0 ,5
I4
O,S
19 ( 10
0 ,5
gr
1 10
gn

1 19 I 25 <D
1,5
-:::" gn gn/ge
sw =blac k sw =b .ack bl/ ro br/ro ro/gn tx/sw R 36 R 36 R 36 ()
gn

l
gn/ge

l
br
I
20 l l brl:/9 ro= red
g1 =green
ro ='ed
gn =green
! T 3ag11
I
h 3ag/2
r
J.TJaht1
J
q
I
3aht2 . ...+
........
,_ ,_

L J /2 ,l
"'T 3a1 "'T 3a111 ro:T Jam ro:T 3am11 br=brown 1,0 1,0 1,0 1,0

L J /2 J
br =brown
J 429
bl =blue bl =blu e gr/~ gr gr/ge gr ()
I
gr =g ray gr =g ray fT3an12 h 3an/1 !.J'3 aotJ T 3ao/1 OJ
J 2_-1
____.rl~--
1,0 Ji =VIOie! 11 =VIOiet
'---
;- 1= ;:::: ge =yellow ge =yellow
2
+ I -r 1

~
1,5
or =Orange -,
R 21 R 23 -, br ~

15 16 17 18 19 20 21 22 23 24 25 26 27 26
R ts R 34 3 R 11 R 35
........
29 30 31 32 33 34 35 36 37 38 39 40 42
97-50635 :J
97-50636
co
J 21 S - Instrument Cluster Como1nat1on =>roc essor
J 429 ·Control -nodu le for c erira l loc<irg
T
- 15
10 z · Co"lnector 10 p1r . red. co:i:1ector radio JV
a - Connector 15 pin. black . connector station A;:> li ar. rt ;'.3n:
J
'I
R
189

15
· AJtO Cnec< SysteT
. Radio
· Left '\ ear Woofer
G -Groun o connect C'1, on le't A ·p Ila·. lowe r part
0
" ·Radio ~ 32 - Conrector 32 p1r clue . en ·nst·ume"'t cluste·
R 17 · R a - t 'iear Wca'e'
~ 2 1
- Left Front Woofer

", 23 · R1aht Front Woofe r

R 34 ·Left near M1dranae Speaker
- R grit Rear M1dra ~ge Speaker
OJ
R
R
26
27
- Left Front M idrange Speaker
·R ight Fron1 Midrange Speake· 8 - :Jrouno connec?1on . ori left A-p1 !1ar lower oart
;:::,
H
R
35
36
43
- '7"elephone Transceiver
- c:i ont Rear Wocfer/ AMp l1 f 1er (f) co
........
R
-
41
1
- CD Changer Un11
e - Smgle connect or. on Radio 0 - Plus connect·on t58d), 1n 1nstrJrnent patie l wiring
rarness (Display 11lum1nat 1on 1
T
-
3 ag . Connec:or 3 pin. blue in B oli lar, le':
3 ar Connect0r 3 pin, b ue . 1n B pil•ar. right
a
c:: OJ
T 2
T 3
ar - Connector 2 pin. black. behind mstr1...--e'1 : oare center
ae - Connector 3 pin, brown. connector stauon A pillar. left 0 -Wi re conneciron (sh1eldtng). tn CU Changer w W';! harness -
-
3
3
· Connec: or 3 p in, back. 1n le t rear door
Connecto· 3 p in. b l ac~. 1n rig n: rea r door :::J 3
T 3
at· Ccnnector 3 pin, brown, CO'l'lecto r stat ion A pillar. r·ght
- 6 w - Ccnnecto· 6 pm, yellow , con'1ector rad io Q
T 3
al - Connector 3 o•n. black, •n dr•ver's door
- 6 '( - C~nnector 6 pin, g·een. connector radio ! - 2
CJ)
T
T 8
am - Conn ector 3 pin. ::llack, 1 passenger 's ooor
3
e - Connector 8 pin , brow"'I con nector radio 11
- · 0 o. Con:ec t or 10 oin. wn 1te. con.,ect cr sta tion A pillar. eh
!f!
-m
- Veh icles wi t h CD Changer - · O ; Conn ector 10 p1r p1ri<: . connec tor stat ion A. 01llar r1gnt . Ve h•cles wrt h Telephone
T B ' ·Connector B P•n. ~lack. connector radio Il l
T B g - Conn ector B pin . b 1ue. connector radio I 3
T · 0 z - C:nnector 10 p1r, red . co nnector radio IV (/)
- 20 · Ccn:iect or 20 p'. r red/wh ite on 1ns:rument c1us te r
Edition 10/98 Radio Concert, CD Changer Unit, Ct)

-..._ ~
Radio Concert, Right Rear Woofer/Amplifier, Edition 10/98
W42 USA 5602 04.21 Front Speakers
Rear Speakers W42 .USA.5602 .04 .21 :3
-.l. 0
co I
co ~
~ <D
 :r:
CD
m
Audi AG Wiring diagram No. 21 0)
~
8: 0
ca·
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I
(J1
Headlight Washer No. 21/1 Wiring diagram Audi AG .........
0
1998 m . y.
30
15
30
15
~
(/)
x
31 --
---·
--- 31
x ::J
CD m
Fuse Panel
-c
, --..... CD
""'"'
-.i.. (")

r~ ,~
· f ftf I rI -· iJI
(Q
Fuse Colors:
30 A - Green
'""'-j:"________J:' I (Q --.
.....+

25A
20A
15A
W hite
Yellow
Blue
- vis 1~r5· ~ (")
tu
0,5 2,5 0,5 1,0 1,0 0,35 0,35 0,35 1,0 2,5 6,0 10,0
10 A Red

~- -1·
ge/ bl ro / ws ge bl/ro bl/ro ar/ sw

~
5A Beige _J_ _L I I
2 • 9 7

--.
Starting with fuse pos1t1on 23. fuses 1n t he fuse holder :J
are 1dent1fled w1 h 223 1n the wiring diagram
T6ac / 6 TBi/ TBi/ TB i/ Te i/ T8i/ {Q
1 Pot_ - - - - - - - ' -1 _Bi_53a
_ 1 3/ 53e ~ . 1 4 / 53c 0 5/ HW
_

», r?{.;f2 -L:: -- - ~ -- - -"7}_-::- . ~ : ~--- ~~- H

*1= i 0
i TSac/ 5 E 38 i. TBi/ i ra;1 r2/31
TB i/ E~
6/53b 1/53

--.
.
0,5 0,35 0,35
gn/U gr/ sw
Relay Location :
br
I
1 2
I
10 •-
7 14 tu
B- W iper/Was her Inte rmittent Relay. J31
I
2,5
ro/ ws
I
0,5
ge
I
10,0
sw/ge 3
D -W iper/Washer Inter m ittent Relay, J31 ! T 2b12
-f ~}I
CJ)
I ,224
~
ws=wh1 te
sw =black
2,S 2,5
ge ns22j
~
ro=red
gn =g reen f El 2
l ./56
t··
I I I
A B C
br=brown
bl =blue
gr =gray
li=v1o let 1
ftl v1 1,0
bl/ro
I
ge =yel low I 6
0,5 2,5
br br

1~ ( ,~
10 12 13
97-19818

E 1 - Light switch
-Grouria conn ect ion. 1n engine compartment. left
E 22 - Wodsh1eld W•pe•/Washer Switch
E 38 - Windshield W·per 1nterm 1ttem Regu.awr
-Ground conn ect1on -1-. 1n mstr ument panel wiring harness
J 31 -W1pe rNl/ashe1 lnterm1t:em Relay
S 22 4 Fuse
r 2 b- Connec:or 2 pin. blaCr" CQl"'nector stat ion A pt Jar, left - Plus connect•on 130). 1n instrum ent panel w1r1ng rarness
f 6 · Conrec:or 6 p1r brown. on w1ndsh1e.d wiper 1nterm1t:ent
-Wire connect ion 156), m mstrument panel w1rmg harness
1egula:ar
- 8 1 - Corinec:or 8 pin, on w1ndsh1eld wiper/washer switch
v 5 W1ndsh1eld Washe r Pump
v ' 1 · Headl1gh1 Washer PJmp

He a dlight Was her Edition 10/ 97

W42.USA5602 01 21

Edition 10/97
W 42 USA.5602 .01 .21
Audi AG Wiring diagram No. 22

Headlight with Hight Intensity Gas discharge Lamps and No. 22/1 Wiring diagram Audi AG
automatic Headlight Beam Adjusting
- 30
30 -
15 ----
----
-- - - - -- - - - - - - - - -- - - - - - 15
x ·- - · - - - --- x
1998 m . y . ~ - ··-- - - -- - - - - -- - - - - - - - - - - - - - -- - - 31
_1.8/ 85 7713~

Fuse Panel lZ: --~- ~ El

-~ J 59
.!. 51ss .!. s/ 87

r --T~
---~

r
Fuse Colors:
30A Green
25A White
20A Yellow
15A
lOA
B ~ ue
Red
1,0
17"'
I
2,5 s.o
-.
26
I
2.5
21
I
2,5
9
4 ,0 0,5 0 .5

I LL I·---~-2 ·---·~i~i
7.5A Brow1 ge/ sw /;' ro

- r-~. _J
5A Beige

2,5 2.5
Starting with fuse position 23 , fuses in the fuse holder
are identified wi th 223 in the wirin g diagram.

Micro Central Electric Panel

Relay location :

fJ -Load Reduction Rela y, J59

ro
m
ws = wh.te I T32/20
CD
sw =black ()
J 21s r-+
ro =red
gn =green :::::!.
br =orown ()
bl =blue
A B C
gr = gray
l1=v1ole1
ge=yel1ow °'~
10 12 13 14 ':J
:r: (Q
(t)
13 - Fold Relay Pa nel
c - Generator iG ENI -P,us connec:: ion 1151. rn :nsirument panel w iring i-iarness n:i
Relay Location : D
59
- lgn11 tOi/Sta1er Switch
· Load ReducHOn Relay -Wire connecnon (86sl. 1n instrument pane l wwng harness 8: 0
IJ -lamp Control Module. Jl 23 207 - Starting Interlock Relay cQ'
°''
- Plus connewon (301. m .nstrume'1t panel wirrng harness
218 - Instrument Cluster Combmat1on Processor ::J-
lliJ -Lamp Control Module. J 123 32 - Conr'1ector 32 p 1r. blue. on instrument cluster
~Ci)' (Q

fu<
:::J
a
°'3
CJ)
:::J

~
Ignit io n/ S ta rter Switch,
Lo a d Reduction Rel ay
Edit ion 10/98
W42 USA5602 04 .21
-~ m~
........__
Edition 10/98
-.a. 0
co I
W42 .USA.5602.04 .21 co 01
~ -L
 :r: m
Cl)
tl)
Q ~
No. 22/3 Wiring diagram AudiA6 cZ 0
AudiA6 Wiring diagram No. 22/2 ::J-
I

__Ci) 01
30 - 30
I\)
30 30 15 15

~
15 - 15 x - x
x ---- x 31 - - 31
31 - - - - - - - - - - 31

~ 75 :::J
- - 75 ~
0
:::J
m
CD

Jj
----- - - - --- ----

-
~ ()
,..+
-....
~ ()

u
J
1,5
ge/sw
218

1~~~/20 l I 27
I
-... fl)
0,35
1,5 1,0
9 ge
1,5
WS -....
f
' 236
::. 8 236 gr/ bl (Q
l - A 1~1
..
I

~
1- 15A _w
_f,__1e _ _ _ 20 , 21 ' 19
(Q
I
5 4 ·I 236• 0,5
gr/bl
-~
S-2_
0 _ _ __
~
2,5 2,5 1,5
-• ' - 10A - 10A - 10A - 10A
~-
ro

~3~1 ---~
ge/sw

E 23
gr/ gn
~ 21XR K 13 K 11 Ls L 40
27
r-118~
0 ,35 1,5
12°·
1,0
f· h
1,0 1,5 0 ,5
::::J
(Q
ws/ ge ws/ge ge/ br ge/ gn ws/ sw ws/ sw

----------·---~- !.-
21
I
1,0 I T32/17 _J 14/56bR _ am J~1~6bL I s
19
r
1,0 0
6;-
1,0
- fi315BL1 i6158
0 ,5 1,5
1 14/58-R --~f4/56 l8'NL 1 9/ NSL - - - - - 1 17/sas 1 10131
0 ,5 2,5 1,5 1,0 0 ,5 A5
sw/ gn

I
Kl j 5
,,- _. I
sw/ ws
w·
81_ , __
gn/ sw gn~sw ~r gn/ro ~e ws~ge gr~ws gr/ bl
1~0
I I \.LI
1,0 0 ,5 1,0 56bL1 0 ,5 1,0
-....
,- •2 I 27 ge/ws
::; 3 0 ,35 sw/ gn gr/ ro
fl)
J5 ·~-T61<12·h6kf1 ·; T 6k/ 4
ri
h s1<13

A 51
.......-1
0 ,5 1,0
I
0 ,5
I
1,5
I
1,5
3
(/)
1.0 1,0 1.0 1,0 2,5 -7 8
-r42 30
,-
gn/sw

L/PL
gn,/ro

~/PR
gn:'o
62
1.0
sw/ws

~ ~_'.l'_R
1,0
sw/ gn
ge

la-
-
I
ge -,

~;
~7/~ , 1/30
-. -

~;
, 2/30
WS =·Nhtle
sw =black
ro =red
\~./S

ro= red
=W
sw =black
J e

gn =green gn =green
-cil-
- -~~~~~----=-i. - _ E==<.-~;: hr=brown br= brown
bl =blue

I·----·I
~ ---- bl =bl ue
- y ; ; ; -1- 4-/ p- - -

~
1,0 . 1,0 ••
E 4 1 8156b ~
1,5 1,5 1,5 0 ,5
gr =gray
11 =VIOiet
ge=yellow
gr =gray
II =vio le t
ge =yellow I T10ao/8 T1 0ao/10 I;~oan I; 1gan
1
i
sw/ ws/ gn sw/ws/gn ge/ gr is ws br 0,5 1,5 1,5 1,5 1,5 0 ,5

- -! -~ - l!l_ 1~1
1 br br br br br br

I~76,
I 3/ 49a 1149a
~.3
1 \~ _ ( 111~ 1£U ~·
E 3
( 11791
../

15 16 17 18 19 20 21 22 23 24 25 26 27 28
29 30 3t 32 33 34 35 36 37 38 39 40 41 42
97·20095
97-20108
L1gr,1 Sw1:ch
- - vr S101a Sw1tcr. 0 -Ground CO'lnec:1or, - - 1n 1ns1rumt:n: par'\el w1r111g harness
J 5 Fog L1gnt Relay S 21 - Fuse
- E'Tlero;'lCY Flasher Sw1:ch
f-leadl~gr t 01mme·/=Jasher Swrtrh 0 Wire conrecttcr i58sl 1n 1nstruricn1. panel \'Wtng harness
1Sw1t ch
123
343
- La"1p Ccnrol Module
- Control tvodule for n1gh-•rHens1ty gas d1scrarge larrp
T 6 ' · Connector
10 a - Connector
6 pin. p.nk. connector station A oillar riaht
10 pin. pink. connector station A pillar. ie tt
19
23
- Pa·~ Light S\v1 t c~
- Fi"'g Light S1.v1:ch 8 1n lt'Strumen: ri.JnCI w1r1ng 1-..lfnl'";S
J 344
K 1
- Control Module tor H1gh- 1nt ens1ty gas discharge lamp
Head 'ght f'1gn Bear' nd cat or L 1ght
10 an - Connector
I 0 ao Connector
1O pin. on heaolight left
10 pin, o n headl,gh t righ\
- Fr.<;; L ght Relay
lrstrume"lt Cluster Comb-iat on Prcc~sscr 8 V\11re connect1011 (:; 7rl. 11~ 1ns'.r ir-iprr pane wu rg ti amess L 13
L 14
High 'nter's ty gas discharge lamp le ft
- H1gn .ntens ty gas a1scha1ge lamp r.ght
32 - Connector 32 pin, blue. on insaume'1t ciuster

'17
13 - gear f og ._.ght Indicator Ltght
Fcg L1gh· lnaica:or Light
- neadl1grt s"'
l!Ch L,ght
8 M 1,
rv 3
\I 5
- Left Park r.g L1gh·
· Right Parking L ght
·Left Fron: Turn Signal L•ght - Ground connect on, 1n right headlight wiring harness

- 40 - hoot llnd Rear Fog Light Sw en L,c-t \ti 7 R·ght Front Turn Signal L1gh1
M 18 - Le ft . Side Turn S gnal L·ght -G ro und connect ion. in left headlight wiring harness
- 46 Le ft Rear 'og Light •
s 3 - F... se M 19 - >light Side Turn Signal L'gh \
Plus connection (right turn signal). 1n .nstrument panel
s 236 - r1..se Cha.:;s1s ,.,u~1ber . . . ::ito 50CO M 30 - Left High Beam Headlight
T 32 •• -Chassis n ..mitcr ;ro'11 5001 \tl 32 Righ t H1gn Beam Headlig ht w1rmg harness
- Ccrnectcr 32 pin. b ue. O'"' 11stru1T'ent c!u ste1
s 18 - Fuse - Plus connectton Oeft turn signal). 1n 1ristrumert panel
WH ng harness
s 19 - Fuse
Edition 02 / 98 Light Switch, Turn Signal Switch, s 20 - Fuse

W42.USA 5602 03 21 Headlight Dimmer /Flasher Switch High intensitiy gas discharge lamp, Edition 02/98
Control Module for High intensity gas discharge lamp W42 USA 5602 03 .2 1
Audi AG Wiring diagram No. 22/4 No. 22/5 Wiring diagram AudiA6
30 - · · - - - - - - - - 30
15 - - - ---------- ·- - - - - - - - - - 15 30 - 30
x - - - - - -· ---------- x 15 t5
31 -------- - 31 x - x
31 3t

t4
,- 15
I
9 0 ,5 t,0

~l
gn/ sw

-,-
25
0 ,35
Tl
0,35
ws/bl
0 ,35
gn gn
66
I
0,35
br/ws
-.
57
0 ,35
ge/gn - S 10 ,
L23
~ S 223
ge ws/bl

!,li5c/ 4
r
0,35
I T32/3 tli5c/1
J 216
0 ,35
lli5c/2~Tt6an!Tt5c/6
I
0 ,35
r
i< 0,35
IT15c/ 5
I
0 ,35
I 5A

10a
'

r-1 22.-
- 5A

~
- 5A

0 ,5 0,5 0 .5 0.5 0 ,5

j
ge ws /bl

,- -,
gr/ro gr/ ro gr / sw
gef/gn A n• I

' 5/56 , 1
__br.!__
L _· _ _
7
31
I
M2
I
4Q

0 35 0 .5 0 ,5
J)
-•
n r
_ _ _ _ _ _ J 431 ge/gn ge/ gn ge/ gn

8 9 I 10/31 I 20/31 _.__

54 69
- ~ -
In 1 13 _;

0,35
11/sw
0,35
Ii/re
0 ,35
11/br
0 ,35
11/ge
0 ,35
11/gn
0,35
lilws
-
1
,
1 1 1
T1 0an
12
TlOan 1 TlOan
/6 /4
V 46
I ;~oa;;-1 T10ao/6 Iv 49
T1 0ao/2

r r
!T15c !Tt5c 1Tt5c/9
ltO
0 ,35
16
0,35
1
0,35
0,5
ge/gn
t,O
br/ws
t,O
br/bl
1,0
br/bl
1,0
br/ws
0 ,5
ge/gn
m
li/ge li/gn \i/ws WS=Wh 1t e ws=w~1te I I l l·T 6i11 1 J CD
rt ah
sw=blacr ' •' T 1oa " :T1ob ··T10b19 " T 6112
~Ttoa !.T10a ~Ttoa/9
sw =black

I 1
IT6k/6
ro =red 14 (")
ro =red ........
r r' 8
1 gn =green
~'I :::grei;;!r
--- n

T t_J "f;,;r T T
05
0 ,35
/10
0 ,35 0 ,35 br =hrown
br =brown :::::::!.
bl =blue
bl =blue (")
11/ro lilsw lilbr
gr =gray
gr =gray
_!
°'~
11 =v ·ole t
~+ __! 11- _ li=v1olet
1 _4/S 51+- ' 1/- ' 4!5 ge=yellow
ge =yellow _§I_ t,O 62 5£ 58

0,35 0 .35 br/bl

G 16 --=.._, ~

h
G 16 -· - _ br/bl br/bl br/bl
1[
0 1

__J ~1J~a1 J 3ot 43

57 58 59 60 6t 62 63 64 65 66 67 66 69 70 :::::::!.
43 44 45 46 47 48 49 50 51 52 53 54 55 56
97-20062
'vi 2 ·Righ t Ta.I L1gh'.
97-20063 :r:
CD
::1
CQ
tl:l
G 76 Le't Rear Level Control Sys te m Sensor
G ·Ground connect1or er r1gl"'t A-p'ltar lower pan \\ l
S 10
Le' t -011 _ gh1
Fuse
9:
G 78 · Leit Fron: Level Con tra, Sys1e Sensor
J 2'8 ·I nstrument Cluster Comb1nat1on Processor
G Ground ccnnect1on. 11 headlight iange adjustment 'w\ iring S 22 - Fuse -Connection \Beam Ad1us t1 ng).
harness
in 1nsirumen1 pnnel wiring

<Q'
0
" 431 - Control Un t for Beam Ad1ust1ng
e rarness S 223
T 3
·Fuse
c Cornector 3 pin, whte. connector stat1:::in /I.. r1lla1. righ1

°'-.
Ccnnector (K-d1agnos1s wire) 1n instrument panel wring
' - DLC !Data L•nk Connector! Rapid Da ta Transfer
T 10 a Connector 1O pin. pink, connector station A pillar le11 harness - 6 I Cor1e::::or 6 p '1, rec. C0'1ncctor !'>tat1on A pillar ng ht :::t
CQ
T ·5
T 16
Connector 15 pin, white. connecto' station A p1lla• r.ght
Connector 16 pin. data link connector
8 Wire corinec:1on (ver11cle speed signal, 1n 1nstrumP.nt
panel wmrg narness
7
- 10
7 I0
It;· Connector pin. pink. connector sta tion A pillar right
a Connec 1 0~ 10 :::i1r'. i:: rl... connector station A pr·lar le ft
b Co1ne:::to~ 10 pin. red . connector s:at•on A pillar. left
'"Ci)

3°'
· Conrector 32 pin. blue. on instrument cluster

~
T 32 r 10 an- Ccnnector 10 pin. on headlight. le't
T 10 aQ· Co~nect0r 10 p1'l, on headlight, righ 1
V 48 - Leh headl1gh: Beam Ad1ust1ng Motor
V ~ 9•ght "leadl gr t 9eam Ad1ust•ng Motor :::J
a en
:::J
~
Edition 10/ 97
W42 USA 5602 02 21
Control Un it for Be am Adjust ing,
Left Rear Level Control System Sensor
Hea dlight Bea m Adju st ing Moto r Edition 10/97
W42 USA 5602 02 .21 -m
-S2 ~
----
~ 0
c.o (Jl I
c.o
~ w
 m
AudiA6 Wiring diagram No. 28
No. 28/1 W iring diagram AudiA6 ~
0I
Central Locking System/ Anti Theft Alarm System/
Ultra-Sound Interior Monitor Ul
~

1999 m. y.

Fuse Panel

Fuse Colors:
R
30 A - Green
--jL ~
25A
20A
-
-
White
Yellow Q GtJ O 0,5 0,35
15 A - Blue -, ~,
____,,~ ~
I I 1' T1e ro/ bl gn/ge •----
10A
7.5 A
-
-
Red
Brown 0,35 0,35 0,5 0,35 0,35 0,35 1 I
I 4 I 3
I.
0 ,5
I, 1

5A - Beige
k 15dt2 rol l ro wl~15d wslt gn bJJ~~15dt9 . ,.,
I.
~.-~-~' '<Y
I r st
w
/br -r:i F2~8
Lf:J
Starting with fuse position 23 . fuses 1n the fu se holder i
0 35
T32
/30
r
86s 0,35
/10 T32a
/ 30 0,35
1
1

0,35
1 E165
0,35
.. r
• 10al/9
(1'

0,35
,.

0,5
2

.
are ident ified with 223 in the wiring diagram J 218 D ws/bl J 218 br/gr
;0 li/gn sw/ br sw/br gr/bl

II 4/5
J_
...1Q._
II 5/8
~
' 4/13 ' 4/15 ' 3/9
13 - Fold Relay Panel

II -Start ing Interlock Relay. J207 0,35 ......

OJ

r
. ge/ ro ge/ ro
\
' /
10
~··
tr 15d/12 ~51 112 3
T en
o,35 0,5""

..
sw/ br ge/ ro ge/ ro

WS=White tr~~ ~ I
10-f/6_ _. .

' Ho
sw =black ~I

~F120
0,35 .. 0,5
ro =red
ro/bl ge/ro
gn =green
br= brow n
bl =bl ue -
,1 '2
. -~

gr =gray
Ii =violet
ge =yel low
1,5
br
1,5
br
1,5
br
r
0,35
br
F2·4·8 r i. ® V1s1·
t2 t1
0,35 •• 0,5
br br
I

@@@ @ @)@
10 11 12 13 14

97-19741 I
D - Ignition/Starter Switch -Ground connec t ion, on right A-pi llar, lower pan
E 165 - Trunk Lid Release Switch
F '. 20 - Hood Ala rm Switch - Grou nd connection -2-, 1n rear wiring harness
F 248 - Switch for unlocking. rear lid lock cylinder
H 8 - Alarm Horn -Ground connection. 1n rear lid w iring harness
J 218 - Instrument Cluster Combinat ion Processor
J 429 - Control module for central locking - Ground connection -1-. 1n central locking system wiring
R -Radio harness
R 47 - Antenna w ire for central locking and anti-theft warning - Wire connection 186s), 1n inst rument panel w iring harness
system
T 1 e - Single connector. on Radio - Wire conneC11on (veh icle speed signal). 1n instrument
T 1o f ·Connector 1O pin , brown. connector station A pillar. left panel wiring harness
T 15 d - Con nector 15 pin, black. connector stat ion A pillar, right
T 15 I - Connector 15 pin, black. 1n luggage compartment
T 32 - Connector 32 pin. blue, on instrument cluster
T 32 a -Connector 32 pin, green. on instrument cluster • -only seda n
V 151 - Motor for re mote unlock rear lid -only wagon
Edition 07 /99
W42 .USA.5602.05 .21 Alarm Horn, Hood Alarm Switch , Antenna wire for Edition 07 /99
Central Locking and Anti-Theft Warning System W42.USA.5602.05 .21
Audi AG Wiring diagram No. 28/2
No. 28/3 Wiring diagram AudiA6
30 -~----------------------------- 30
E E _______________ - - - - - 30
x x ~ - · -------___._

~ ~ x - - - -- - - -- - ·.- -- - - -- - - -- - - - 1S
31 - -- -- - - - - - - - - - - - - - - - _ ~1

I 4
l 1 l 2
E4o
w11
0,35
gr/bl

~3

E150
~
0 ,35
gr/bl
J,97
· T20a /7

tT~~ak
0,35

f
sw/gr
I
0,35
sr

E a13111oal/5
r
j 234
. 69
0 ,5
Ii/bl
I
c 22111
r'
E 3

r
0,5
Ii/bl

tT1oav/ 1
,-
157
O,S
ro/ gr

h sa11
I
O,S
, I-1~'" 6,0 2.5
D

r'"
2,5
:
~
t,5
ro/ bl

f 23ea ~o
- S 23s ""St.f roi bi
~ 20A -" 10A ,'

t e - ! 14
~T1ov1
1 ~ TI6
,- T
8
0 ,35
gn/ws
0,35
bl/ws
0,5
Ii/gr
0,35
sw/gr
0 ,35
sw/gr
0,5
Ii/bl
0 ,5
Ii/bl re/ gr
j _L Lj _ 6.0 O,S
ro/bl
0 ,35
ro/~
0 ,35
ro/bl
0,5
ro/bl

k,T, Ei
114
lr:T. 15 i/13 ~T2s11
• T
h 5dl151
12 F
0 ,35
!r,Ot/7
0 ,35
&z ~ 1 1-----& I 0 ,5
~i: .~:
0,35 0 ,35
gn/ws bl/ws j 135
.. Ii/bl ro/ gr ro/ bl

' 4112 ' 4 /1 4 j 429

' 4/8 ' 4117 ' 4/ 4 J _, s_11_o_ _ _J_ . _29_ _ _ __,,~1n
@ ·~

i
"?
J
> L___1 ---------~
3/1 1213 12/TI
rm I 5 /2 3/6 i 3/12
12'2
i2'1
I 1 5/3 5/lt 1312
44
,-
0,35
bl
0 ,35
br/ ge
0 ,35
gnlbl
0,5
gr/br
0 ,5
gn/ro
0.35
re/ gr
0 .35
ge/ gr
0,5
gn/ br
O,S
ws/li
0.35
ro/bl
0 ,35
ws/ re m
iTish/4 135 h IBh/3 .hsh/2!r,Sh/1 ~Tish h sh111
CD
ili5i!3 ili5i!6 tli5i/5 tTEi12 r 5i11 ws =wh1te
WS=Wh lt8
sw =black
1
0,35
I
0,5
I
0 ,35
T
O,S
T
0,5
T 1t2
0.35
r
0,35 (')
0,35 0 ,35 0 ,35 0,5 0 ,5
sw =black
ro=red
ro =red re/ gr ro/ gr ge/ gr gn/br ws/li re/ bl ws/ ro ........
bl brfge gn/bl gr/br gn/ ro gn =greer I ~

'2 't
IM
,3 ts f 5 , 2 '1
gn = ~ireen
br = brown
or=brown
bl =blue ' 4 '3
~'----'------·

~'\: ot-'\: ~
' T2u/1 ' T2u/2
(')
0)
k
bl = blue gr =gray
c~ ® gr =gray l1=v1olei
F3 I 8
F 133 V s1
l1 =v1olet ge =Yellow

~
F131 F241 18 V56 ge =yellow 0 ,5
br
0,5
br

I@
0 ,5
br

1@ 29 30 31 32
J@ 34 35 40
~
33 36 37 38 39 42
::::l
IB 16 17 18 19 20 22 23 24 25 26 27 97-t9743 (Q
D - lcn111on/Staner Switch

C 22 - lnterierence tilter 15 1 - Connec1or 15 pin . brown. connector station A pillar. leit

0

F
3
• 33
- Door Contact Switch - Passenger side
- 'light Fron; Central Lock ing System Act1vator/Sw.tch
·Ground connection. m passenge''s do'.Jr wiring tiarness

- Plus connection (30), in 'lst rument panel w rmg harness

0
E 3 · Emergency Flasher Switch 20 a ·Connector 20 pin. red. on Control Mocule for Leve l J 429 - Control module for central locking
E 40 - Left Front W indow Swnch Control M 28 - Right Door Warning Light
·Plus connection (30a ), rn powe~ window/centra l lock1na
0)
S ·4 ·Fuse
E 150 - Switch tor interior lock. drive· side V 56 - Driver's Door Central Lock1rg System Motor
S 238 ·Fuse syst ef""I and door contact switch wm:ig harness - (') (Q
F 2 ·Door Contact Switch - Driver's side

-- 3
F 131 - Left Front Centra l Locking System Ac t1vator/Sw1ch
T 2 t.J ·Connector 2 pin, black. 1n front passengers door) Ct> ~
T 5 a · Co•nector 5 om. black. behind instrument panel. right ::::i 0)
241 - Switch 1n door lock. driver's s1oe
136 - Memory Seat Contr ol Module
197 - Level Control System Control Module
234 ·Airbag Control Module
e. Ground connecuon, In driver's door wiring harness
T
T
V
10
15
57
t · Co•nector 10 pin. orange. connector station A pillar. right
h · Con•ecto· 15 p1r . brown. connector station A pillar. right
- 0 assenger's Door Central Locking Sys:em Motor 03
U>
429 - Control modu le for central locking
1 d - Single connector. brown. connector station A pillar rignt
r-
2 s - Connector 2 pin. black. connector station A pillar. right 0
(')

s· m
- 1O a<- Connector 10 pin. green . connect or station A pillar. left
- 1o al - Connector 10 pin. brown. below driver's seat ;);;;'"
T 1 O av- Connector 10 pin. yellow. connector station A ;iiilar. right -Vehicles with Level Control System

~
Lock Unit for Central Locking Passenger Side, Edition 10/ 98
T 5 a - Connector 15 pin, black. connector station A pillar. left •• -Vehicles w ith Memory Seat (Q
T 15 d - Connector 15 p1r . black. connector station A pillar. rig ht Right Door Warning Light W42.USA5602.04 21
Edition 10/98
W42.USA5602.04.21
Switch for Interior Lock, Driver Side,
Lock Unit for Central Locking, Driver Side ---coco
~ 0 I
(Jl
~ (Jl
 ()
(t)
m
:J
.-... ~
AudiA6 Wiring diagram No. 28/4
No. 28/5 Wiring diagram AudiA6 ~ 0 I
r- (Jl
0 (j)
C)
~50 - - - -- - -_-_ -_ -_
- _- _-_- -_ _- ~50 ~
;1 - - - -- - -- - - -- - -- - - -- - -- - - __ ;1 :5'
<Q
-...... m
~ -.I.
co ()
CD
co ......
~ .......
'36 @ :~ ()
--.-- I I I I I
1,5 0 ,5 0,5 0,5 0 ,5 0,5
r r'--' r '-, r-.~r- 1 1 OJ

t
ro/bl ro/gr

J~:Ll"~.;
11
0 ,35 0 ,35 0 ,35 0 ,35 0 ,35
@ 0 ,35 0 ,35 0 ,35 0,35 0.35

~
r 10V8 li Ii Ii Ii h ro/br rotbr ro/ br ro/br ro/ br

.f:riod/1 ~1i5kni1ioag i1ioahfilioai/9

J n J19 r
C'
1,5
I l r
i1iodnJrri5k filioag hioah hioai

121
--.-- 40
-r
ro/bl

H
0 11
rl I I /3 /3 /3
0 ,35
Ii
0 ,35
Ii
0,35 0.35 0 ,35
~
0,35
ro/br
110
0 ,35
ro/ br
/4 /4
0 ,35
ro/br

I
/4 I
0,35
J l
0,35 0 .35
.......
:::::'.)
0,35
ws/ro
0 ,35
ws/ro
1,5
ro/bl
0 ,35
ro/bl

~
0,35
ro/ gr

uh
0,5
ro/ gr

J :&
0,35
ro/ gr
0,5
ro/gr
0 ,5
ro/ gr
0 .5
re/ gr

~
--.161 --.--
164 p 5d/8 1 JTist/3
r h;5dn
I I T~ T~ {Q

I
8
1 l 1 11-
0 ,35 0 ,35 0 35
,~7i;; ~!
2

V 14 V 15
sw/ ro swill '1; V 14

13
V 14 V 15 V 26 V 21
0
I 1/TI
J 24
I 4/19 {Q

=-t=
r l l/4
r1 >
I 5/4
12/4 12'~
I 3-n - -----,,-1/-1 -j-,-~- - - --~
.......
OJ
0,35 0,35 0 ,5 0 ,5
!t3! ~
s
1 5 /5
3
TT
bl/gr bl/ gr 0 ,35 0 .5 0 ,5 0,35 0,35 (J)

r.·1i5; r.11i5il~
~ Jk
Pi
0 ,35 0 ,35
ws=wnite
sw=black
ws=wh11e
1¥
bl ~i

r 5g/3
br/ bl

T T
gr/h

!1is912lTis911
ro/ gr

ili5d/ 6r
re/gr

5!/8

r--f
sw =black

l l
0 ,35
112

0 ,35
gn/ge gn/ge
ro=red
g n =g reen
ro =red
gn =green
0,5
sw /ro
0,35
bl/Ii
0,5
br/bl
0, 5
gr/Ii
0,35
re/ gr
0,35 ·
re/gr

Jk-1
11otl4 tT15;14

e'2
_ '1
ro/bl ws/ro br=brown br =brown '4 ' 3

~ T2t/1 ~ T2t/2
bl = blue bl =blue liod/6
0,35 0,5 0,35
gr =gray gr=grav
c~'\: c~'\:
gn/ge gn/ge gn/ge 0 ,5
iJ ~ ~
II = VIO iet
ge=yellow
11 =viole t
ge = yellow
Fm isf 132 V115 ro/ gr
-~
0 ,35
br

J@
43 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
I 97. 19744-
97-19745

J ~29 - Control -nodu e for central locking Plus connect1cr 1301. 1n power window/centra l loc<:ng F 10 ·Left ~ear Door Corta ct Switch
M 27 - Le ft Door Warning Light system anc door co'ltact sv·:1:cti w ,· ng narness F i 32 - Left ~e a r Ceotra l Locking System Act vator/Sw1tch ·Ground conrect io.'1. 1'1 ief· ~e ar :J':JO' w1w1g harness
T 2 t - Connector 2 p n. b!ack. 1n driver s door - 01us connection (871 1n power w1rdow/certra lock rg J 2£5 - Po•Aer Sunroof Co 0 trol Moaule
T 3 n - Connector 3 ~ 1 n. red, connecto· station A pillar . left syste m ano door cont2ct sw11cr w1' 1ng ha·ress J 4 29 · Coo1rol module for central locking · Co'"':iect1or lcpenl. m w1 ~ '19 ha'1ess inte rior
- -. 0 t - Connector 10 pin , orange. connec tor station A 01llar, r ght - P!us connec t 1or :30a ), 1n powe· w1r.dowl centra loc<ing 10 a - Connect:)r 10 pin. green. connector station A 01llar. left
· o ag - Connector 10 pin, red . connectc· station A p illar, righ'. systeri ard door con:act sv.·1tch w iring harness 10 ac Co1nector 10 pin. reo. connector station A pillar. rignt - Connection !closed). 1n w 1r·ng t-arness 1:1tenor
t 0 ah - Connector 1O 01n. red , 1n B pillar. left -Wire connection {?1n 5111. 1n cen tral locking syster- w 1cng 10 ah · Coooe:tor 10 pin. red . 1n B 01llar. leit
10 a1 - Ccnnector 10 01n, ·ed. 1n 9 pil lar, ri ght narness 10 a1 · Coonector I 0 pin. ·ed. in B 01llar. right
- 5 1 - Connector 15 pin, brown. connector Station A pillar left 15 d · Connector 15 pin. clack. conn ector stat1or A pillar. rrgrt
V l .d - Le ·1 Window Motor 15 g - Connector 15 pin, blu e. 1n connector station B pillar. left
V 15 - R1gnt Wind ow M otor T 15 k - Co·v1ector 15 ptn, red, :onnecto' sta tion A pillar leh
T 15 ~ - Connec tor 15 pin. grey connector station A pt!lar lef:
\' 14 - Leh W indow l>/otor
V 15 - R1grt W inoow Motor
V 26 · Mai.Or for Window Regulator, rear. left
\' 27 - Motor for Window Reg ulator, rea·. right · Vehic les w1tr Power Sunroof
V 115 - Le't Rear Central Locking System Motor

Edition 10/98 Left Door Warning Light Lock Unit for Central Locking rear left Edition 10/98
W42 .USA.5602 .0l .21 W42 .USA.5602.04 .21
Audi AG Wiring diagram No. 28/6
No. 28/7 Wiring diagram Audi AG

30 - - - - - - - 30
15 - - - - - - - - - - - - - - - - - - 15
x -----------~------------------ x
3t - - - - - - --------------------~ - 31

15
0 ,5
F 125 B D
rA) "i'_________ 17/B 150 I 50b E3 J 218 J 216
·"J ~-----.
2,5 0,5 2,5 2,5 0 ,5
16 I ;;;• l T32a /6
0,5 0 .35 0,35

Ts brt/ws slw ro~swT912 ro~s~914 sw/ gn ge/gn ws/ge

!r,5d/ 4 !r,5d/1! r15d/14

'· 1Ss
i - SA '
T 15rt 8 1.: -------GJ ID T 1 T 1i6
I
119
I
---,-----,- J 207
p;- i T 2/1 I T9 /8 I T9/6
0,5
sw/ gn
0,35
ge/ gn
0,35
ws/ge
_L
0.35
gn/sw
0.35
ws/gr

0,5 0 ,5 2,5 2,5 0,5

"__ b__ _ J_ 42_9_ _ _ _ _ II 4/16 J!;l_. _ ' 4/ 18 t 4/2
sw/bl

h ov2
br/ws

h 5d/11 +A:,
ro/ sw

hoo
ro/ sw br/ gri

h ovs
i r /9
T
0 ,35
sw/bl i~s LJ:w'-' ~: 0,35
4/20 1 3/5

0.35
j
0,35
5n 93
I
0,35
1 2/6

0,5 0,5
-

J 429 ' 4/3 ' 3/ 4 ' 313 gr/ ws

1
bl/ro
I
ws/ ge
~
ws/ ge ws /sw br/sw

~
l

nT~'~
)
)
~2 ~4
i 5/ 13
I 5/6
i 2/5 i 2113
I 3/8
i 1/2 .-:--1 115 i~5 5 0.5 0 ,5 0,5

0 ,35
bl/Ii
0 ,5
gr/bl
0 ,5
br/li
0 ,5
br/ws
0 ,5
ro/ ge
1,5
ro/ge
1,0
ro/li
ws bVro

T 1511• f T 15115
ws l ge

! r15118
ws/sw

! r1s1n
br/ sw

!T15116
m
3¥ h 15112 ffii5111 r-15d/5
tr~~;f r ovsl 0,5
• 0,5
J .. 0,5
I .. 05
T ••
0 ,5 0,5
T ••
0 ,5 0,5
• 0,5
l .. 0,5
ct>
r 5f/ 3
T T 0 ,5 • 1.0 ~
WS = Whlle
sv1 = black
ws = wh.te
s.v = black gr/ws gr/ ws bl/ro bllro ws/ ge ws/ ge ws/sw ws/ sw br/sw br/sw (')
~ T3o/1 kd
....+
~
0.5 0,35 0 ,5 0 ,5 0 ,5
sw/ ro bl/Ii br/bl gr/Ii br/ ws rolge ro l ge ro=red •: = red
gn =green kd @kd .......
~Ti5v2 1 1 gn =green
or = brown (')
'4 '3 '2 '1 ,.,. J 151;9 'i' T 3aV6
T. 1,0T
br=brown
bl =b lue bl = b !ue ~\: ~ F 218 ~'\: F 2os
OJ
ls
0 ,5
br/ws
0 ,5
rolge ro l ge
gr =gray
L =v1ole
gr =gray
l1 = v1ole t
ge =yellow
F 12H T3o/2
r.::; V53

~
F 11 F 134
0,35
-k_ I ~ ge =yellow 0,5 . 0,5 • • 0 ,5 0,5
br br br br
W3
br

I§ 1~ 1~ 1~ I@ .......
n 72 73 74 75 76 n 78 79 80 61 82 83 84
85 86 87 88 89 90 91 92 93 94 95 96 97 98
:::J
97-19746
97-19747 (Q

S -Star.er T 15 r - Connector 15 pin. !:Jrowri. connecor s1at1or. A p·l lar. rignt

E 3
F l 2L
- ::-ergency Flasier Swncn
- Trun< Lock Ala•m/C entral Locking Sw1tcn 0 -Grounc corne::t:o'"l-2-. :n ·ea~ w1r.rg harress
0
) - lgn111on/Star.er Switch V 97 - Double Cab "11gh Rear Dcor Central Loe< ng System
Motor
c: 206
c: 2i 8
- TrunK _ d Clo sed Pos1t1on Svv1tc1
-Switch for centra l locking, trunk lid 0 · GroJnd connec11o:i. m rea · lid wiring harness
F 11 - Right Rear Door Contact Sw1:ch
125 · Wult1-rur.ct1on Transmission Ra nge ITRJ Sw1tcn W 3 · Lcggage Compartment Light .,
J
2i 8 - Instrument Cluster Combination Processor
429 - Con:rol module ~or centra l lo::king
OJ
F 134 - Right Rear Central Locking System Act1vator/Sw1:ch
T 2 v - Connector 2 pin. black, luggage compartment () (Q
J 207 · Sta'11ng Interlock nelay
J 429 ·Control module for centra l locking
T 2 w - Corriec:or 2 pin. grey. luggage companment ([) .......
S 6 - Fuse G -Ground connection. n r:ght rear door w1ong harness
~
T
3 o - Con.,ec:o· 3 p;n, olack. 1n rear ! d
1

1Oa f . Connecto~ 1O p1r v1ole:, connector station A pillar, left

:::J
........ OJ
8
-05 en3
T 2 - Connectcr 2 p11. grey, 1n engine corrpartm ent. ·1gh: T 15 d - Conrector 15 pin. black . conrector station A pd!ar. ngnt
T 3 at - Connector 3 pin. grey, connector station A pillar. left -Plus connec11on (15). 1n instrument panel w1r11g harness T 15 I - Connector 15 pin. black, 1n luggage compar.meot
7 9 - Connector 9 pr1. brown, on starnng interlock re av
T · 0 o ·Connector 1 O pm, brown. connector station electroni::
box plenur.1 cha'l1ber
e. Pies connecuor (50i. In 1nstrcmert panel w1-·ng ha•ness
T
\
32 a Corrector 32 ptn, gree"" on ·nstrurent cluster
53 · Dec<l1d Central Locking System Moto•
.,.
-only seaan
-only wago.,
r-
a
10 t · Connec10· 1 O pin. orange. connector stat ion A pillar. ·1g'1t
10 ai - Connector 1O prn. violet. connector stat1or A pillar. left (')
i 5 d - Connector 15 pin, black, connector station A p .ar og ·n
15 f - Connector 15 pir.. blue , 1n connector sta t ion B pillar right
-only wagon
Switch for Central Locking, Trunk Lid Edition 10/ 98
::s:;--
5· m
~
- '5 . Connecto• 15 p11. black. 1n luggage compartment
Lock Unit for Central Locking , rear , right,
W42 . USA.5602 .04.21 (Q
Edition 10/98
-..._
W42 USA.5602.04 21 Starting Interlock Relay
.....a.. 0I
co
co (J1
~ .......i
 ()
(t)
m
Audi AG Wiring diagram No. 28/8 No. 28/9 Wiring diagram Audi A6
::J
........ ~
~ 0 I
r- (Jl
30 - - - · -·- - - - ·- ·-- - - - - - -- - - -- - - - 30
~ --------·----~--------------~·----- ~
a(') (X)
~ ~
25:
~
::J
(Q
--..__
._... m
-
~ <D
- -···- - - - - - - - - - -- - - -- - - -- - - - - - - ~ ()
.....+
V2 V 2
~ ......
9
I +. - 1 2

, 8- -11 I
t
0 ,35 2,5 2,5 ()
~
J 210

0 ,35 0 ,35 0,35 0 ,35

I
0 ,35

.
r~~~o
0 ,35
.---
gnlge

~-1
-.-
4o g+ -..- sw/ gn

96
~·
43
I +~--
G;~··

C)
tu
-
gnlro
_ _
igT 0 ,35 0,35 0 ,35 0,35 0,35 0 ,35 0 ,35 0 ,35
~
"LJ
f :.~·:•:P'
9n1/:I gn
l gln
ro Lgt15d/3
J gntge gnl ge rolbl swl gn wslgr gnlro ws/ ro
L)gQJ E 41
T32125 T16an
0 35 0 ,5 0 ,5
rB
0 ,35
l I, 4
~'-i <5s''
,3
l
E163

<if;:.~
~.

p
J 210 K ·
gnlro gr / bl gr lb! gr / bl ::::J
'i"IT 2ah

ih k '
l ~. co
___________L_n
f... ~
J..
J.6~.
' 12 0 ,35 0.35 0 ,35

,,,··-,J..
10d/ 2f 10ag/ 9 ·1 t
~.u i 2

J4~
\LL...__ _ _ _ _
@_ _ _ _~ 0 ,5 0 ,35 0 ,35 0 ,35 0 ,35 0 ,35 0 ,35 0 ,35 0
i2n grlbl grlbl gnl ge gnlge grl ff'N gnl sw bVgn sw/ gn or, gn , _- __ _- _ _ .- - ,
m·
i 2110 iV6
~ +oi L L L L I.. on
- •n

rr+.s
0.5 05 "~
( l.i...l
91" ......
I
ro/ gn
·1··
~T1oaft6 ' tu
T ,, 1 ~. T10aft 8

J~·· ~
'i'T10af in

17'1 ..

~135• ~'"'H :t~M ',1~· 'f

3
0 ,35 0 ,35 0 ,35

r z,
rT.. I ·r-~I
0 ,5 0 ,5 0,5 0 ,5 " CJ)
gnlgr gnll i ro/ gn

I 0,35
W 3 ws=whi t e rolbl
.,.T l5111 WS=White
sw = black sw = b lack ~ oflws
0 ,5 ~ 0 35 1531 ro = red ro = red o.35 .. 1.0 .. 2.5 .. 2.5· : _ _ ___ - r~
gn = g re en
w~
grlbl gn =g reen
br=brown
'°i.g_n,______.,® c& br = b rown , 2 t 2 )", 12 14 11 13
_,,_
I.. I
bl =blue
gr=gray
Ii =vio let
bl =b lue
gr = g ray
Ii = v iole t
; - '_ 1 1
~ J Tsat4 0
1

V155 · ® I

t_
0 ,5
reign
0.35
ro/gn
ge = ye llow ge = yellow
0 ,35 0 ,35 ..
G 104
..
G 103 2,5
ws/li ....
Gm
l 2 I, br br
W 3 W43 I@1@ Ea1
• Fl

no m 112 113 114 115 116 117 118 1t9 120 t21 122 123 t24 125 126
-- --
I 91.1914e 97-19749

E 41 ·Right From W indow Switch E 87 -AJC Control Head

-Wire connect ion (58s) . 1n instrument oanel wiring harness -Ground connection -1-, 1n centra l locking svstem wiring
J 218 - Instrument Cluster Combination Processor E 183 - Switch for passenger compartment monitoring
J 429 - Control module for central locking harn ess
-Connector (K-d1agnos 1s wire!. 1n instrument panel wirin g G 170 - Ultra - sound sensor, leit for ant i-tneft warning system
K - DLC (Data Link Connector) Rapid Data Transfer -Wire connection, 1n AJC w1nng harness
harness G 17 1 . Ultra - sound sensor, right for ant1-tneft warning system
T 1O d - Connector 10 pin, green . connector sta11on A pi ll ar, left G 183 - Sensor for broken w indow glass rear left
- Wire connect 10 -1 -, 1n On-Board Diagnostic IO BDI wiring -Wire connect ion -2-. 1n AJC wiring harness
T 1O al - Co nectar 0 pin. violet. connector stauon A pillar. leit G ; 84 - Sensor for broken window glass rear right
harness
T 1O ag -Conn ector 10 pin, red, connector station A pilla r. right J 347 . Control Modu le for Ultra-Sound sensors
-Plus connection (581, •n power w indow wiring harness -Wire connection -Hsw1tch/control module !. cent ra l
T 15 d - Connector 15 pin. black, connector statioi A pillar, rigm T 2 ah - Connector 2 pin, blue. connector stat ion A pil lar, right
T 15 k - Connector 15 pin. red, connector station A pilla r, left locking system w1nng harness
-Wire connection. 1n rear wiring harness T 3 v - Connector 3 pin, black. 1n luggage compartment
T 15 I - Connector 15 pin, black. 1n luggage compartment T 6 a - ConneClor 6 pin, blue. connector sta tion A pil lar, left
T 16 a - Connector 16 pin, data link connector T 6 b-Connector 6 pin, whi te. connector station A pillar, left
T 32 - Connector 32 pin . bl e. on instrument cluster T 1O t - Connector 1O pin, orange . connector station A pil lar. ri ght
v 155 - Motor f or fuel tank lid unlock V 2 - Fres Air Blower
w3 - Luggage Compartment Light -only sedan
-on ly sedan Z 1 - Heated rear window
w 43 - Rea r courte sy lamp, 1n rear lid ·only wagon
... -on !y wagon ... -Veh icles with soar cells
.... -Veh•cles w1:hou: reao a rbag

Edition 07 /99 Motor for Fuel Tank Lid Unlock Control Module for Ultra-Sound Sensors Edition 07 /99
W42 .USA.5602 .05 21 W42 .USA 5602 .05.21
Audi A6 Wiring diagram No. 28/10 No. 28/11 Wiring diagram Audi AG

30 30
30 30 15
15 15 15 x
x x x 31
31 31 31

~ ~ ~ ~

l
lr lr
0,5
V '26

0 ,5
0 ,5
swl1i
¥
tT15tt4

0,35 0,5
:s6l

0 ,5
V 21

0,5
~
0 ,35
grlbl
lJT10a1110
0 ,35

T~
sw/ ro sw/ ro ro/ gr ro/ gr sw/ ro sw/ ro ro/ gr ro/ gr

~T 4ct2 l-T::' ~fo12 Yr::'

'~
E 54
'i;,J150,5 oM35 f?5 oM35
gn/ ge gn/ge gr/ bl gr/b1 gnV g1ge gr/bl gr/bl

,2

W33<f W31~ L110 @'

L L 't @ ' L4s
12

W34~ W380 Lm ® '

L Lf l.1
L49

1. 1 t t It I2 i1 t 1 I1 I2

ws =wh1te ws =wh11e
r~lf:)J
"'T4c11
~~!T4d11
sw =black
ro=red
sw =black
ro =red
T
0 ,5 0,35 0,35
T
0,5 0 ,35 0.35
gn =green gn =green ro/li br br ro/li br br
br=brown
bl =blue
gr=gray
li =violet
br =brown
ol =blue
gr =gray
!T15g115
I
k:'
T
lrl 151115
1
K::'
li=violet 0 ,5 0 ,5 0,5 0 ,5

--r~1-li_ _ _ _btr----~~
S~2-·~11-/li_ __
ge=yellow ge =yellow

w u a m ~ m m ~ m m m m m ~
S2

i 01-19150 I
S2

- - -- - - --
141 142 143 144
--lt-§-==o==--
145
n-
146
--------'~@
147 148 149
__
br-

150
_________
·- --

151
- - -- - S2

152 153 154

E 40 - Left Front Window Switch -Ground connection. 1n driver's door wiring harness E 52 - Left Rea r W indow Sw~ch . (In LR Door) -Ground connection . 1n left rear door wiring harness
E 41 - Right Front Window Switch E 54 - Right Rear Window Swnch. (In RR Door)
G 170 - Ult ra-sou nd sensor. left for anti-theft warning system -Ground connection. 1n passenger's door w1nng harness L 48 - Leh Rear Asht ray Light - Ground connection . 1n right rear door wiring harness
G 171 - Ultra-sound sensor. nght for anti-theft warning system L 49 - Right Rear Ashtray Light
J 347 -Control Module for Ul t ra-Sou nd sensors -Wire connection. in central locking system wiring harness L 110 - Door Opener Illumi nation. rear left -Wire connection. 1n centra l locking system w1nng harness
L 108 - Door Opene r lllum1nat1on. Driver's S1oe L 1 1 1 - Door Opener Illuminat ion. rear right
L 109 - Door Opener lllum1nat1on. Passenger's Side 4 c - Connectoc 4 pin. black. in left rear door
T 4 a1- Connector 4 pin . on C pillar. righ t 4 d - Connector 4 pin , black . 1n righ t rear door
T 5 b-Connector 5 pin . black. 1n driver's door 10 ah - Connector 10 pin , red. in B p illar. left
T 5 c - Connector 5 pin. black. 1n passenger's door 1O a1 - Connector 10 pin , red. in B pillar. nght
T 15 h - Connector 15 pin. brown. connector station A pillar. right 15 f - Connector 15 pin . blue . in conn ector station B 01llar, nght
T 15 1 - Connector 15 pin. brown. connector station A pillar, left T 15 g - Connector 15 pin. blue . in connector st ation B pillar. left
W 30 - Door warning light, driver side V 26 - Motor for window regula tor, re ar, left
W
W
31
32
- Entry light front. left
- Entry lig ht front. right • - Vehicles wnh head airbag
v
W
27
33
- Motor for window regulator. rear. nght
- Entry light rear. left m
~
W 36 - Door warning light, passenger side W 34 - Entry light rear. nght
W 37 - Door warning light rear . left
W 38 - Door warning lig ht rea r. nght
Edition 07 /99 Door Warning Lights Front,
Entry Lights Front
Door Warning Lights Rear, Edition 07 /99
W42.USA.5602.05 .21
0I
W42 .USA. 5602 .05.21 Entry Lights Rear
(Jl
co
 ()
CD
m
::J ~
AudiA6 Wiring diagram No. 28/12 No. 28/13 Wiring diagram Audi AG ~ 0I
r- (j)
0 0
w w
~
30 - - - - - - 30
IB IB 15 - - - - 15
x x
~ ~
x - --
31 - - - - - - · - 31
x
:s·
~ ~ ~
(Q
m
~ ............
.......
c.o ('")
CD
c.o r-+
~ ~­

D
j 218
I T32/21
('")
o.>
-,~; I
~o
gn/ge
o.35

0 ,5
l@I ...!
05 l
0 ,35

~·,·
T T 1oa
119
t8 8
¥
1,0
ro/ge

'~-
B:;-\ r
,-+--- - - - 6129
~
.....
gr,i 0 ·35 0 ,35.19 19 I

rT -£ ""'!;..J ge ~
0,35 0 ,5 0 ,5
j gr/bl ro/ge br/ ws ::1
(Q
W 1o g W 9T § L:.I .~
~
' T6m/5 w
' T6m/ 4 ' T6m/2 0
r ni ' 1 I 1~0 I rff 'i' g

r1
'°3
fro sw/li
.....
SW
,~ t IB~ 1 ~ 1 ~ · ~ 1 IB~ IB~ , IB~ ~ IB~
1

0 ,5
1
0 ,5 0 ,5
1
1,0
bh/
2 2
0 ,35
1 wr2bv2
0 ,5 1,0 0,35 o.>
ro/ge bl/gr sw/ro sw/ ro sw/ ro sw/li sw/li swfli 0,5 0 ,35 0 ,35 0 ,35 0 ,35 0 ,35

lJT I ~ I lri ~ I! 2 ~
br gr/bl br/ws ro/ ge ro/ gn br/li

~,~ L~':tt
5a/2iT15d/13
(J)
12
0 ,5
re/Ii
0 ,5
bl/ gr
w /0,
45 'O'
w 0I 46 ws=wh1te WS=Whl t8 I
T19 ~ 1'1 11 sw =black
ro=red
sw =black
ro =red
I ®' ~' I 10,
1,0 1,0 gn =green gn =g reen
b r =brown br =brown

@:j
t 0 ,5
re/Ii
l~2bM
1,0
re/Ii
l~2~~
1,0
re/Ii
bl =blue
gr =gray
Ii =violet
ge =yellow
bl =blue
gr =gray
ll=VIOlet
ge =yellow
-.fo
0
""fa
0
-~
0
I
I
2
S2 I I I W 11 W 12 W 43 0 .5
br

E M m M s ~ B ~ m ~ - ~ fil - t69 170 in 172 173

- --
174 17S 176 m 178 179
L~ ---
180 t8t 182

~ 97-19753
J 136 - Memory Seat Control Module
e -Wire co.,nection (driver's door contact swnch), 1n instru- ~ 6 rr · Carnector 6 pin, on inte rior light. frcnt
G
e
J 218 - Instrument Clus1er Comb1nat1on Processor ment pane w iring harness
1
T 6 n · Cornector 6 pin. on interior light. fror.t · Grouno connect1on. in sunroof wiring harness
- g - Single conn ector. black. conn ector station A pillar. right ·Wire connection -1- , in left rear door w 1r 1ng harness T 6 o · Connector 6 pin. on 1n;eri or light. rear
T
T
5 a - Connector 5 pin, black. oeh1nd instrument panel. nght
2 bh - Connector 2 pin. black. be low drive r's seat
@ -Wi re conn ecti on -2 -, 1n nght rear door wmng harness
W
W 11
- Front Interi or Light
·Left Rear Reading Llgnt
8 · Connector J1nterior light 3/Li. in wiring harn ess interior

T 2 b1 - Connector 2 pin. black. below passenger 's sea t W 12 · Right Re ar Rea ding Light
T
T
T
10 ak-Connector 10 pin. green. connector station A pillar. left
1O al- Connecto: 10 pin. brown. below driver' s seat
· 5 a. Connec tor 15 pin. black. connector station A pillar. left
0 -Wi re corinection, 1n central locking system wiring harness W 43 ·Rear courtesy la mp

T i 5 d ·Connector 15 pin. black. connector station A pillar. right

T 32 - Connector 32 pin. blue. on instrument cluste r
W 9 ·Left Footwell L1aht
W 10 - Right Footw ell light
W 45 - Leit Fao1well Light. rear
W 46 - Right Foatwell Light, rea r
-Veh1c 1es with Memory Seat

Edit ion 10/ 98 Footwe ll Lights Interior Lights, Reading Lights Edition 10/98
W42 .USA.5602 .04 .21 W42.USA.5602 .04.21
 AudiA6 Wiring diagram No. 28/14

~ ~
E E
x x
~ ~

8129
@
~
0,5
gr/bl
I II
0 ,35
ro/ge
0,35
ro/ ge
0 ,35
ro/ge
1
JT15t/4 _

OJ
0 ,35 0, 35
gr/bl gr /bl

. k : 1 W19 1 T3p/ 3 fT 4e/ 2

: ·~· ®' ~
1w13 ~1 ~1
THIS SPACE INTENTIONALLY
Qf'~ ~i ¢'
~
- ~ I LEFT BLANK m
r: r~ · n~ I
F i47
I
2
~
-=-----.1
I

CD

,
F i48 r
ws = wh1te ('")
,,
r-------1 0 ,35 0 ,35
sw=black ......+
0 ,35 0 ,35
ro/gr
,
ro/gr
~o =red
gn =green ~- ....
br/sw ro/ gn br = brown ('")
~ e L~ eL~ Q)
'6 i
bl = blue
gr =gray
11 =VIOi et

~
Y 7 2 12
ge=yellow
0 ,35 0 ,35 0,35 2,5
b< br b< b<

j@ 1@ 1@ @ 8'
""""'Ii

::J
183 184 185 186 187 188 189 190 191 192 193 19 4 195 196
(Q
i 97-=is 167
147
148
- Len Make-Up M irror Ligh t Switch
- Right Make- Up Mirror Light Switch
8 - Ground connecti on. on left A-pilla r. lower pact 0
31 - Make-up Mirror Light @ -Ground connecti on. 1n sunroof w1r1ng harness Q)
1
3
4
f - Single connect or. black. on front inte rior light
p- Connector 3 pin, on reading lamp front 11ght
e - Connector 4 pin, on reading lamp front lett
8 -Connector l1ntenor light 3/LJ . 1n wiring harness interior () (Q
<D """"'Ii
T 15 t - Conn ector 15 pin. grey. connector station A pillar. lett ::J Q)
~
W 13 - Right Front Map/ Reading Li ght
W i9
v 7
- Left Front Read ing Light
- Automatic day/n ight mtenor mirror 3
-
r- CJ)
a
-Vehicles with Automatic Dimmer Inside Mirror
~ m
Make-Up Mirror Light
<2'
.-._,
~
Edition 10/98
W42 USA56Q2 _Q4 21 -.4, 0
co I
co (j)
~ ~
 CJ
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AudiA6 Wiring diagram No. 35
No. 35/1 Wiring diagra m Audi AG
""'3
:::?".

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Daytime Running Lights with Fog Light and Rear Fog Light :::0 l'V
(Canada) ~50 - - - - - - - - - - - -
x
·------==-=----------_-_-_-____ 30
~
c:
::J
31 -- ~ ::J
1999 m. y.
:s· m
(Q
Fuse Panel r- CD
c0· ()
....+
::J'- ......
Fus e Colors: Ci)"
()
30A
25A
- Green
White
--.
-4 Q)
20A - Yellow (Q
15A - Blue
(Q
--.- ~
~
17 5 1 17
lOA - Red r T
7,SA
SA
Brown
- Beige
2,5
ro
2,5
ws/ge
2,5
ge/ sw
1,5
gr/ gn
~
' 15130 El E 23 ' 2/XR K t3 K 11 Ls L4o
:::::::!.
' 51560 ' 1/XZ ::::J
Starting with fuse posi tion 23, fuses in the fuse holder
are identified wi th 223 in th e wiring diagram .
"Ji:- ;A_ Qi[' ii-· ~· cc
1
9 / NSL i 17/ 58s I 10/31
0
gr/bl
......
Relay Location :
[~

1,0
s+ 0,35
Q)
El - Load Reduction Relay, J59
J21s J21s
ws/ ge

,1
ws/ge
_L
...L.
19
gr/ws

!r6a11
gr/bl

I 58s
T32/ 20
3
CJ)
WT32126 I T32127
0 ,35 0,35 IJ
Of-
2,5
---.-
2,5
T
1,0
J 218
ws = wh1te gr/ gn gn/gr ~ S 2s re ro gr/ws

~ 81 r
s w =black

I,
L2-.J 12A
ro = re d
I 7156 ' 1130 L /30

:..~F==t: . ~ L
gn =green
br =b rown
I I I b l =blu e 0,5
gn/gr
0 ,5
gn/ gr
1,5
ws/ gn
\- ·- 46
A B C gr =gra y
_L E 4 i st 56b h
11=VIOiet .Kl :ii ~ 12

ge =yellow t, O 1,5 1,5 1,5 1,0 0 ,5

c& ~ A ~ }@ br

1~
10 12 13
13 - Fold Relay Panel
97-5 0661
Relay Location :

Ill - Fog Lig ht Relay, JS

E -
E 4
- Light sw·tch
- Headlight Dimmer/ Flashe r Switch
C0 -Ground connec11on -l . 1n instrume nt pa nel w1nng harness
E 23 - Fog Li g ht Sw1:ch
II - Lamp Control Module. J 123 j 218 - lnstrumen: Cluster Comb1na11on Proce ssor
0 -G ro und con;iect1on -2-. 1n rear wiring harness
K 13 - Rear Fog Li g ht Indicator Light
ll!J -Lamp Control Module. Jl 23 K 17
L 3
- Fog Light Ind icato r Lig ht
- Headlight Switch Light
8 -Wire connection (58s ). rn instrument pan el wiring harness
!Swnch illum1nat1onl

m- Fog Light Circ uit Brea er. S28

L 40
L 46
- Front And 'lear Fog Light Switch Li ght
- Left Re ar Fog Light
8 -W ire conn ection 1561. 1n 1ns11umen1 panel wiring harness

s 28 - Fog L1gh1 Circui t Breaker

T 6 a - Conn ector 6 pin. blue, connector sta tion A pillar. le t
8 - Connector {daym me runni ng ligh ts). 1n instrument panel
w1nr.g harne ss
T 32 - Connector 32 pin. blue, on instrument clu ster 8 - Connector -2- (daytime running lights) . 1n instr ~ment
pa nel w1n~g harness

Light Switch, Front And Rear Fog Light Switch, Edition 10/98
Headlight Dimmer/ Flasher Switch W42 USA. 5602 .04 .2 i
Edition 10/98
W42 USA 5602 04 21
Audi AG Wiring diagram No. 35/2
No. 35/3 Wiring diagram Audi AG

30 -----------·---------~ ·- - - - 30
15 - - - - - - -· - - - - -- - -- - - - ------- 15
x - - - - -- - - - - -- x
f a1a5 1 rt30 31 - - - - - - - - - -- - - ·- - - - - - - - - -- - - - 31

;cn--- ~~ ·1 e
I
l .-- J59
~5/86 ~6/87

r·nJ r rT§f~
1,0
get sw
2'
I
2,5
C1fl
I
2,5
ro
9'
I
2,5 6,0

§
0,5

"i
J 21 8

fll T-r i
1
ge
0
ge
0 ,5
gn/gr
0 ,5
gn/gr
t---
1,5
ge/ gr

lt3 I i i I I 20 I 21 , 22 J, 223
' 236

Y3r
2,5 2,5 4,0 1,5 1,0 0,5 - 8 20 - 8 21 - 8 22. - S 223 ~ 8 2:i6

L o L o D
;k ' - 10A

IS (':-, ~ IS h
- 10A - 15A + 15A - SA -

-~
SA

I;:.-
-£_ J! . . · ,s3 .-s4 1,5 0 ,35 1,S O,S 1.5 1,0 1,5 1,0 0,5 0,5 0 ,5 0 ,5 1.S

T ~'' T T I v I v
!J SA - 5A ge/br ge/br ge/gn ge/gn gr/ re gr/ws gr/ sw gr/ ge gr/gn
' rs
4
I
I SOb I SO 115 1
P i 86s
I 3a I 4a
I /2
49 I
4812
_I_
_R. ~
l_

l~~Lmm
+
2,5 1,5 2,5 0 ,S 4,0 O,S 14/ 56bR 11/56bl ' 10/58R
1 1
bl __I...,
ge/ sw ws/ gn ro/sw

1 ;32m1
...I_ I I " T sk!4 '<'T 1oat 4
& --
, J 123

,,.--.
B C1
K
I
11S/ 56bR1
I
113/56 bl1
-.
37
I
112/ 58bR1 v 1 17/58bl1

1,5 I~ 1,5 1,0 0 ,5

1,S 1,5 0 ,5 0 ,5 0 ,5 0 ,5
ws/ ge ws/ sw ge/ws ge/ sw
ws/gn ws/gn gr/gn gr/ge
~T6kt3 ·~lioat5
!r1ob15
l
1
TT6V3
~ 9f 1
JT101n
WS = White
ws =whne
l
1,5
ge/ws
I
1,5
ge/ sw

I
,,
1,0 1,0 1,S O,S 0,5 0.5 sw = b ac~
ws/gn ws/ gn ws/ gn ws/sw gr/gn gr/ ge sw = black
ro =red
56a 56a JT10ao/5
56b 5sb
1 T10ao/ 1 T10a n/1 1 1 T10a n/5
I
~ 8187
ro = reo 1

f ,6185 _ 1I_1 _ _ gn = gree n

g., =Q'een
~ M 31

r Ws
1 br =brow1 & M J2 & M 3o g M 29
br = brown I

I
bl = b lue
g L 22 \: --- ----:b D 'g 0 x bl = blue gr = g ray
L 23 J 1 ~0an/8 i ~Oao/10

[_f
I 5 T10ao/8 ·1no. n110
t 2
J2 j 2
gr =g ray
11 = VIOi et
II = VIOiet
ge = yellow
1,5
31

1,S 1,S 1,S

31

g e =ye llow
1,0 1,0 1 s o,s br br br br
br

I@ I@
br ws
...I_
~
/ge br

1~
1@ 1@ -I'8
29 30 31 32 33
J@ 35 36 37 38 39 40 42
15 16 17 18 19 20 21 22 23 24 2S 26 27 28 97-50663
J 123 - La":"p Ccn1rol 'Viodule T 10 a Connector 10 c1n. p1n i< , connector s:at1on A pilla·. left
' 1 -1-eadhgt"'t h1gn Beam Indicator Light T 10 ar · Corriec:o~ l 0 01n er headlight, e ft
B · Starce· ·Ground conn ect ion ·2·. n rear wiring harness M 1 - _eit Pa'k 1ng _1gj:
T 1Cao Connec: or · 0 ::r'1, on headlight. rig1t
C 1 - Vol tag e Regul ator (V R) M 2 · ~ gh1 Ta _1ght T 32 ·Connector 32 ::i1n. blue on instrument c luster
D - lgn1t1on/Star1e• Switch -G~ound connect1cn. 1n r1g 1 t headlight w1r1ng harness M 3 · rt1gh1 Parking L1gm V 48 · Leit Headlight Beam Ao1cst1ng Motor
J 5 · Fog Li g ht Re lay M 4 ·_eh Ta I L1art V 49 · ~1ght l-ieadl1ght 3eam Adjusting Motor
~ 59 · Load Reduct ion Rela y -G roun d connection. 1n left headlight wiring harness M 29 - _eit Lo"' Bea -n Headlight
_ 218 - Instrument Cluster Como1na t1on °rocessor M 30 - Le '1 H1gr Beam Yead l1gh1
-Plus connection (151. 1n instrum ent panel wir ing narness M 31 - R £nt Low Sea-o rleadl1gr1
L 22
L 23
· Le ft Fro nt Fog Lig ht
- Rig ht Front Fog L1gh1
W
S
32
18
- ~ gh1 High Beam Headl1gh1
- =cse
@ -G round conriect1on. 1n right headlight w1r 1ng harness
• Wire connection {86sJ. 1n instrument oanel w iring narness
S 3
S 4
- Fuse
- Fuse
S
S
19
20
- 0 use
-Fu se
@ ·Ground connec11on. H"' left headirgnt w1nng harness
T 6 1 - Connector 6 pin. rec. connector station A pillar. rignt . Wire conriect ion (58al. 1n instrument panel wiring narness
S 21 -=cse
T 1O b - Connector 1O pin, red. connecto r stat ion A pillar. left
- Plus connection 1301. in ·nsULr'lent oanel w iring haness S 22 - FJse
T 1O f . Connec tor 1O pin. brown. con nector station A pillar. left S 223 · F JSe
T 32 a - Connec tor 32 pin, gree n. on instrument clus ter S 236 · FJse
W6
X
- Glove CofT'pa ri men t L gh1
- License Plate Light
- Plus connection 15Bbl. 1n instrument pane! wiring harness

. co~nec t : on 2 ldaywne •unning lights) . 1n instr Jment panel

- c < - Conrec:or 6 p1r oink. cornector siat1on A pillar. r gh1

Hea dlight Left a nd Right Edition 10/98

m
Edition 10/98
wring harness
Ignition/Starter Switch, Fog Light,
W 42.USA.5602.04.21
~
W 42.USA.5602.D4 21 License Plate Light 0I
(j)
w
AudiA6 No. 54/1 No. 54/2 Wiring diagram AudiA6 0 m
-
Wiring diagram ct>
~~~~~~~~~~~~
::J ~
Central Locking System I Anti Theft Alarm System I ~~~~~~~~~~~~~~~~~~~~

Ultra-Sound Interior Monito r

x
31
x
31 ~ 0 I
r- 0)
a
(') ~
;)\

2000 m. y.
:3"
(Q

Fuse Panel
I
0.35 8 t 0.5 A
I\)
m
Fu se Colors:
30
25
20
15
10
A
A
A
A
A
~5 A
Green
Whne
Yellow
Blue
Red
Brown
J,,,,,.
0,35
ro
t
D
Q¥.J I'
0.35
br/gr
1e

t T15v/9

0.35
br/gr
a
a
~
CD
()
r-+-
~-
()
Q)

~~
5 A Beige

~
f. /13 J 429

®
~
Starting with fuse pos1t1on 23. fuses 1n the fuse holder
are 1dentil1ed wnh 223 111 tl1e wiring diagram
11 112

ro
0,35
gr/ro
r r
1.5
sw/ge
0,35
br/gn
2.5
ro/s w
r
0.35
br/ws
~-
:::J
(Q

0
13 - Fold Relay Panel

:tr
IJ -Starting Inter lock Relay. J207 0,5 2,5 2.5 0.5 ** 0.5 * Q)
0,35

~Ho ~l- --1~•• .,,.:.,.,,,~)~

9
3
CJ)

r r
f,,,

,J,
,, , : , , .
ws =white
SW= black
ro =red
br = brONn OM
=
gn green 1,5 0,35 0,35 1,5 0
1U 12,5 2 . 5 0,5 0.5
bl = blue br br gr/ro br ro/sw ro/sw ro/sw br/ws br

gr = grey
Ii =violet . T32a/25
J 216
1 50b '50 1 718

ge = yel lON
§ D B Fm @)
14
! 91-s1141 I

B Starter Groundconnec tion -1-, in ce ntra locking system wiring

D lgnlioniStarter Switch harnes..'5
F120 Hood Alarm Switch Groundconn eaion , in instrument panel wiring harness
F125 Multi-Fu naion Transmis sion Rang e ITR ) Switch
F194 Clutch Pedal Position IC PP ) Switch
Wire conneaion 186s ), in instrumen t panel wiring harn ess
HS Alarm Horn
J207 Starting lnterbck Relay
Plus connection (50), in instn.rment pane l wiring harness
J218 Instrument Cluster Combination Processor
J429 Controlmodue forc entra locking
R Radi o Conneaion (drivers cab lock I. in instrument pan el wiring
T1 e Singe conneaor, on Radio harness
T2 Connector 2 pin , grey, in engi1e compa rtment, right
T9 Conneaor 9 pin. brC>Nn , on start ing 111terlock relay Vehicles with manualy shifted transmission
T10o Conneaor 10 pin, brCM1n, conneao r station elec troni: box Ve hicles with automatic transmission
plenum chamber
T10t Conneaor 10 pin , orange, conneaor station A pi Ila-, right
T15r Conneaor 15 pin, blue , conneaor station A pi ll a-, right
T 15v Conneaor 15 pin, orange, connea o r stati o n A pi Ila-, right
T32a - Connector 32 pin, green, on ins trum ent cluste r

Edition 06/00 Control Module for Central Locking, Edition 06/00

W42 USA.5602 07.21 Ala rm Horn , Hood Alarm Switch W42. US/I.. 5602.07.21
 -

Audi AG Wi ring diagram No. 54/ 3 No. 58/4 W iring diagram Audi AG
30 30 30 30
15 15 15 15
x x x x
31 31 31 31

~ ~ ~ ~
E3 8

n,,~
I I f
8
Fl Fl'
0,35 0,35 0,5 I
0,35
ws/gn ws/gn sw/gn ro br rolge
x/9 xrr T10.110
I T32/31 I T32c/12 I T32cl 13 I T32c/11

t"""°
0.35
J 218
t"""
0,5
0.5
gr/ro
J 218 0,35
ro/br
J 218 0,35
ro/ge
J 218
0,35
gn/ro
ws/b l

,4/15 J 429
sw/gn

'1 19
I I Clock
! T6'18
Data
I T6x/9
I Enable
I T6'110 ' TBl/3

~ ©
~ ~ ~
r
llllllllllllltlllllllllllllllllllllllll l lllllllllllllllllllllllllllllllllllllllllll l l

r /17 J 136 • t T6w/3 R r V1 r v3 r V4

r n r /1 r /6

0,35
Ii/bl
0,35
sw/gr
··:
0,35
sw/gr
0,5
br/ws
0.5
ge
0,5 0.5 0,5
gr
0,5
gn
0,35

l©~·
SW

~ ~: Ir. ~ Ir. ~
lr. . ,r,.,, L
t ~ I Ir....
0,5
Ii/bl
0.5
II/bl
0,35
sw/gr
11 5

0.35 .
sw/gr
rf"·i· f
E i sai

0,35
grfbl
0,35
gr/bl
0,35
gnlws
0,35
bl/ws
:4131I
I
r ;.=r
2.5
rolbl
0,5
bl/gn
0,5
br/ro
rr
0.5
rofgn
0,5
br/sw
I R 43

05.
gr
0.5
gn
* 05 .

l Jn
~
cAi ~
I E 4o
t T10><15
c!J 1 ,0
R 36
1 19
R 36
5C
R 36 m
-
[l] CD
lfo+·
T10aklS ws =white ws =white
C 22 13 11 4 / 13
sw =b lack sw =black (')
I ro =red ro =re d
r-+
IT·""' br
gn
=brown
=green
br
gn
=brown
=green
1,0
ro/ge
1.5
br
""'"'
'"''
0,5 0,35
SWL
0.35 0,35 0.35 0.5 ~

II/bl Ii/bl gn/ws

~ ~
bllws br bl =blue bl =blue
dJ (')

le
gr =grey
1 69 la gr
11
=grey
=violet 11 = VIOiet
Q)
J 234 E3
I@ ge =yellow ge =yellow

15 16 17 18 19 20 21 22 23 24 25 26 27 28
j 97-51587 1
29 30 31 32 33 34 35 36 37 38 39 40 41 42
197-516611
~
~.
C22
E3
Interference filter
Emergency Flasher Sw1 ch
9 Ground connection. in driver's door wiring harness J218
R
Instrument Cluster Combination Processor
Radio G Ground connection. on leh A-pillar, lower part
::::J
E40
E150 -
Leh Front Window Switch
Switch for interior lock, driver side 8 Wire connection !vehicle speed signal), 1n instrumen t panel R36
R43
Telephone Transceiver
Right Rear Woofer/Ampl1f1er 8 Connecto1 IK-d1agnos1s w1rel. in instrument panel Wifing (Q

.
wifing harness harness
J136 Memory Seat Control Module T6w Connector 6 pin, yellow, connector radio I - I
J218 Instrument Cluster Combination Processor T6x Connector 6 pin, green. connector radio I - 2 0
J234
J429
Tld
Airbag Cont10I Module
Control module for central locking
Single connector, brown, connector station A pillar right
Vehicles with Memory Seat TBf
Tl Ox
Tl Oz
Connector 8 pin, black, connector radio Ill
Connector 10 pin, green, connector station A pillar. right
Connecto1 10 pin, red , connector radio IV
* Vehicles with Telephone
-·
Q)
TIOak
T IOal
·
-
Connector 10 pin, green, connector station A pillar, left
Connector 10 pin. brown. below driver's seat
T15s
T16a
Connector 15 pin. blue, connector station A pillar, leh
Connector 16 pin, Data Link Connector IDLCI
CJ
(1)
(Q
TlOav
T15a
T151
T15v
T32
- Connector 10 pin. yellow, connector station A pillar. right
Connector 15 pin, black, connector station A pilla1 left
Connector 15 pin, brown. connector stauon A pillar. le
Connecto1 15 pin. orange. connector station A pillar. right
Connector 32 pin, blue, on instrument cluster
T32c - Connector 32 pin. grey, on instrument cluster

-- en3
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Edition 10/ 99
W42 .USA.5602 06 .21
Control Module for Central Locking ,
Switch for Interior Lock Driver Side
Radio , Right Rear Woofer/ Amplifier Edition
W42 USA 5602 06 21
10/ 99 (Q
~
I\) 0
a I
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-8 01
Audi AG Wiring diagram No. 54/5 No. 54/6 Wiring diagram Audi AG 0
CD
rn
~o 30 30 30
::J
....... ~
81. 0I
15 15 15 15
~ x x x
31 31 31 31

~ ~ ~
r-
~
(j)
0 (j)
(')
;)\
30
D D
s·
6,0

I
. 30
2,5
. 30
2,5
6r h
'i 'i I I s14 ~ s238/
ro
.,,,4 T238
I
1,5
rolbl
8 I
0,35
ro/bl

~
410

'jD ~
21s G
CQ
B
rn
-
a CD
8 ..--114a 10A 20A
T 1ov8
is S 6
SA a ()

r -2 r-+
E •1
f /58s f 38a -.
0,35
0,35 1,0 1,5 1,5 0,5 ()
ro/bl ro/bl re/bl ro /bl sw/bl
grfbl
I I
~ tu
~
J 429
E 91 1s
J 42 9 L, ~
~ r2 ©
~ ~ ) ~ ©
~ -·
0,35
gn /ws

c!i
r14
0,35
bl/ws

r!J
r rr
0,35
ge/g r
0,5
gn/br
0.5
wslli
- r 0,5
ro/bl
- r
0 ,35
sw/bl
-.
::J
(Q

0
1,til
---
2

T i sh lT1sh T 1sh11 lc~

,,,f:·
LLJ M 28
/3 12
(Q

""f~'"'
-.
T1
0,5 0,35 0,5 0.5 /2
T 1ov1 I
11
I T 1ov2 tu
ro/gr ge/gr gn/br ws/li
3
4·~' 8·1
0,35 0,35 0,5 0,35 0,35 0,5
ws/ro ro/bl ro/bl ro/bt ws/ro swfbl U>
ws =white ws = white
~
I sw =black sw =b lack

T T }T'+ """ er T1
F3 F 133 V s1 ro =red ro =red 112 112

r
0,5
br
gn
bl
=brown
= green
=blue
br
gn
bl
=brown
= green
=blue
}fo; '"""
0 ,35
ws/ro
0,35
ro/bl
0,5
ro/bl
0 ,35
ro/bl
0,35
ro/bl
0,35
ws/ ro
0 ,35
ws/ro
0,35
wsfro

br gr =grey gr =grey
r& I I I I I I I
Is
Ii =violet 11 =viole t
ge =yellow ge =yellow
8 0
43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
I 91-s 1sa9 I [97-51590 1

E41
F3
Right Front Window Swnch
Door Contact Switch - Passenger's side 9 Ground connection, in passenger's door w1'1ng harness D
E97
lgn111on/Starter Switch
Memory Program Sw1 ch G Plus connection 115). 1n instrument panel w1nng harness

F133 -
J429 -
Right Front Central Locking System Act1vator/Sw1tch
Control module for central locking
J429
M27
- Contro l module for central locking
Left Door Warning Light
@ Plus connection -2- 1301. 1n instrument panel w1'1ng harness

T15h -
V57
Connector 15 pin, brown, connector station A pillar, nght
Passenger's Door Cen11al Locking System Motor
M28
S6
S14
- Right Door Warning Light
Fuse 0 Plus connection (30al, 1n power window/central locking
system and door contact switch wiring harness
5238
T2t
-
Fuse
Fuse 38 1n fuse holder
Connector 2 pin, black, 1n driver's door
0 Plus connection t30al. 1n oowe1 window/central locking
system and door contact swnch w1'1ng harness
T2u Connector 2 pin, black. 1n front passenger's door
Connector 10 pin, orange, connector station A pillar, nght
@ Wire connection, 1n central locking system w1'1ng harness
TIOt
T15h - Connector 15 pin, brown. connector station A pillar, nght
T151 Connector 15 pin. brown , connector station A pillar. left

Edition 10/ 99 Control Module for Central Locking , Door Control Module for Central Locking , Edition 10/99
W42 USA 5602 06.21 Contact Switch Passenger's Side Left and Right Door Warning Light W42 USA.5602 06 21

.__
Audi AG Wiring diagram No. 54/7 No. 54/8 Wiring diagram Audi AG
w w w w
15 15 15 15
x x x x
31 31 31 31

~ ~ ~ ~

J 429 J 429

~ ~ ~ ~
r -T r 4
®
- r, r r 3

r
0,35
®
r
0,35
9

r
0.35

:,:. 13
:1::1:.
12 11
=,:. /3
:,:: ,:.
/2 /1

"''".vf: vf; vI! vf~ "'"'""vf~ vf; vf~ vf; "l"fo..

lJ r u: JJ r LI,
T rrr
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

lTrrr
·+~+~+~~"·· l· l ::l: l: ~l ~' " ' "
m
'
I
F10 F132
M

Vm
I I
Fn F134
M

V19
I ws
sw
ro
=white
=b lack
=red
ws
sw
ro
= whrte
=black
=red F,. CD
()
........
......
1
= browr
rr
br br = browr

·~f ·~f ·~f y· y·

gn =green gn =green
0.35 0.35 bl =blue bl =blue ()
gr =grey
gr =grey Q)

le 78 BO
ls
81 84
197-5159 1 1
Ir
ge
= vrolet
=yellow
11 = vrolet
ge =yellow 8 8
94 98
197-515921
~
F10
Fl 1
Leh Rear Door Contact Sw.tch
Right Rear Door Contact Switch
e Ground connect•on. in leh rea• door w1rrng harness J~29
T6u
- Control module for central lockrng
Connector 6 prn. grey. connector statron A prl!ar. eh s Connection lopenr. 1n wrrrng ha•ness nterro•
~-
::::J
F132
F134
Leh Rear Central Locking System Act1vai0r/Sw1tch
Right Rear Central Locking Systen1 Act 1vator/Sw1tch
Q
~
Ground connection, 1n rrght rear door wrr1ng harness TlOag -
TlOah -
Connector 10 pin. red, connector statron A pillar. rrght
Connector 10 prn. red. rn B prl lar, left 8 Connectron !closed), 1n wiring harness rnterror cc
J429 Control module for central locking T10ar - Connector 10 prn. red. 111 B prllar. rrght
T15f
T15g
Connector 15 pin. blue. 1n connector station 8 pillar. rrght
Connector 15 prn, blue. rn connector statron 8 prllar. left
T15k
T15v
Connector 15 pin, red. connector statron A prllar. leh
Connector 15 pin. orange. connec tor statron A pillar. rrght
0
V97
V115
Double Cab Rrght Rear Door Central Lockrng Systern Motor
Left Rear Central Lockrng System Motor
V1 4
V15
Left Window Motor
Rrght Window Motor
Q)
V26
V27
Lefl Rear Door Wrndow Motor
Right Rear Door Window Motor
CJ cc
......
-3
(1)
::J Q)
~
- CJ)
r-
a
()

Edition 10/ 99
W42. USA.5602 06 .21
Control Module for Central Locking , Left
and Right Rear Door Contact Switch
Control Module for Central Locking ,
Window Motor's
Edition 10/99
W42.USA 5602 06 21
ii ~
!\) 0
a (j)
I
a
-8 -....J
.
AudiA6 Wiring diagram No. 54/9 No. 54/10 Wiring diagram AudiA6 m
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
~
x
31
x
31
x
31
x
31
0 I

~
0)
co
~
J 210
0.5
m
~
' T32a/6

0.35

·F~,
q , - - t - J E 164

0,35
rr
0.3S
li/gn
0,35
gn/ge
ge/gn

, 4/16 J 429
I
'14/5
~
~
rr r r ,
® ®
ror
0,35
gr/ws
0,35
bl/ro
r r rr
0,5
ws/sw
0,5
br/s w
0,35
ws/ge
0,35
ws/ge
r
0 .35 0,5 0,5 0,35 0.35 0,35
::! .
:J
(Q

-
ge/ro gn/gr gn/ li swfbr gn/ro

T 0
T 10a1 T 1oa1/7 I T 10al/5 I T 10a114 T 10a112 I T 15vl1 4
T 15v T 10116 T 10a119
/3 11 2

......
0,5 0,5 0,35* m
,,.,
0.5 0,5 0,5 0.35 0. 35 0,5 0,5 0,5 0,35

1Tl, 9[_ 3
ws/sw br/sw wslge ws/ge ge/ro gn/gr gn/li sw/br gn/ ro

t"'~
f' v,,,, V155~
~ ~'r "'
CJ)
,T,..,
F1 24 F 218 tT
3012 !""' V 53 F 206 I T2w12
I
O.Js*
ge/gn
WS
SW
ro
br
white
black
red
brown
ws
sw
ro
br
=wh ite
=black
=red
=brown
K J 210
f 16a/7 , ~32a/28
gn = green gn =green
0,5 0,5
br
J 445
.
I T23112
bl =blue
gr =grey
11 =violet
ge =yellow
bl
gr
Ii
ge
=blue
=grey
=violet
=yellow
0,5
br
0,5
grlbl
0.35
gn/ro

I 8
0.35
gn

I
0,35
gn/bl

I
99 100 101
'®
102 103 104 105 106 107
'®
108 109 110 111 11 2
1 97-515931
11 3 114
'®
11 5 116 117 118 119
'®
120 12 1 122 123 124 125 126
197-5 15941

F1 24 - Trunk Lock Alarm/Central Locking Switch Ground connection -2 -, 1n rear Wifing harness E164 - Luggage Compartment Release Switch Ground connection -2-, 1n rear wifing harness
F206 · Trunk Ltd Closed Pos111on Swttch F248 • Switch for unlocking, rear ltd lock cylind er
F218 · Switch for central locking, trunk ltd J2 18 . Instrument Cluster Comb1nat1on Processor Connector IK-<:J1agnos1s wtrel. in instrument panel w1r1ng
J218 . Ins trument Cluster Comb 1nat1on Processor Vehicles with parking aid
J429 . Control modu le for centra l locking harness
J429 . Control module for central locking K Data Link Connector iDLC) Rapid Da ta Transfer
J446 . Wire connec tion -1-. 1n On-Board Diagnostic IO BDI w1r1ng
Control module for parking aid T10f Connector 10 pin, brown. connector station A pillar, leh harness
T2v Connector 2 pin, black. luggage compartment T10a Connector 10 pin. violet, connector station A pillar. leh
T2w Connector 2 pin. grey, luggage compar ment T15v Connector 15 pm, orange. connector station A pillar. right
T3o Connector 3 pin, blacf- , in rear ltd Tl6a Connector 16 pm, data link connec tor
T10af · Connector 10 pin. violet. connector station A pillar. left T32a Connector 32 pin, green. on instrument clus ter
T15q Connector 15 pin, whtte. connector Station A pillar, right V 151 Motor for remote unlock rear ltd
T15v Connector 15 pin, orange, connector station A pillar. right V155 · M otor for fu el tank lid unlock
T23 Connector 23 pin, black , on co ntrol n1odule for parking aid
T32a Connector 32 ptn, green. on instrument cluster
V53 Deckltd Central Lock ing System M otor

Edition 10/99 Control Module for Central Locking , Trunk Control Module for Central Locking, Luggage Compartment Edition 10/99
W42 USA.5602 06.21 Lock Alarm/Central Locking Switch Release Switch , Motor for Remote Un lock Rear Lid W42 USA5602 06.21
 -=·~
.:31L..._-.. ..... -- -- -
-- -

AudiA6 Wiring diagram No. 54/11 No. 54/12 Wiring diagram AudiA6
30 30 30 30
15 15 15 15
x x x x
31 31 31 31

~ ~ ~ ~
G I
0.35 0.35
I I
0,35
~
0,35

1b:rl
41...
gn/ge gnlge gn/ge ro/bl

rrLi ~
COR•1

~"r"
T0,5
ro/gn
? T T T T1 T T
0,5
bl/gr
0,5
bl/gr
0,35
gn/sw
0,35
ws/gt
0,35
sw/ro
0,35
swlli
1,0
ro/li
f T TTf
0.35
ro/ bl
0,35
gn/sw
0,35
ws/gr
0,35
gn/ro
0,35
ws/ro
0,35
gn/ge
0.35
gr/sw
0.35
bllgn

~ :"r
J •29

®
h.
~
:~·
r /10
, 412 , 5112 , 5/14 , 2115

I I ;: ;
t
..
, 20

r:12
h
r'.'°
"3 J 347

®
, 9

:"
rrrr
~

I
0,35 0,5 1,5 0,5 0,35 0,35 0.35 0.35 0.35 ## 0.35 # 0.35 0,35 0,35 0,35 0,35

l·l-I
gnl ge br/ws ro/ge ro/ge rolgr ro/gr br br ws/ro ws/li wslbl ws/ge

~
0,35
lh 0.5 0,35
IT'"'
0.5 1,0
ro/ge
T 1ou5

0,5
T 10U7

ro/gr
'T' "'
0.35
ro/gr
0,35 *
br/gn
12

0,35 *
sw/gn
11

Gia•
Gm
I
r r r r IT·+ ·++·"
0,35 0,35
G 71~
®

0.35 0.35
I

0 ,35 0.35 0,35 0,35

r
gn/ge gn/ge gn/ge br/ws

~
ef f0
gn ge SW gr wslro ws/li ws/bl ws/ge

m
-
T 15,14
IT•M ,T.., L iil L l/2 L l/3 L l/4 L

®
k/2 L J T4ak/J 4ak/1

CD
...............
IT·• ws
sw
ro
= whi te
=black
=red
ws
sw
'O
=wh ite
= black
=red
2.s *
br/gn
2.5 *
sw/gn

1,,.
I
..
G171
I ()
.....+ -
br = browr br =brown 12/- r ~ .
'"'"
0.35 0,35 0.5 1,0 0.5 gn = green gr =green
gn/ge gn/ge br/ws ro/ge ro/g r V2 1.5
bl = b'ue bl = olue ()
~ ~ ~
br

~ ~
le
gr =grey gr =g rey
Ol
11 = violet
ge =yellow
11
ge
=violet
=yellow
(§ (§ (§
-
127 128 129 130 131 132 133 134 135 136 137 138 139 140
197-51595)
141 142 143 144 145 146 147 148 149 150 151 152 153 154
) 97-51596)
~
......
J429 -
R-17
Control module for central locking
Window artenna for centra iock ng and anti-theft warn ng
El83 - Switch 'or passenger corroartn·ent nion1toring
G Grocnd connec.,on, on right A-p1 lar. lower pan
~
co
1
Gl70 lrter101 Monitoring sensor, le 'or ant1-:neft warning
system sys tern
8 Ground connection - 1-. n central locking sys tem w1r1ng
T3at
T5a
T10t
T15h
T15
Connector 3 pin, grey. connector sta ti on A pillar leh
Connector 5 pin, blacf behind instrument panel, right
Connector 10 pin. orange, cornec10r station A pillar, right
Connector 15 pin, brown, connector station A pillar. •1gl1 1
. Wag or
G171

G183 -
ln•erior Monitor ng sensor. rigrt for anti-theft warning
system
Sensor for broken window glass rear left
@
8
t1arness
Wire connection. ,n NC wiring harness

Wire connec11on 2-. 1n NC w1rin harness

0
-·
T15t
Connector 15 pin, browo. connector station A pdlar. left
Connector 15 p,n, grey connector station A pillar, le'
G184 - Sensor for bro.en window g1ass rear right
@ Ol
T15v Connector 15 pin. orange, connector station A pillar. righ t
J3J7 Control Module for Interior Mon11oring sensors Wire connection - 1- 1sw11ch/con1rol modulel. central locking
(') co
.
system wrr1ng harness
Cb ......
T3bv Connector 3 pin, orange, connector station A pillar ri ght
T4a1 Con nectar -1 p1r, on C pillar, r19ht
....... Ol
::J
Vehicles with Sun 1oof with Solar Cells
T.!ak Connector -1 pin, on 111terior nionitorir.g senso 1 11ght Vehicles with head airbag
**
T4al
V2
Connector 4 pin, on interior mon1tor•ng senso1 nghl
F,esh A11 Blower
#
##
Sedan
Wagon ~ 3
(/)
r-
0
(')

s· m
::x:;--

Edition 10/99
W42 .USA.5602 06 .2 1
Control Module for Central Locking , Window Antenna
for Central Locking and Anti -Theft Warning System
Control Module for Interior Monitoring Sensors, Switch for
Passenger Compartment Monitoring, Interior Monitoring Sensor
Edition
W42 .USA.5602 06 21
10/99 (Q
~
!\) 0
a I
a (j)
-2 c.o
-
AudiA6 Wiring diagram No. 54/13 No. 54/14 Wiring diagram Audi AG ()
(1)
m
30 30 30 30
::J
........ ~
~ 0
15 15 15 15
x x x x
31 31 31 31 I

~ ~ ~ ~
r- ""-J
0 0
()
;:J\"
:5"
(Q
!\) m
-
a CD
a (")
...+
-2 .......
(")
tu
-
~
J 347

::::!.

f=HJ ®f=l+s
0.35 0.35 0.35 0,35
ge
0.35 0,35
gn
(Q
:J

0
-·
tu

fJ.J OJ
I ff""'I

=n
.......
.L
..t,/w~5c/4
tu

1 -2
1 -40 11 !31
l • • '~' . , ~'"'' lT·~ " 3
(J)

l~"'" l~"'"'
I 0 I ws =white ws =white
sw =black sw =black
G 110 Gm ro =red ro =red
br
gn
bl
=brown
= green
=blue
br
gn
bl
=brown
=green
=blue
T u
1,0
ro/H
u u u
gr =grey
gr =grey
11 =violet
ge =ye llow
I!
ge
=violet
=yel low
I i - --
---- G "I' T
-8------ - --S-5
"
I' - s2

155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 110 11 1 112 173 174 ns 11s 1n 11a 119 1ao t e1 1a2
) 97-51742 ) 1 97 -517431

G170 -
G171 -
lnterirn Monitoring sensor. leh for antHheh warning system
Interior Monitoring sensor, right for ant1-theh warning
E40
E4 1
Leh Front Window Switch
Right Front Window Switch
(§Y Ground con nec tion. 1n driver's door wiring harness
system L108 Door opener l1ght1ng. driver side 0 Wire connection. in central locking system wiring harness
J347 - Control Module for In erior Monitoring sensors L 109 Door opener l1ght1ng. passenger side ~
T5b Connec or 5 pin. black. in drivei's door
T5c Connector 5 pin. black. 1n passenger's door
T15h Connector 15 pin. brown. connector station A pillar. rigl1t
T151 Connector 15 pin. brown connector sta ion A pillar !eh
W30 Door Warning Light
W31 Entry light front. leh
W32 Entry ligh t front. right
W36 Door warning light. passenger side

* Vehicles without head airbag

Edition 10/99 Control Module for Interior Monitoring Door Warning Light, Entry Light Front Edition 10/99
W42 USA.5602.06.21 Sensors, Interior Monitoring Sensor W42 USA.5602 .06.21
Audi AG Wiring diagram No. 54/15 No. 54/16 Wiring diagram Audi AG
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 30 30 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~30

15~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 15 15 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~15

x ~~~~~~~~~~~~~~~~~~~~~~~~~~~~ x x ~~~~~~~~~~~~~~~~~~~~~~~~~~~~x

31~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 31 31 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~31

~ ~ ~

. T32/21

.F:·ll
T
0,5

1 ' ls
51

0,5

l~151 4
152 Tl r1 e e
0,35

·1+·~
0,5 0,5

'~' -i·~
v1:
0,5 0.35

1
0.5 0.5

~·
v;;
0.5

Jr wl I l·~ I I I 9--------i
0.5

;b TT l
l 1.----.1
1.0 0.35

T 2bh/2
0
0,5

~ T
T J;
1,0 0,35

T 2bi/2

015 n

gntr-J gl" g[
5 0.3 5 0.35

T gntr-J
n 5

gl" g[
0.35

Tl
0.35 0,5 0,5 0.35

w}
11
wJlL1}~;11 I~•s
t
w}
11
wJi1 L111f;Y, I~.9
t
r-~ l'"'" l"'~ Ll Ll
·fll I ·flJ·
0,5 0,35 0,35 0,5
11
0,35 0,35
0,5

rlom l
0,5 0.35

gnl/ge
1,0

I~ ~ .
1,0

r.., m
CD

l~""" l~"'"'
ws =white ws = whne

td td
T 3bv/3 : 10al/9
sw =black sw =black ()
ro
br
=red
=brown
ro
br
= red
=brown 1
.......
-..
gn =g reen gn =green J 135

Te
0,5 0.5 0.5 0,5 0,5 1.0 1,0

Is
bl =blue bl =blue ()

., r 188
T
191
Is 196
S2

197.51744 1
gr
II
ge
=grey
= violet
= yellow
gr =g rey
Ii =violet
ge =yellow
S2

198 200 205

T
206 207 208
T
210
197-517451
~

~
~.
L48 Ground connection, 1n leh rear door winng harness J136 Memory Seat Control Module Wire connection (driver 's door contact sw1 chi. n instrument
L49
Leh Rear Ashtray Light
Right Rear Ashtray Light J218 - Instrument Cluster Combination Processor panel wiring harness :::J
L110
L111
Door opener l1ght1ng, leh rear
Door opener l1ght1ng, right rear
Ground connection, 1n right rear door winng harness L 106
L107 -
Footwell l1ght1ng, leh rear
Footwell l1ght1ng, right rear
Wire connec tion -1 , 1n leh rear door w1r1ng harness co
T4c Connec or 4 pin, black, in leh rear door T2bh - Connector 2 pin, black, below driver's seat
T4d
Tl5f
Connector 4 pin, black, in right rear door
Connector 15 pin, blue, 1n connector station B pillar. right
Wire connection, in central locking system wiring harness
T2b1
T3bv
-
-
Connector 2 pin, black. below passenger's seat
Connector 3 pin, orange, connector station A pillar. right
Wire connection -2-. 1n right rear door wiring harness
0
W11e connection, in central locking system w111ng harness
T15g - Connector 15 pin, blue, 1n connector station B pillar, left T5a
TIOak -
Connector 5 pin. black. behind instrument panel, right
Connector 10 pin, green. connector station A pillar, left ~
V26
V27
W33
Leh Rear Door Window Motor
Right Rear Door Window Motor
Entry light rear, leh
TIOal
T15a
Connector 10 pin, brown, below driver's sea
Connector 15 pin. black, connector station A pillar, left
()
CD
co
-..
W34 Entiy light rear, right T15v Connector 15 pin, orange, connector station A pillar, right
W37 Door warning light rear. leh T32 Connector 32 pin, blue, on instrument cluster :J
....... ~
W38 Door warning light 1ear, right W9
WIO
Leh Footwell Light
Right Footwell Light

-
~
r-
0
(")
3
CJ)

s· m
~

Edit ion 10/ 99

W42.USA.5602 06.21
Entry Light Re ar, Door Warning Light
Rear, Door Opener Lighting Rea r
Footwell Lighting Rear, Footwell Light Edition 10/99
W42.USA.5602.06.21
<Q
~
I\) 0
a I
a ~
~ ~
AudiA6 Wiring diagram No. 54/17 No. 54/18 Wiring diagram AudiA6 m
30 30 30 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~30
~
15
x
31
15
x
31
15
x
31
~~~~~~~~~~~~~~~~~~~~~~~~~~~~

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 1
1 5

0I
~ ~ ~ ~
I'\)

m
8
T I
0,35 1.0
I
0.5
T
0.5
81 29
8129-=-----1
8 ______._,__-----illl
TI Tl. 0,35
rolge
0,35
ro/ge
0.35
ro/ge

l "T.
0,3 5 0,35

•,
ro/gr

ws
sw
ro
br
=white
=black
=red
=brown
ws
sw
ro
br
=white
=black
=red
=brown
r lw' lw,
gn =green gn =green
bl =blue bl =blue

fe~J~ l~
0,35
W11 gr =grey gr =grey br

le
11 =violet 11 =violet
ge =yellow ge =yellow

211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238
1 97 -517461 197-51747 1

T6m
T6n
Connector 6 pin, on interior light. front
Connector 6 pin, on interior light. lront
@) Ground connect ion. 1n sunroof wiring harness F147 -
F148 -
Le , Make-Up Mirror Light Switch
Right Make-Up Mirror Light Switch 8 Ground connection. on left A-pillar. lower part
T6o
w
Connector 6 pin, on interior ligh t. rear
Front Interior Light 8 Connector (interior l1gh 31 LI. 111 wiring harness interior L31
T3p
Make-up Mirror Light
Connector 3 pin. on reading lamp front right
@) Ground connection. 1n sunroof wiring harness
Wll
W12
W43
Left Rear Reading Light
Right Rear Reading Light
Rear courtesy lamp
T4e
T15t
W13
Connector 4 pin, on reading lamp front left
Connector 15 pin. grey, connector s at1on A pillar. left
Right Front Map/Reading Light
8 Connector (interior light 31 LI. 111 wiring harness 111terior

W19 Left Front Reading Light

Edition 10/99 Front Interior Light, Rear Reading Make-Up Mirror Light, Front Reading Light Edition 10/99
W42 USA5602 06 21 Light, Rear Courtesy Lamp W42 USA5602 06.21
Audi AG Wiring diagram No. 54/19 No. 54/20 Wiring diagram Audi AG
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30 30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30

15 15 15 15
x x x x
31 31 31 31

~
ITjID
.~~~20
0.35
I
0.5 18 1 1 1 0,5
ro/gn

~ ~~ ~~:;1~b-l~·-·..
4 0,5
rolgr
0.35
ro/g r

l , ~ vl , rrb
o.s
ro/gr
0.35
ro/gr
0,5
ro/gr

rrb
0,5
ro/gr

~
~0,5
UfJ
0,5 0,5
T 10a116

**

l~·-·
0,5 0,5 0 ,5
V 14 15
~ gtr/bl ~

0.5
T 6u/2

0.5
l ...
0.5
F.
0.5

I
0,5
T I
0,5
I
0.35

r ... l,.~·
ws
sw
ro
br
gn
bl
gr
=white
=black
=red
= orown
= green
= blue
=grey
ws
sw
ro
b•
gn
bl
gr
=wh ite
=b lack
=red
=brown
=green
= blue
=grey
1
l#Ji ~w:: 0,5 0,35
m
CD
()
r-+
......
()
Q)

le
11 = v1ole 11 = violet

'®
ge = yel low ge = yel low

239 252
I 97-m4s I
266
1 97-SH49 1
~
Wire connection (58s1. 1n nstrur'1ent panel wiring harness Connector 6 pin, white. connector station A pillar. lek Ground connection · 1-, rn rear w.rrng harness
~-
E52 Left Rear Window Switch, iln LR Doorl T6b
E54 Right Rear Window Switch. fin RR Doon TlOaf - Connector 10 pin, violet connector station A pillar. le :::J
J2 18 Instrument Cluster Combination Processor Plus connection 158sl. 1n power w indow wiring harness T151 Connector 15 pin, black, 1n luggage com partment Ground connection, 1n rea r lid wiring harness (Q
T3n Connector 3 pin. red, connector station A pillar. left W3 Luggage Compartment Lrght
T6u Connector 6 pin. grey. connector statron A pil la r. left WlB Wire connection. n rear w1nng harness
TlOag
Tl Oar
Connector 10 prn. red, connec or station A pillar right
Connector 10 prn, red. 1n B pillar, left
Plus connection 1871. rn power w1ndow/centra1 lockrng
system and door contact switch wiring harness W~3
Leh Luggage Compartment L.ght
Rear courte sy lamp 0
T10a1 ·
T15k
Connector 10 pin, red, 1n B pilla r. right
Connector 15 pin. red, connector station A pillar. left Wagon
only Sedan Q)
only Wagon
T32 Connector 32 pin, blue, on 111strument cluster () (Q
VI~
V15
Leh Window Motor
R1gl1t Wrndow Motor
CD ......
::J Q)
.......

- en3
~
r-
0
()
;:J:\'" m
s·
Edition 10/ 99
W42 .USA5602 .06 21
Plus Connection 58s Luggage Compartment Light,
Rear Courtesy Lamp
Edition 10/ 99
W42 .USA5602 06 .21
(Q
~
I\) 0
a I
a -.....)
-2 (J.)
AudiA6 Wiring diagram No. 58/1 No. 58/2 Wiring diagram AudiA6 (/)
a m
c:
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Q 0
Radio-Stereo, Concert with and without CD-Changer I

!R ""
m~
(/)

2000 m . y. 3
Fu se Panel
I\)
a
m
Cl)
Fuse Colors :
a ()
30 A Green
~ ..-+
25
20
A
A
White
Yellow '
()
15
10
7.5
A
A
A
Blue
Red
Brown
m
5 A Beige

~
1ct]'''''f~~,,,,,,,,~·:;,,,,,,,(J ' ' ' ''''''''''''''' ' ' ' '' ~-
Starting with fuse pos1t1on 23. fuses 1n the fuse holder ::::J
are 'dent1f1ed wnh 223 1n the winng diagram.
1J**
HF
o.5
ws
** ~J *
HF
E 15 (Q
(
2.5
0
Micro Central Electric Panel T10x1s m
cp ** L I. I Tsa14
'
m
Ir.
1.0 ** 1,0 1.0 2.5 2.5

3
ws
sw
ro
br
=white
=black
=red
=brown
v:. IjY ~I~~..~ I ~· 1
Z24 *
U>

gn =green
bl =blue
1.0** 1,0 ** 2.5

gr =grey
Ii =v iolet
ge =yellow

'® '® 14
197-516591

D lgn1t1on/Starier Switch Ground connection, 1n luggage compartment. left

E15 Rear Window Defogger Switch
R Radio Ground connection, on right rear pillar
R1 Antenna Connection
R45 Telephone/Radio Antenna Ampl1f1er Plus connection 115), 111 instrument panel winng harness
S5 Fuse
S237 · Fuse 37 1n fuse holder Wire connection 115al. 1n instrument panel wiring harness
T6a Connector 6 pin. blue. connector station A pillar. left
T8f Connector 8 pin, black, connector radio Ill Plus connection 130asl, 1n instrument panel wiring harness
T10x Connector 10 pin. green. connector station A pillar, right
V21 Power Antenna Vehicles with rear Window Antenna
Z24 Rear Window Defogger With Window Antenna Vehicles w1 h Automatic Antenna

Edition 10/99 Radio, Rear Window Defogger with Window Antenna Edition 10/99
W42 USA.5602 06.21 W42 .USA.5602 .06 .21
 - - .-.a..__ .......

Audi AG Wiring diagram No. 58/3 No. 58/4 Wiring diagram Audi AG
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30 30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30

15 15 15 15
x x x x
31 31 31 31

flr,, ,.
0,35
Ii

lr10z
I 110
1.5
gr/ge

I1T1oz19
I
0,35
gr/ge

I T32/15
58d
J 21a
Fl Fl
0 .5
g r/ro

I Clock
I T6x18
J 218
5

I T32c/ 12
o.35

'°f~•1•
1T6x/9
b'

J 21a
5

I T32c/13
I

0.35
T 1ox110

'°(:nable
! T6x110
I
0,35
rol ge

I T32c/ 11
J 219 n
0,35
gn/ ro
8"

' TBf/3
AT1san

1 11lf:'.~:r:f '~~~/~~11I111:~~~/:~111 I I !~ !!II11 l :~~~;;;~~~;;I:~~~;~;~~:/;,'

l ! l l l l ! l !!l ! ! ! ! ! ! ! ! ! l t ! t ! l ! ! ! ! ! ! ! t l l ! ! l l ! t l l l!l!!! ! !!l! ! ! ! ! l l ! l l l !l !l!!l l t l !!!!! !!tl !

I I I I IIII
NF -A NF -31 NF-l Data in Clock gesch. Dauer Da la r w/3 r w/2 r w/1 r w/6 R r oz11 r Oz/3 r Oz/4
Plus Plus out

f
r .:::=r ~ I.©:: 1.1"., !"'~ IT·~
-
:~T, b.J:1.l.., l~ :;~, ~'" :~"'"
1
11 12 13 1• 111 @ 15 19 11 110
:;" '"
1 13 I R :

1
ws =white
s111.' = blac
ro =red
ws = wn1te
sw =black
ro =red
1

u
,otlbl J;
u

T 1ox15
~
u u
,i ~
u u *
L
R 3s
u *
t
R 3s
j"'.
u *
'C
R 3s m
-
CD
(")
......+
O' = c·o:.r1 b' = b·ow~ 1,0
gn = green Q'."\ =greer ~.
2,5
b' b1 = oiue bl =blue
gr =grey I (")

le
gr =grey
11 = v1ole: 11 = V'Olet OJ
ge =yellow ge =yellow
or =orange
15 16 17 18 19 20 21 22 23 24 25 26 27 28
j 91 .5166o l
rs = p1nK 32 33 34 35 36 37 38 39 40 41 42
1 97-51661 1
:E
~.
J216 lcstrunoert Cluster Con1b1na: on Processor @ Ground cornect1or, or rigt·t A-p 1lar loNer part J218 lnstrJ ert Clus;e• Co,,.-b1ra• or Processor
8 Ground cornect1on. on left A-p liar, lower port
::1
e
R Rod10 R Radio
R41 CD Changer Uni;
Plus connection 158dl. 1r nstrurnent panel .w1rg harness R36
R~3
Telephone T•ansce ver
Right Rear Woofer/Amplir er 8 Conr ctor IK-d1agnos1s w11el. 1n nstrument panel wiring
t1arness
(Q
Tlg
T2ar
Single connecto1 blac< connec tor station A p1l1ar. rrght
Connector 2 pin, blac , behind 1nstrumen panel cente1
8 Wire connection t58sJ. ,, 1nstn.. .,.,er.~ par·el w r ng tiarness
1 T6w
T6'
Cornec:cr 6 pin. yellow connector raa o I - 1
Connector 6 Piil. green. connector rad o I 2 0
~8' Connector 8 01n hlad connector rarl·o Ill 8 Wire connection 1veh1C1e speed s gnall 111 instrument panel
w1r1ng harness
8'
TlOx
Connec;or 8 pin. black connector radio Ill
Connector 10 pin. green. connector station A pillar, 11ght
Vehicles wnh TP.iephone

OJ
-·
T8g
107
Connector 8 p111, blue, connector radro I 3
Connecto1 10 pin, red connecto1 radio IV
8 Wire connect1or lsh1elcling). 1n CD-cha1'ger "iring harness TlOz
T15s
Tl Ga
Corwector 10 pin. red connector radio IV
Connector 15 pin, blue conrcc or station A pillar le'
Connector 16 0111, Data L,n• Connecto1 IDLCJ
(Q
C/) ......
T32 Connector 32 rnn. b:ue 011 1nsuument cluster
* Vehicles with CD Changer T32c - Connector 32 p1•1 grey. on instrument cluster
a
c:: OJ
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Q 3
en
~
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(D' m
Ed ition 10/ 99
W42.USA 5602 06 21
Rad io, CD Ch anger Un it Radio, Right Rear Woofer/ Amplifier Edition 10/ 99
W42 USA 5602 06 21
:3
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:E
0 I
0 ~
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Audi AG Wiring diagram No. 58/5 No. 58/6 Wiring diagram Audi AG m
~
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J 429

r
..
0 ,35

l~ Cf ~ Cf ~

r, r, r r·
R
11 11 111 111 1 1 111 111 1 11111 111111 1111 11 1 1111 1 1111111 11 1 1 J l ! l ! ! ! ! ! ! l ! ! l l ! ! ! ! ! ! l ! ! l l ! ! ! ! I !

5 6 3 ~ """"'.[.:lP IA
r+-~ r+--·
l·- l·- l·~ l'fr,,".',
0,35 1,0 1,0 1,0 1,0
ws/ge gr/ge gr gr/ge gr

l T 3an T 3a n/1 I T 3ao I T 3ao/1

/2 /2
T 5.i1

1.5 1.5 1.5 1,5

""""(

T 3a111 T3am12
OJ
3
(/)
11- 12+ 11-

1 ~ ~1 1~ ~ 1 ws white ws =white
sw black sw = bla ck
R23 ro red ro = red
br brown br =brow
gn =green gn =green
bl = blue bl =blue
gr =grey gr =grey
11 = VIOie Ii =violet
ge =yellow ge =yellow

43 44 45 48 49 53 54 55 56 57 58 60 61 64 68 69 70
1 97-5 16621 1 97-5 1856 1

R Radio J429 - Control module for central lac 1ng

R21 Le Front Woofer J453 - Control module for mul t1 -funct1on steering wheel
R23 Right Front Woof r R Radio
R26 Le Front Midrange Speaker R15 Left Rear Woofer
R27 Rig t Front Midrange Speaker R17 R1gh Rear Woofer
T3ae - Connector 3 pin brown, connector stauon A pillar lef R34 Left Rear Midrange Speaker
T3af Connector 3 pin, brown, connector station A pillar, right R35 Right Rear Midrange Speaicer
T3al Connector 3 pin black, in d11ver' s door Tle Single connector, on Radio
T3ag - Connector 3 pin. blue, in B pillar left Ve!'1cles w1 h mult1-funct1on steering wh el
T3am Connector 3 pin, black, 1n passenger's door
T8e Connector 8 pin, brown. connector radio II T3ah - Connecto1 3 pin, blue. in B pillar righ t
T3an Connector 3 pin, blac . in le rear door
T3ao - Connector 3 pin, blac~. 1n 11ght rear door
T6x Connector pin . green. connector radio I 2
Ti5v - Connector 15 pin, orange, connector s at1on A pillar. 11gh1

Edition 10/99 Radio, Front Speaker Radio, Re ar Speaker Edition 10/ 99

W42 USA5602 06 21 W42 USA.5602.06.21
Audi AG Wiring diagram No. 59/1 No. 59/2 Wiring diagram Audi AG

Radio Concert, Symphony, Bose with and without CD Changer ~

31
=----.----============~~ "~5 ~ 30

30
2000 m . Y·
4.0 /5 G !o 110• K

T ~
~r·
i237
Fuse Panel
iT1san
;i; 0,35

Fuse Colors:
30
25
20
15
A
A
A
A
Green
Whi te
Yellow
Blue 4.0
ro/ge
$ 237
20A
r 0~5
1,0
ro/ge
ef 0,35
gn/ro
10 A
7,5 A
5 A
Red
Brown
Beige
8
I TBl/3

OL1111 1 11111111111111111111111111 1111111 111111111 1 1111111111111111 .111111111~11~

I TBf/6 R ·TBf/B ~
I l
I TBl/1 5Bs 31
Stan.ng w:rh fuse position 23. !uses 1n the fuse holder
are 1dent1 f1ed with 223 1n the wiring diagram 0.35 2.5

Micro Central Electric Panel

fefe
0,35 0,35
IT'"
2.5

w
r T32/31
r Bs
T32/20
b'

m
~
J 21B J 21B

ws = whi te CD
sw = black ()
ro =red ..-+
I I I br
gn
= brown
=green
--.
A B C bl =blue ()
gr = grey
I A97-011 0 I 11 =viol et OJ
ge =yell ow
@
14
197-51 85 71
~
~-
J2 18
R
Instrument Cluster Combination Processor
Radio
G) Ground connection. on right A-pillar. lower pan
:J
S237 ·
Tlg
Fuse 37 1n fuse holder
Single connector. black connector station A pillar. right
8 Wire connection 158s), 1n ins trument panel wiring harness
(f)
co
T8f Connector 8 pin, black. connector radio 11 1 @ Wire connection (vehicle speed signal), 1n instrument panel
w iring harness a 0
T10x Connector 10 pin, green. connector station A pillar. right
Tl6a Connector 16 pin , Dara Link Connector (DLCI @ Plus connection 130as). 1n instrument panel wmng harness c::
T32 Connector 32 pin. blue, on .ns trument cluster ::::s OJ
8 Connector (K-d1agnos1s wnel. in instrument panel wning
Q. co
e harness
Plus connection (301. 1n rear spea>er wn1ng harness

!f: al
Vehicles with Automatic Antenna
~
CD
3
CJ)
__:3
en m
a(J)
Edition 10/ 99
W42 .USA5602 .06.21
Radio, Data Link Connector Edition 10/ 99
W4 2 USA.5602.06.21
CD ~
I\) 0
a I
a ~
~~
 Audi AG Wiring diagram No. 59/3 No. 59/4 Wiring diagram Audi AG (f)
0
m
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ ~~
c::
::::> :E
x
31
x
31
Q 0 I

!#
CJ)
-....J
00
©
118
4,0 2.5
J 210
I T3 2115
... ... .I..
J 401 J 401 J 401
__3
m
•• 5 ~
58d
f 20bl13 f 20b/1 5 T20b/14 to -
·; , 5
o,3s * 0.35 0 CD
~ S5
.:,
0,35 0.3 5 0.35
D br gr/ge CJ)

0,35
sw/ro
r
1,0
sw/ro
10A

0,5
sw/ro
IT
0,35 *
2 arl1
e-J- 1,5
·F- Tr..... l~·- rl h
rr :.
(1)

t\)
a
a
(")
r+
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(")

' p"'::;. "' .' '.':~, ' "'"'~'"''µ"'",',"', '.,":,'. ":, '"' "'
II gr/ge ~ ~ ~ ~ ~
Q)
L~ I
I
~
gn II/gr

~
SW

8 L,. Lv10 58d

1 nov9 R
:E
I TBg/20 I TBg/18 I TBg/19
NF-l
I TBg/1 3
CD-Bus Data In
I TBg/15 i TBg/17 I TBg/16 I TBg/14
Clock gesch. Daue r- CD-Bu
/I
l t ! ! l! ! t l t ! l l l ! ! ! ! ! l l ! t ! ! ! ! ! ! ! ! ! ! ! ! l ! ! l l ! t l l l ! ! ! t ! ! l ! l ! l l ! l ! ! ! ! l t ! t ! t ! ! ! ! ! l ! l ! l ! ! ! l ! l l

TBe/5 I TBe/6 -·
~.

1 ::::J
Plus plus Dal a 4 1
out

0,5 0,5
HF
0,5
HF HF (Q

h
gn SW
\ r- ---' 'i
0
~ R.~
-·
~
ni:;. 0.5 05 035 0.5 0,5 0,5 0,5
I ® 't' I
-""""t
_.
~II

CH .
CLK
j9
t,
j7

ws = whi te ws = whi te
1.0

®
A

R l~#

Rf.# I
L L I.
1,0

b 'f~··
2,5

l z2~
,T,.,
Q)
3
CJ)

r
sw = black sw = black
ro =red ro =red
br =brown br =brown
gn =green gn =gree n
2,5 2,5
bl =b lue bl = bl ue br ws/li
gr =grey gr =grey
11 =violet Ii = v iolet
ge
or
=ye ll ow
= orange
ge = ye ll ow
or = o range I@ I F/1
E 15

23 26 27 28 32 33 37 40 41 42
197-518581 197-518591

D lgnn1on/Staner Swnch Pius connection (151. 1n ins rument panel w1Mg harness E15 Rear Window Defogger Switch Ground connection, 1n luggage compartment, left
J218 lnstrumen Cluster Combination Processor J401 Control unit for nav1gat1on wnh CD rive
R Radio R Radio
Pius connection 158dl, 1n ins rument panel wiring harness Ground connection. on right rear pillar
R39 Speaker (telephone. navigation) Al Antenna Connection
R·ll CD Changer Unit All Antenna
S5
T2ar
Fuse
Connector 2 pin, blac<. behind 1nsu ment panel. center
@ Wire connection 1l5al. 1n 1ns1rurrent panel wiring harness R24 Antenna Amplifier Vehicles with r ar Window Antenna
R-15 Telephone/Radio Anienna Ampl1f1 r Vehicles with Automa 1c Antenna
T2av
TBe
TB!
Connecwr 2 pin. black. for loudspeaker. B pillar. I h
Connector B pin, b1own, connec tor radio II
Connector 8 pin, blac . connector radio 11 1
8 Wire connection (sh1eld1ngl, 1n CD changer wiring harness T6a
TB!
Tl Ox
Connector 6 pin. blue. connector station A pillar, left
Connec or B pin, black. connector radio Ill
Connector 10 pin, green. connector station A pillar. right #
Vehicles with Nav19a11on
Sedan
TBg Conn c!Or B p111, blue. connecwr radio 1 - 3 Tl Oz Connector 10 pin, red, connec tor rad io IV
Vehicles with CD Changer ## Wa on
Tl Oz Connector 10 pin, red. connector radio IV T15w Connector 15 pin. green. connecto1 station A pillar. nght
T32 Connector 32 pin, blue. on instrument cluster Vehicles with Telephone T20b Connec tor 20 pin, black. on control uni for nav1gat1on
V21 Power An tenna
Z24 Rear Window Defogger With Window An enna

Edition 10/99 Radio, CD Changer Unit, Speaker Radio , Antenna Amplifier, Power Antenna Edition 10/99
W42 USA5602 06 .21 W42.USA 5602 06 .21
Audi AG Wiring diagram No. 59/5 No. 59/6 Wiring diag ram AudiA6
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30 30~~~~~~~~~~~~~~~~~~~~~~~~~~~~-30
15 15 15 15
x x x x
31 31 31 31

T 3al ) T 3al/2 ~ T 3am j T 3am/1 l T 3an l T 3an/1 T 3ao l T 3ao/1

11 12 12 12

m
ws =white ws = whrte ~ CD
SW= black sw =black ~ ()
ro =red ro =red
.....+
r br =brown
gn =green
or
gn
=brown
= green :::::::::.

lee 'I~
1.0
br
bl = blue bl = olue ()
gr
Ir
ge
=grey
=violet
=yellow
gr
Ir
ge
= grey
=violet
=yellow
ro
~
or =orange
46 47 53 54 56 69 70
1 97-518601 ( 97-51861 1

J218 - Instrument Cluster Comb1na t1on Processor Ground connection. on left A-pillar. lower part
J429 Control module for central locking
R15 Left Rear Woofer
J453 Control module for multr-funct1on steering wheel Grouna connection, rn speake 1 wiring ha 1ness
R R17 Righ t Rear Woofer
Radio
R36 Telephone Transceiver R21 Left Front Woofer
R43 Righ t Rea r Woofer/Amplifier Vehicles with Telephone R23 Right Front Woofer
Tie Single connector, on Radio Vehic les w1 tl1 mult1-funct1011 steering wheel R26 Left Front Midrange Speaker
T6w Connector 6 prn, yellow, connector radio I - I R27 Right Front Midrange Speaker
T6x Connector 6 pin. green. connector radro I - 2 R34 Lett Rear Midrange Spea'-er
TIOx Connector 10 prn. green, connector station A pillai. right R35 Right Rear Midrange Speaker
Tl Oz Connector 10 pin. red, connector radro IV R43 Right Rear Woofer/Ampl1f1er
T15s Connector 15 pin. blu , connector station A pillar, left T3ae - Connector 3 pin. brown. connector station A pillar. left
T15v Connector 15 pin, orange, connector station A pillar. right T3af Connector 3 pin, brown. connector station A pillar, right
T32c Connec tor 32 pin, grey. on instrument cluster T3ag - Connector 3 pin, blue, rn B pillar left
T3ah Connector 3 prn, blue. 1n B p1lla1 right
T3al Connector 3 pin. black, 1n driver s door
T3am Connector 3 pin, black. rn passenger's door
T3an Connector 3 prn, black, 1n left rear door
T3ao Connector 3 pin, black. 1n right rear door

m
Edition 10/99
W42 USA.5602.06 .2 1
Radio, Right Rear Woofer/ Amplifier Right Rear Woofer/Amplifier Edition 10/99
W42 .USA.5602 06 21 ~
0I
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co
Audi AG Wiring diagram No. 59/7 No. 59/8 Wiring diagram Audi AG (J)
0
m
~~ ~~~~~~~~~~~~~~~~~~~~~~~~~~~~ ~~
c::
:::i ~
x
31
x
31
Q 0I
~ ~
Cl)
00
0
.._
ct>
~3
* ** ***
OJ m
-
Z 24 R11 R11 R11 0 CD
Cl)
't' AM 't' FM1 't' FM2 't' FM3 't' FM4 I
~ LE:J
l vr
ct> ()
_...
.......
t\)
a ()
2,5
a OJ
-2 -
,r. , -~·
~-
:::::J
2.5 (Q

I~1 0
E 15
Q.) .

p
I ® I

p
bl It '" I '-·- I 1
ro J s 15 I ge I u..J
.......
1..J r.J OJ
3
HF ZF HF
CJ)
~ ws = whi te ws = w hite c!J ~
sw =black sw = black
ro =red ro = red
br =brown br =brow n
2,5 gn =green gn =green
br bl = blue bl =blue
gr =grey gr =grey
=violet
I@ 11 =violet
ge =yellow
11
ge =yellow

71 72 73 74 75 76 n 78 79 80 81 82 83 84 86 96 97 98
197 -5 1862] 197-518631

E 15
J515
Rear Window Defogger Switch
Conirol unit for aerial selection (aerial d1vers1ty func tion)
G) Ground connection, on right rear pillar J515 Control unn for aerial selection (aerial diversity function)
R 11 Antenna
R82 TV Anienna Amplifier 1
R83 TV Antenna Amp l1 f1er 2 R82 TV Antenna Ampl1 f1er 1
R84 TV Antenna Ampl1f1er 3 R83 TV Antenna Ampl1f1er 2 Roof Antenna
R85 TV Anienna Ampl1f1e1 4
R84 TV An tenna Amplifie r 3 Window rear left
T6a Connector 6 pin, blue, connector station A pil lar, left
Z1 Rear Window Defogger/Heat Element R85 TV Antenna Ampl1f1er 4 Window rear ri ght
Z24 Rear Window Defogger With Window An tenna

Edition 10/99 Control Unit for Aerial Selection. TV Antenna. Control Unit for Aerial Selection , Edition 10/99
W 42 USA5602 06.21 Rear Window Defogger with Window Antenna TV Antenna W42 USA 5602 06 .21
AudiA6 Wiri ng diagram No. 64/1 No. 64/2 Wiring diagram Au diA6
30 30
15 15
x x
31 31
Driver's Information System
~
2000 m . y. J 220

I
0.35
Fuse Panel ge

Fuse Colors:
30 A Green
tT,~o
25 A White
Yellow 0,35
20 A ge
15 A Blue
10 A Red I T3V25
~5 A Brown
5 A Berge

@ J 1a9
~
Starting with fuse pos111on 23. fuses in the fuse holder
are 1dentrf1ed with 223 1n the wiring diagram T32c IT32c IT32c I T32c/1 5 T32c/ 12 T32c/13 T32c/11

I
0.35
/19 117

0.35
118

0,35 0,35
IClock

0.35
I Data

0.35
I Enable

0.35

lo~ l"~ lo~

gr bl gn

l""'°
13 - Fold Relay Panel
Relay loca t ion :

Iii -Lamp Control Module. J123 0.5 0.35 0.35 0.35

m
~Fn 1 J~. , , ..r~.,,,J'.' ,o, , l
-=lJP)! ~ -Lamp Control Module. J123
m
5 6
ws =wh ite CD
()

UlT'w'
9 10 11 12 sw =black
ro =red r-+
br =brown
gn = green ::::!.
bl = blue R:;: ("")
gr =grey
11 =violet O>
ge =yellow
s e
10 14 ~
E91
E92
F77
Board Computer Function Selector Switch
Board Computer Reset Bunon
Windshield Washer Fluid Level Warning Switch
e
Q
ls7-s1s1s f

Ground connection -1-. 1n instrum ent panel wiring harness

Ground connection -2-. 1n 111strument panel wiring harness

-
::J
fJ'J
.........
::::!.
:::J
(Q
~
J189 - Auto Check System
Q 2
:3 0
J220 - Motron1c Eng ine Control Module IECMI
Ground connec tion -3-. 1n 1nst1ument panel wiring harness
R Radio ~
T6x Connector 6 pin. green. connec tor radio I - 2 Q CD
::J O>
T10a Connector 10 pin , pink. connector station A pillar. left 1(5 Ground con nector (sensor ground) -1-. 1n ins trument panel
wiring harness
TlOb - Connector 10 pin . red, connector station A pillar. left
TIOo Connector 10 pin, brown. connector station electronic box Ci)" (Q
plenum chamber Bmh are possible ~
T10x
T32
Connector 10 pin. green. connector station A pillar. right
Connector 32 pin. blue. on instrumen t cluster
!:l:i
::J
O>
T32c - Connector 32 p111, grey, on instrument cluster
Q. 3
(J)
CJ
a
::J
.........
C3 m
Edition 10/ 99
W42 USA5602 .06 .21
Board Computer Function Selector Switch,
Windshield Washer Fluid Level Warning Switch
Edition 10/ 99
W42 .USA5602 06 21
Ci)
~
I\) 0
a I
a (X)
-2 --L.
AudiA6 W iring diagram No. 64/3 No. 64/4 Wiring diagram AudiA6 -
::J m
2 0~
CJ)
........
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ ~

x
31
x
31 :3
([)
I

::J 00
Ci)" (\)
!l)
J 211 I I ::J
I
.. 25
* I 8 2.5
8 2,5
ge
Q
V ~I~ I.------------------. 1,0
ge
Q
m
-
~

L ~.......
4.0
o.s
sw/br (')
S s
10A
t /56 m 1

S 21
1 20

~ S20
0
::J
CD
()

r·:"
E1 ........
rO~SA
,....+
Jr'""
*
0,35
D
.. s.
1,0 aCi)" ~.
()
I
swlbr sw/ro
1.5 1,5

I\) OJ
-
0.35 0,5 gelgn ge/br
' T32a/31 I T32c/16
gr/Ii sw/ro
nm
:~·
a
I I a ~
' 11/56bl J ,23 " 4/56b R

~
, 1115

~ Vs G , os~ ® J 189 D~I:

r /KB
®
~ ®
1 2131
-2 ~.

I
r 3/56bl1 r 5/56bR1

I I 8jJ
0,5 1,5 1,5
~
0.5
::J
(Q
r~
0.35 gr/sw ge/sw ge/ws grlro
T32c/14

'I I T10a12 T10a/S T10ay/S lT10av12 0

0.35
br/ge
~ m
c& 1 (Q
0,5

grilsw
1,5

ge,1sw g•1:10an12
1,0 10 1.S o,s
-...
g•c o.:•l'w• 9'!''° OJ
SS L 56b
V 4B
v:: 56b SBA
3
CJ)
T1 0an/7 1 T1 0a n/5 Tn oao/5 TT1 0aol7

ws =whi te ws =wh ite M1 M 29 ~ M 31 ~ M3

sw
ro
= b lack
=red
sw
ro
=black
=red
1 T 1Oan/8
31
IT1 31
Oan/1O IJ T10ao/8
31
.i' T10ao/10
31
br =brown br =brown
gn =green gn =green I
bl = b lue bl =blue

r8
gr =grey gr =grey
Ir
ge
=violet
=yellow
11
ge
=v io let
=yellow r@ r@ r@
26 27 28 32 40 41 42
197·516161 j 91-s1s11!

D Ignition/Starter Switch Plus connection 1151. 111 instrument panel wmng harness El Light sw11ch Ground connection -2-. rn instrument panel wmng harness
G106 - Outside A11 Temperature Display J 123 Lamp Control M odule
J123 Lamp Control M odule Wire connection I 15a), 111 instrument panel wiring harness Ml Le Parking Light Ground connection. rn righ t headlight w mng harness
J189 Auto Check System M3 Right Park ing Ligh t
J217 Transm1ss1on Con trol Module ITCM) M29 Left Low Beam Headlight
S5 Fuse Vehicles w1tl1 automatic transmission 01 V Ground connection, 1n left headlight wiring harness
M31 Right Low Beam Headlight
T15r Connector 15 p111. blue. con nector stauon A pillar. righ t
S20 Fuse
T32a Connector 32 pin. green. on instrument cluster Ground connection -3-, 1n instrument panel wrnng harness
521 Fuse
T32c Connector 32 pin. gre y, on ins tru m ent cluster
Y6 Transm1ss1on Range !TR) Selector Lever Display TIOa Connec tor 10 pin. pink. connector station A pillar. left
TlOan - Connector 10 pin. on headlight. left Wire connec tion 1561, 1n instrument panel wiring harness
T lOao - Connector 10 pin, on headlig ht. righ t
TlOay - Connector 10 pin, pink, connector station A pillar, right
V48 Le ft Headlight Beam Ad1usung Motor
V4 9 Ri ght Headlight Beam Ad1ust1ng Motor Both are possi ble

Ed itio n 10/ 99 Lamp Control Module, Outside A ir Temperature Display Lamp Control Module, Parking Light Edition 10/ 99
W42 .USA 5602 06 .21 W 42 .USA.5602 06 .21
AudiA6 Wiring diagram No. 64/5 No. 64/6 Wiring diagram AudiA6
3 0~~~~~~~~~~~~~~~~~~~~~~~~~~~~30 30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30
15 15 15 15
x x x x
31 31 31 31

F
o o.sI
l '(J
1,0 1w:
I
o.s 8 I
\,0 ~
gn/sw 0.3S

g~n~~~223
ro/sw gn/ro gn/ro
br/ge

r 1 223a
SA
. 13/SB L
E 1

te l 14/SBA
E 1

r 1 22a
®2
5 22
SA

fe I
8
I
o,s
gr/sw

~
o,s
gr/ge

•LJl•
ro/sw ro /sw
o.s
gr/ro

~
0,5
gr/ws

~·~"
0,35
br/ge
0 ,35
br/ws
0 ,35
br/ws

IT·~·
Dllii.I 1 07 I A12
L SBL iS/S4 t /S 4HE J 123 E a1 E a1

r4l
1.0
r

o.s
7/SBBL1
©
r

1,0
4H r

1,0
4A
r·,
O,S o.s
br/ws

l~ l·~
ro/sw ro/ge gr/ro

t,
tfo tT·~ tT·~ ,,G
't u."
\ ,0 1.0 0,5

ir...
ro/sw ro/sw gr/ro
o.s
br/ge

,T,,~ m
ro{;___j
t

M9 M4 M2 ws = whi te ws = white CD
sw =black sw =black (')
r /31 r /31 ro =red ro =red r+
br = browr br = brown
1.0
b•
o.s
b•
1.0
b•
gn
bl
= green
= blue
gn
bl
= green
=blue
0 ,3S
br/ge
'
(')
gr =grey gr =grey
11 = violet Ii =viol et
l B9 Q)
I@ I@ I@ ge = yellow ge =yellow
E a1

43 46 49 so S6 57 S9 61 70 ~
-
fg1.s 1s1a l l91.s1essl

El
F
Light switch
Brake Light Switch
Ground connection -1-. 1n rear w1•1ng harness E87 -
G 17 -
NC Control Head
Outside Air Temperature Sensor
Ground connection -2-. in NC wring harness ::J
Cl)
'
:J
J123 Lamp Control Module Wire conrection 154l. 1n instrumert panel winng riarness TlOb - Conrector 10 p'r •ed. connector station A pillar. lelt Connector !outside tempe•ature 1nd1cator). 1n instrument ...... (.Q
M2
M4
Right Tail Light
Le h Ta il L'ght
panel wiring harness
2
3 0
Wire connection 15711. 1n instrument panel wiring harness
M9 Leh Brake Ligh t
MlO Right Brake Light
M25 High-mount Bra ke Light
Wire connection 157rl. 111 instrument pane wiring harness
<t> Q)
S22 Fuse ::J
(.Q
S223 -
Tlb
Fuse 23 1n !use holder
Single connec tor, black. connector station A pillar 11ght en-
T6a
Tl Of
Connector 6 pin. blue. connector station A pillar. Ifft
Connector 10 pin, brown, conn ector station A pil lar. leh !.:b
::J
'
Q)
Q 3
CJ en
a
::J
......
a m
Edition 10/99
W42 .USA.5602 .06 .21
Lamp Control Module, Brake Light, Tail Light Outside Air Temperature Sensor Edition 10/ 99
W42 .USA. 5602.06 .21
Ci)"
~
I\) 0
a I
a 00
~ VJ
AudiA6 Wiring diagram No. 65/1 No. 65/2 Wiring diagram AudiA6 CJ
o:i
m
"-.:::: ~
Daytime Running Lights with Fog Light and Rear Fog Light
(Canada)
30
15
x
31
30
15
x
31
3·
(1)
0I
1£ §1 ~
5

Ell 00
lJ ~
5186 i6/87
J sg
c:
:::l
:::l
s· m
s1n5 30 15
2000 m . y.
0,5
8 1 I I I I
0,35 0.35 0.5 0,5 0,5 {Q
Fuse Panel

Fuse Colors:
1,0
T T T
2.5 2.5 2.5 6,0 cL
gn/gr gnlgr

1;3L2/27 1;3~26 ~ cb
gn/gr gn/gr gn/gr
r- <D
c0· ()
i
ge/sw
::J- ........

II 'i J 218 J 218

30 A Green ~
25 A White (j)"
20
15
A
A
Yellow
Blue
2,5 2,5
8 Cf
1.5 i\) OJ
()
10 A Red gr
a
7.5
5
A
A
Brown
Beige
I L Io D I
~
a
~
Starting with fuse position 23. fuses 1n the fuse holder
are 1dentif1ed with 223 in the w1nng diagram

~
2,5
ge/ sw
fr
0,5
gr,gn
0,5
gr/ge
:::::!.
::::J
co
0
Ws
OJ
Relay Location : ~

El -Load Re duction Relay, J59 OJ

3

iM!4P I I I
ws
sw
ro
br
gn
=wh ite
=black
=red
=brown
= green
.=1
r
CJ)

A B C 0,5
bl =blue
gr = grey
11 =viole t
ge =yellow
f0 14
197-519651

13 - Fold Relay Panel

B Starter Ground connection -2-, in rear w1r1ng harness
Relay Location : Cl Voltage Regulator (VRI
D lgni ion/Starter Switch Plus connection 1151. in instrument panel w1r1ng harness
II -Fog Light Relay, J5 J59
J218
Load Reduction Relay
Instrument Cluster Combination Processor
Wire connection 186sl. instrument panel w1r1ng harness
llJ -Lamp Control Module. J123 S3
S4
Fuse
Fuse
111

Plus connection -2-1301 . 1n instrument panel w1r1ng harness

lliJ -Lamp Control Module, J 123
TlOt
T32
Connector 10 pin, orange, connector s1at1on A pillar. nghr
Connector 32 pin, blue. on instrument cluster

m -Fog L1gh1 Circuit Breaker, S28

W6
x
Glove Compartment Light
License Plate Light
Connection 2 (daytime running lights). in instrument panel
w 1nng harness

Ignition/Starter Switch , License Plate Light, Edition 10/99

Edition 10/99
Load Reduction Relay W42 USA5602.06.21
W42 USA5602 06 .21
AudiA6 Wiring diagram No. 65/3 No. 65/4 Wiring diagram AudiA6
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30

15 15
x x x x
31 31 31 31

~ ~
~
1,5
ge
1,0
ge 0.5
gn/gr

L I(--'

if'.,
L•o 1 223

It.,·;.. ~+ .R8Ff r fJt r

S19 S 21 S 223
10A 15A SA

r 1 19a f.,
t WI wslsw
0.5 1,5 1,5 0,5 0,5
gel/gn grl/ge
~ l u~
/g• wslge ge ge"o 1• g•,~
8 11/56bl : 18/SBL
gr/sw

OJ]
om ) I
v
f'V\ (
I

TT
J 123

r-,.
03 T sa11 o.35 \ 1.s 1.s
~

I'~"
gr/bl :

C!J [[) l5as

T32/20
8
I I J 21a

'b T T·~ "F·~ i:. ~

1.5 2.5 2.5 2,5 1.0 1,5 0.5 1.5 1.5

~ ~I :t r&SJi~ ,. T·~·

1..,':~~:1~_1: ~._:;__;~-10a-n/2-l~:.~ •t l,,

f 8/56b f12/56•
1
1.5

Ji
ws/gn
1.5 1.5 1.5

g~t6 l l
37

___
~
I
ge
1,0
E 102

r•
0,35
f's.
1.5
~i3s

1.0 0 ,5
WS
sw
ro
br
gn
=White
=black
=red
=brow~
=green
ws
sw
ro
br
gn
= white
=b lack
=red
=brown
=g reen
f"··· ,,,.... r f·
I
b• b• 1.5 1.5 1.0 1.0
bl = blue bl =b lue

8
L le le le 18
gr =grey

le
gr =grey
Ii =violet 11 = violet
ge =yellow ge =ye llow

22 28 30 31 32 42
J 97-51966J 1 97-S1967 J

E1 L•ght swnch Ground connection - t-. II' instrument panel wring harness J5 Fog Light Relay Ground connection. in rigl t headlight w1r ng harness
E..1 Headlight D mmer/Flasher Sw• c J123 Lan· p Con:ro Module
E23 Fog L•ght Switch L22 Le~ Front Fog L1grt Grouncl co11nect1or. 1n le :t 1·eadl1 h1 "'1r ng haroess
Grm.. nd connection ·2~ in rear wiring harness
E 10 Headlight Ad1uster L23 Right Front Fog Light
J218 Instrument Cluster Combination Processor Ml Left Park ing Ligh t
V\1 re connec.: on (58sl. panel harness Connection 3 lclayt1rne running l1 ght sl, 1n 1ns rr11rnent panel
1ri 1nSHL1ment w1ring M~ L f1 Tail Light
"13 Rea• Fog Light Indicator L1gt>t wiring harr,ess
r-.17 M29 L ft Low Bean' Headl1gl t
Fo Light Indicator Light
Wire connection 156!, "'instrument panel wmng h;irness M30 Left H1gn Bear'l Head'ight
L9 Headlight Switch Light
519 Fuse
L..10 Front And Rear Fog Light Sw1tcl1 Light S21 Fuse
L..16 Le Rear Fog Light Corwector ldayn1me runnmg l1ghtc;), in 1nstrumen par' I 5223 - Fuse 23 111 '.ise holde1
528 Fo L 1ght Fuse wiring harness TlOa Connector 10 pin, pin. connector s:at1on A, pillar. le
5236 Fuse 3 111 luse ho1der Tl Ob Connector 10 pin, red. connector station A pillar ieft
T6a Connector 6 pin, blue. connector stat ion A rlllar. leh TlOan Connector 10 pin. on heacll1ght. leh
T32 Conr. ctor 32 pin, blue. on instrument cluster TIOaz Connec tor 10 p111. 1ed, connector station A, pillar, right
V·18 L ft Headl1gl1t BPar Ad1us11ng Motor

Edition 10/99 Light Switch , Headlight Dimmer/Flasher Switch Lamp Control Module, Front Fog Light, Edition 10/ 99
W42 .USA 5602 06 .21 Left Beam Headlight W42.USA5602.06.21
Audi AG Wiring diagram No. 65/5 CJ
Q)
m
~ ~
30
15
~~~~~~~~~~~~~~~~~~~~~~~~~~~~30

3· 0I
fl
~~~~~~~~~~~~~~~~~~~~~~~~~~~~15

x ~~~~~~~~~~~~~~~~~~~~~~~~~~~~x
~~~~~~~~~~~~~~~~~~~~~~~~~~~~3 1
Ct)
00
lJ (j)
c:
::J
::J
LljJ cyJ UjJ LJ.iJ s· m
I·f 11'
1.5 1.0 0,5 0.5
(Q
r-- CD
i..
~.~:
? S 1s S 20
A
2 c0· ()
,.....+
::J"" .......
0 ,35

w
1::. wsl/ge
1,5 1,5

ge,/br
h
0 ,5 o.s
Ci)"
I\) Ol
()

a -
T32/17

K l
o m
a/56bA
·
®
~.:'"· a
-2 ~
J 123 .......
15/56bA1 . 12

1
/58BA1

1
1.5
ge/ws
0 .5 (Q
::::J

T
M 2
0
w T 10ay/4 W T 10ay/S T 10ay12 __m
fil
1,5

ws,/ge
f1.0

g•co.:•1/ws
1,0 o.s
THIS SPACE INTENTIONALLY .......
Ol
LEFT BLANK 3
56a 12 56b TBA CJ)
v.9
4
~
1011 Tnoao1s

~ M3 1
4T::on ws white
sw black
I T 10ao/8 t 11oao110
ro red
br brown
gn =green
1.5 1.5 bl =blue

i8 18
gr =grey
11 =violet
ge =yellow

45 46 47 49 so 53 55 56
54 197-5 19681

J123
Kl
Lamp Control Module
Headlight High Beam Indicator Light
6) - Ground connection. 111 right readl1ght wiring l1arness

M2 Right Tail Light

M3 Right Parking Light
M31 Right Low Beam Headlight
M32 Right High Beam Headlight
518 Fuse
520 Fuse
522 Fuse
TlOao Connector 10 pin, on headlight, right
Tl0ay- Connector 10 pin. pink. connector station A pillar. rigl't
T32 Connector 32 pin, blue. on instrument cluster
V49 Right Headlight Beam Ad1usi,ng Motor

Edition 10/ 99 Lamp Cont ro l M odule,

W42 .USA 5602 06 .21 Right Beam Hea dlight
AudiA6 Wiring diagram No. 66/1 No. 66/2 Wiring diagram Audi AG
Headlight with High Intensity Gas discharge Lamps and 30

x
15
30
15
x
automatic Headlight Beam Adjusting 31
8185 mo
31

I ,~- 3 1~
5186 6187

S1n 5 30 15
2000 m. y.

Fuse Panel

Fuse Colors:
30 A Green
25 A White
20
15
A
A
Yellow
Blue 1,0
~ Cf
2,5 6,0
~ cp
4,0
Cf
0,5
10 A Red ge/sw

I I I
7.5 A Brown
5 A Beige

Starting with fuse position 23. fuses 1n the fuse holder

8 8
are 1dent1f1ed with 223 1n the wiring diagram
2,5 2,5

Micro Central Electric Panel

Relay Locat io n:
.,...,. l ~- '.::j lo
·i~
EJ -Load Reduction Relay, J59 2,5 2.5
ro/sw
0,5 4,0 0,5
ge/ sw bl

c!J I d;

~ WS
sw
ro
=White
=black
= red
l T912
J 207 c
ef 0,35
m
CD
('")
I I I br
gn
=brown
=green I 86s
,..-+
~.
A B C T32130
bl =blue
J 215
('")
gr =grey Q)
Ii = violet
ge = yellow

13 14
1 97-519001
~
13 - Fold Relay Panel ~-
Relay Loca t io n:
c
D
Generator !GEN)
lgn1t1on/Starter Switch
Plus connection (151, 1n instrument panel w1r•ng harness
:r:
CD
:::J
(Q
J59 Load Reduction Relay Wire connec tion 186s), 1n instrumen t pane l wmng harness
Ell -Lamp Control Module, J123 J207 Staning lnte1 lock Relay !:l)

ca·::J"9:: 0
J218 - Instrument Cluster Combination Processor
Plus connection -2- 1301. in instrument panel w1nng harness
DlJ -Lamp Control Module, J 123 T9
T32
Connector 9 pin, brown, on start111g interlock relay
Connector 32 pin, blue, on instrument cluster
Q)
~Ci) (Q
......
Q)
fu< 3
::3
a CJ)
::3
~ m
Edition 10/ 99
W4 2 USA 5602 06 21
Ignition/Starter Switch Edition 10/99
W4 2. USA5602 .06.21
-
~ ~
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a I
a OJ
'2 -..._J
AudiA6 Wiring diagram No. 66/3 No. 66/4 Wiring diagram AudiA6 ::r:
Ct)
m
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 30
tl)
9:
~
c0· 0I
15 15
x x
31 31

::J- ())
~Ci) ())

~ ~ fu<
1,5
ge/gr
1,0 :J
a
:J
m
1 236
<D
~ S23s ~
-
()

r·
15A
.....+-
~ 22a ~ 18a ~
c:p cp ~ ()

E
t
0.5 0,35
2.5 2,5 1.5 gr/ro
I I\) m
M2 0
-2 ~
~ J123 DII!J 0

2,5 1,5 1,0 0,35

fJl.
0.5
4
®
~.
:J
(Q
~
ws/ge gr/ ws

•2
I
1,0 o.s 1.5 1,5
I
J s L 4s
sw/gn gr/ ro ws/ge ge/ws
0
n,·
I (Q
~ ~ cp cp I ~
1.0 1,0 1,0 2,5 2,5 2,5
m
'bj~J".
0.5 1,0 0,5 1.5 1,5
gn sw/gn gr/ro ws/ge ge/ws

3
t:; ;:J ....:t I
I BR
4 T10ao/9
M1
I SB A
4T10aon
M3
I ssa
4 T10a o/1
M 32 ®
) ssb
TtOao/5

~1 L 14
CJ)
ws =wh ite ws = whi te
IE..
t M 19 J 344
sw =black sw = blac
l=l==L= = = =E,= l ro =red ro =red t T10ao/8 tT1 0ao/10

1,0
E4 r 1ssb h

1,5 1,5 1,5

br
gn
bl
=brown
=green
= blue
br
gn
bl
=brown
= green
=blue
I
0,5
br
1,5 1,5
br br

l~~
sw/ws/gn

l0 l0 18
gr =grey gr =grey
. 3/49 Ii =violet
11 =violet
E3 ge =yellow ge =yellow

26 27 28 29 30 31 35 36 38 39 40 41 42
(97-5 1952 ) 197-519531

El Light swnch Ground connection 1-. 111 instrument panel w1r111g harness J 123 Lamp Control Module Ground connection. 111 right headlight wmng harness
E2 Turn Signal Switch J34<1 Control Module for H1gh-1ntens1ty gas discharge lamp
E3 Emergency Flasher Switch Wire connect ion 15711. 1n 1nsuument panel wiring harness L 14 High 1n tens1ty gas discha rg e lamp right Plus connection (nght turn signal). 1n instrument panel wiring
E4 Headlight Dimmer/Flasher Swi tch M2 Right Tail Light harness
E19 Park Light Switch M3 Right Parking Light
Wire connection (57rl. 1n instrument panel wiring harness
E23 Fog Light Switch M7 Right Front Turn Signal Light
J5 Fog Ligh t Relay M 19 Right. Side Turn Signal Light
K 13 Rear Fog Light Indicator Light Wire connection 1561. 1n 1nstrumert panel wiring harness
M32 Right High Beam Headlight
K17 Fog Light Indicator Light SlB Fuse
L9 Headlight Switch Light S20 Fuse
L40 Front And Rear Fog Light Sw1 ch Light S22 Fuse
L46 Left Rear Fog Light TIOao · Connector 10 p111. on headlight. right
S3 Fuse T10ay - Connec or 10 pin. pink. connector station A pillar. right
S236 · Fuse 36 1n fuse holder

Edition 10/99 Light Switch, Headlight Dimmer/ Flasher Switch Lamp Control Module, High Inten sity Gas Discharge Lamp Right Edition 10/99
W42 USA5602 06 .21 W42 USA .5602 .06.21
AudiA6 Wiring diagram No. 66/5 No. 66/6 Wiring diagram AudiA6
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30 30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30

15 15 15 15
x x x x
31 31 31 31

~ ~
¥ ¥
1,0 1,0
l4J
1.5
L1jl
1.0

j:::
$ 19 } ~223 ?
~
8
IT
8
IT ~ C!jJ
h
I
0 ,35 0 ,35 0,35 0,35 0,35 0,35 0,35
ge wslbl ws/bl gn gn br/ws ge/g n
1,5 1,5 0,5

~·~ "' ; ~:~. I

ws/sw gr/sw

L t
iT16an
I I""'
M4
UjJ
J 21a

J431 I.
r· ;~ i4's f r ..
\
1.0
I ®
r~·,,
120131
1/+

0,35 0,35 0,35 0,35 0,35 0,35

li/ro 11/sw li/br li/ge lilgn li/ws

t"·~ tr••~ tr,..,,. tr,.,,. tr·~ tr·~

1.5

l~
1.5
ge/sw
T 10a14
0.35
li/ ro
0,35
li/ sw

fr. ,, fr. ,, fr. ,,

0.35
li/br
0,35
li/ge
0.35
liJgn
0,35
li/ ws

it M1a
0.35 0.35 0.35
li/ ro 11/sw li/ br

m
1~I I ~:r rI
( 5sb

I !··
~}
T10an/5
5

ws = white ws =white
1 ,.
CD
sw =black sw = blac~
G1s G1a ("")
t T10an/8 t TlOan/10 ro = red ro =red r-+
I
0,5
br
gn
bl
= browr
=green
= blue
br
gn
bl
=brown
=green
= blue
0 ,35 0,35
~-
("")
gr = grey gr = grey
m
43
f0 f0 48 50 52
f0 56
197 -51954 )
11 =vi ole t
ge =yellow
Ii
ge
=violet
=ye llow

58
lsJe 70
197-519551
~
J123 -
J343 -
Lamp Control Module
Control Module for H1gh-1ntens1ty gas discharge lamp
Ground connection, •n left headlight wiring harness G76
G78
Left Rear Level Control System Sensor
Left Front Level Control System Sensor
Ground connection, 1n instrument panel wiring harness
:r: ':::::l
L13
Ml
High 1ntens11y gas discharge lamp left
Left Parking Light
Plus connection !left turn signa l). 111 ins trument panel wiring
harness
J218
J431
Instrument Cluster Combination Processor
Control module for Headlight Beam Ad1ust,ng
Connector IK-d1agnos1s wire). 1n instrument panel wiring
harness
ct)
tb co
M4 Left Tail Light T4ao - Connector 4 pin black, below rear seat. 'en
9:
c0· 0
Connector !speed s1gna'l. 111 instrument panel wiring harness
M5 Left Front Turn Signal Light TlOa - Connector 10 pin , pink. connecto 1 station A pillar, left
MIS Left. Side Turn Signal Light T10aw- Connector 10 pin. black, connector station A pillar. right
M30 Left High Beam Headlight T16a
T32
Connector 16 pin, Data Linh. Connector IDLCI
Connector 32 pin, blue, on instrument clus ter ::J'- m
S19
S21
S223 -
Fuse
Fuse
Fuse 23 111 fuse holder
~Ci) co
TIOa - Connector 10 pin, pink. connector station A pillar. left
'
m
~
T10a n- Connector 10 pin, on headlight. left

:J 3 CJ)
0
:J

~
Edition 10/ 99
W42 USA.5602 .06.21
Lamp Control Module, High Intensity Gas Discharge Lamp Left Control Module for Headlight Beam Adjusting ,
Level Control System Sensor
Edition 10/99
W42 .USA.5602 06 21
-m
~~
~ 0I
a
a OJ
-2 c.o
AudiA6 Wiring diagram No. 66/7 :r: m
CD
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30
15 15
ti)
9: 0~
x
31
x
31 c0· I
::J- (0
Jn 0

C¥J DjJ ~
~
:::i
0,35
ws/ge
0,5
0
:::i
m
-
I T32/17
CD

sf -
~
J 218
K, (")
r-+
~

0,35
~ (")
grfbl
B OJ
158s a -
T32120
a
~
J 218

-8 -· ~

::J
(Q

0
® ~I
w·

·---•"
I\.i..l
~

,lo THIS SPACE INTENTIONALLY OJ

br/ws

LEFT BLANK 3
CJ)
T 1oaz14 ws white
sw black
ro red
br brown
0,35 gn =green
bl =blue
~ gr
II
=grey
=violet
ge = yellow

76 n 10 79 80 82 83 84
j97·5 1956 1

J218 -
Kl
Instrument Cluster Combination Processor
Headlight High Beam Indicator Light
@) Ground connec11on -2-. in instrument panel wiring harness

SlO
TlOa -
Fuse
Connector 10 pin. pink. connector station A pillar. left
@ Ground connection -3-, in instrument panel wiring harness

TlOb - Connector 10 pin. red. connector station A pillar. left @ Ground connection. 1n instrument panel wiring harness

e
TlOan - Connector 10 pin . on headlight, left
T10ao- Connector 10 pin , on headlight, right Wire connection (58s), 1n instrument panel wiring harness
T10ay- Connector 10 pin, pink, connector station A pillar, right
TlOaz -
T32
V48
Connector 10 pin. red. connec tor station A pillar. righ t
Connector 32 pin, blue, on 1nstrumen cluster
8 Connection !headlight beam ad1ust1ngl 1n instrument panel
wiring harness
Left Headlight Beam Ad1ust1ng Motor
V49 Right Headlight Beam Adjusting Motor Both are possible
*

Edition 10/99 Left Headlight Beam Adjusting Motor,

W42.USA.5602 .06 .21 Right Headlight Beam Adjusting Motor
AudiA6 Wiring diagram No. 67/1 No. 67/2 Wiring diagram AudiA6
30~~~~~~~~~~~~~~~~~~~~~~~~-.io--~~30
15 15
x x
Headlight Washer 31 JJi DD 31

2000 m. y.
0.5 0.3S
'l'
2,5 1.0 1.0 0,35 0.5 0.35 2.5 6.0

·~ ":~+
ge/bl ws/ge
Fuse Panel
Li
gn/li bl/ro

Fuse Colors:
30 A Green 2.5
8
25 A WMe ge
20 A Yellow
15 A Blue 1.156
10 A Red Er
7.5 A Brown
5 A Berge TSI/
~5/HW
r, H2
))(01
E22

ef ~
5131 1 1153 4153c 2131
Start•ng wth 'us pos111on 23. fuses"' •he fuse ~old r
are 1dent1f ed with 223 1n the "'"ring diagram

~ 'f I
Micro Central Electric Panel 2.5 1.0

Relay Location :

El
IJ
-W1perNl/asher lnterminent Relay J31

-W pe•Nl/asre· lntecr'11rtent Relay. J31

TT~
2.5
'h
0,5

T m
~
~I I I
-'IS= white
sw = black
ro = red
or =
orown
fv" Vs CD
()
r+
A B C gr =green
bl = blue
2.5
br
'
()
gr =grey
Ii =violet
Q)
ge =yellow

14
1 97-50437 1
~
El
E22
L1gh1 switcr
Winds reld W p rNl/asher Switch
Ground connec: .on in engine con partment leh '
::J
E38
J31
Wrndsr.eld W per lnterm1 ent Regulator
W1perNl/asher lnterm nent Relay
Ground connection -1- n ·nstr,rnient panel V\ iring harness co
5224 - Fuse 24 n fuse holder Ground connection 2 in 1nstrum nt panel w1r111 harness
T2b Connector 2 pin, black, connecwr station A pillar, leh 0
T6ac

T81
Connector 6 pin. brown on w1ndsh1elcl wiper tntern rnent
regulator
Conriecwr 8 pm, l"1rl vv ndsh1eld w1p r/washer sw tell
Ground connection 3- 1n instrument panel wir ng harness

Plus con1· cilOn 130!, 1n 1ns:r 1ment parel wring harness

:r:
(l)
0)
TIOa Connecwr 10 p.n pin~. connector station A pillar •ett 0) (Q
V5 W1nclsh1eld Wash r Pump w.re connect1on 156). 111 1nstrume111 panel wiring harness
Q
Vil Headlight Washer p, unp
Conrector (53a>. 111 111stru111e!lt panel wiring harness
;:::::..
(Q'
'
0)

Bml1 art possible

:::J"-
....... 3
(/)

~
(J)
:::J"- m
~
Headlight Washer Edition 06/00 (l)
Edition 06 /0 0 .......
W42 .USA5602.0721 W42 USA 5602 072 1
I\) 0
a I
a (0
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Audi AG Wiring diagram No. 72/1 No. 72/2 Wiring diagram Audi AG $::::i m
~~~~~~---.~~~~~~~~~~~~~~~~~~~~~~~ 30
Q ~
x ~~~~~f-----~~~~~~~~~~~~~~~~~~~~~~
15
x 0 0I
~ co
J1 ~~~~~1--~~~~~~~~~~~~~~~~~~~~~~ Jl
Power Windows
~ 1\3 ('\)
a
r--i 30
a
2000 m . y.
2,5 2,5 ~
E 4o

r12~
lm
m ~'i,
Fuse Panel

c: ~
Fu se Colors:
30
25
20
15
A
A
A
A
Green
VVh1te
Yellow
Blue
S J7
J OA

2.5 2.5
h
2,5
S 4J
J OA

2,5
11 . +-14
+ 15

'°,-~.~·,-~.-1..:. :1..:..
10 A Red
75 A Brown
5 A Be'CJEl

18 18 18

Startin with lus position 23. fus s ,n tne fuse holder

are 1dent: ed with 223 in the wir1n d,agram ~ Of 70
C!fl
0,35
cp ~
O,J5
2,5 2.5 2.5 2.5 0,5 O,J5 O.J5 2.5

'J; ';t ';&; ';i;

ro/gr ro/br Ii ro/gn rofgn

T 15• T 15•

·
p ·
O.J5 O.J5 O,J5 O,J5 O.J5 O,J5 O.J 5 2.5

~I I I
w s =wh ite
sw =black
ro = red
br = brown
gn =green Fl
I ©
J 295 r E31
Vu

A B C 2,5 2.5 O,J5 2,5

bl =blue br br rolgr br
gr = grey I
11 = vi olet L 108
ge = yellow

14
1 97 -51873 1

8 - Fold Relay Panel

EJO Left Front Window Swi tch GroLm connection. on left A-p1 lar. lower pa
Fuse Lo cation : J295 - Left Fron t Powe r Win dow Control Module
L 108 Door opener l1gh t1ng, driver side Ground connect1011 1- 111 powe1 window w111ng harness
UlJ -Power Window Circuit Breaker Fror•t. S37 537
S.J3
Power Window Circuit Breaker Fron t
Power Window C1rcu1t Breaker Rear Grounrl connection in driver's door w111ng harness
Ii Power Window Circuit Breil er Rear. S.J3
T3n
T5b
Connec:or 3 pin, red. connecto• station A p1llilr. ef;
Connector 5 pin, black. in drivers door
Plus connection f301. 1n power window wiring harness
TlOa Connector 10 p111, 1ed. connector station A pillar. rigl1t
TlOah Connector 10 pin. red. 1r B rnllar. le
T10a1 - Connec tor 10 pin. red 1n B pillar. right
T15k Connector 15 pin. red. connector sta tion A pillar. left
V14 - Le ft Window Motor

Left Front Power Window Control Module, Edition 10/99

Edition 10/99
Left Front Window Switch W42 USA 5602 06 21
W42 USA 5602 06 21
AudiA6 Wiring diagram No. 72/3 No. 72/4 Wiring diagram AudiA6
30 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~30 30~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 30

1S 1S 15 15
x x x x
31 31 ~ ~

Es3

0,3S

Cfo.s
·1~ . ., T T
..
0.3S 0,3S
0.3S

l~.... tr,.,. 'f~

ro/gr
gr/bl

T 10ag13

b .. d l"
I T1oah/10
0,3S 0.3S
ro/gr 0.3S

o.s
er
0.35
I I I
0,35 0.35 0.35
~
0,35
l"
~: :· . ~ T ~·~1
rolgr

,, m
CD

0.3S
Tsc/3

r r r Fl
J 2gs

0.5 2.5 2.5

V 1s

0 ,35 2.5 2.5

ws
sw
ro
br
gn
= wh1 1e
=black
=red
=brown
= green
ws
sw
ro
br
gn
= wh11e
=black
=red
=brown
=green
()
~

::::::!.
rofgr bl =blue bl =blue ()
~
I
lsI®Is
gr = grey
L 109
blr
gr
11
=grey
=violet 11 =viol et Ol
ge =yellow ge =yellow
~ 32
23 28 36 42
197-51 874 1 197-51875 1

E41 Right Front Window Switch Ground connection - 1-. 1n power window wiring harness E52 - Leh Rear Window Swnch. lln LR Door) Ground connection -1-. in power window wmng harness
E107 - Switch for window regulator. 1n passenger door E53 Leh Rear Window Switch. lln Console!
J296 - Rig t Front Power Window Control Module Ground c0Mect1on. 1n passenger's door wiring harness J245 - Power Sunroo Control Module Ground connection, in left rear door wiring harness
L109 - Door opener l1ght1ng. passenger side J297 - Leh Rear Power Window Control Module
T5c - Connector 5 pin, black, 1n passenger's door J429 - Control module for central locking Plus connection 187), 1n power window/cen ral locking
Tl0ag- Connector 10 pin. red, connector station A pillar right L48 Leh Rear Ashtray Light system and door con ta ct switch wmng harness
T15k Connector 15 pin, red, connector station A pillar, leh L110 Door opener l1ght1ng. leh rear
V15 Right Window M otor T4c - Connector 4 pin, black, in leh rear door
T6u Connector 6 pin, grey. connector sta ti on A pillar, leh
T6ad Connector 6 pin, bl ue. on power sunroof con trol module
TIOah- Connector 10 pin. red. 1n B pillar. le ft
T15k Connector 15 pin, red, con nector stati on A pillar, leh
T15t Connector 15 pin, grey, connec tor stati on A pillar, leh
T15v Connector 15 pin, orang e. conn ctor station A pillar. right
V26 Leh Rear Door Window Motor

Edition 10/ 99 Right Front Power Window Control Module, Left Rear Window Switch , Left Rear Power Ed ition 10/99
W42.USA.5602 .06.21 Right Front Window Switch Window Control Module W42 .USA.5602 06 21
Audi AG Wiring diagram No. 72/5 No. 72/6 Wiring diagram Audi AG m
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ ~~
~
x
~
x
~
0I
CD
~

'.4 cq. t.D-f· ef

E ss D

f
~
~
4,0

l:
0 ,35
0,5

l~· l"~
gn/ge

T lfo~ T J; '""' fr'"" 'f

rr l rl
0.5 0,5 0,35
br/ro gn/ge gr/bl ~­
t T10a1n t T10a112 t T10a1110 ::J
(Q
0,35 0,35 0,35
br/ro

'8
ge/sw

12 E s•
gr/bl

1 7/58s f 0,35
gr/bl
0,5
gr/bl
0,35
I I
gr/bl
0,35
gr/bl
0,35 0,35 0,35
0

0,5
r r Cf
Cf
0,35 0.35 0.35 0,35
T s u/2 T 10a
15
T 10a
15
T 1oa1
15
.....
Q)
ro lgr ro/br gn/ge ws/sw i;

3
tt
~· t rt: ~ 1
0,5 0,35 0 ,35
SW
U>
~ ~ c!J
I
rr J 298

0,35
Fl
®

2.5
b•
2.5
ro/sw
v..
0.35
b•
2.5
1

2,5
ws
sw
ro
br
gn
bl
=w hi te
= b lack
=red
=brown
= green
=blue
ws
sw
ro
br
gn
bl
=whi te
= black
=red
=brown
=green
=blue
0 ,3 5
el 0.35
gr/bl

~ I
b• b•

cb gr = grey gr =grey

ls lslsI® 11 = violet s8s

11 =violet T32120
ge =yellow ge =yellow J 218

53 55 56 58 65 70
197-51876 ) 197·518771

E54 Right Rear Window Switch. (In RR Door) Ground connection .1., 1n power window wiring harness D lgn1t1on/Starter Switch Ground connection, 1n driver's door wiring harness
E55 Right Rear W•ndow Switch, On Console! E39 Window Lockout Switch
J298 . R1gh Rear Power Window Control Module Ground connection, 1n right rear door wmng harness E150 · Switch or interior lock. driver side
L49 Plus connection 1151. 1n instrument panel wiring harness
Right Rear Ashtray L•ght J218 Instrument Cluster Comb1nat1on Processor
L111 Door opener lighting. right rear Connector 6 pin, grey, connector station A pillar, leh
T6u ·
T4d Connector 4 pin. black, 1n right rear door Wire connection (58sl. 1n instrument panel wmng harness
T10ag · Connector 10 pin. red, connectors at1on A pillar. right
T10a1 Connector 10 pin. red. 1n B pillar. right
T15k T10ah- Connector 10 p111. red. 1n B pillar, left
Connector 15 pin, red, connector station A 01llar, leh Plus connection (581. 1n power window wiring harness
V27 Right Rear Door Window Motor TIOa1 Connector 10 pin, red, 1n B pillar, right
T15 k · Connector 15 pin, red, connector station A pillar, leh
T32 - Connector 32 p111, blue. on instrument clus ter Plus connection (75sl, 1n power window wiring harness

Edition 10/99 Right Re ar Window Switch , Window Lockout Switch Edition 10/ 99
W 42. USA.5602 06 21 Right Rear Power Window Control Module W 42 USA .5602 06 .21
Audi AG Wiring diagram No. 72/7
w w
15 15
x x
~ ~

~
J 429 J 429 J 245

f'9 1 4/19
1
T6ad/3

f,. 0,35

l·" l "'"
0.35

l,,. T
0,35 0,35

lT~,
L
0 ,35

8 8
I1 I I 1 I

l'"~ f,.~ f,.,.

0 .35 0,35 0.35 0 .35

~ l . . l'"~' l:·"'
THIS SPACE INTENTIONALLY
I LEFT BLANK m
0,35 0,35 0.35 0,35 0 .35 0 ,35
ro/br ro /br ro/br

~ ct ~ olJ ~ c!J ws
sw
ro
white
black
red
CD
(')
......+
br brow~
gn =green ~-
bl =blue (')
gr
Ii
=grey
=violet m
ge =yellow

80 84
\ 97-S187S I
~
~-
J245 - Power Sunroof Control Module
s Connection lopenJ. 1n wr ng harness 1nter1or
:J
e
J.J29 - Control module for central locking
T6u
T6ad -
Connector 6 pin, grey, connector station A pillar left
Connector 6 pin. blue. on power sunroof control module
Connection lclosedl. •n w1r1ng harness interior co
T10ag - Connector 10 pin. red. connector station A pillar, right
T10ah-
T10a1 -
Connector 10 pin, red. 1n B pillar. left
Connector 10 pin. red. 1n B pillar. right
0
T15t Connector 15 pin. grey, connector station A pllla1. left
m
T15v Connector 15 pin. orange, connector statron A pillar. 11gl1t
co
.,
m
3
~ J en
:5'
g. m
Edition 10/ 99
W42 USA5602. 06 .21
Power Windows
~ ~
I\) 0
a I
a (0
~ 01
AudiA6 Wiring diagram No. 86/1 No. 86/2 Wiring diagram AudiA6 (J)
c: m
30~~___,,---~~~~~~~~~~~~~~~~~~~~~~~~30
::J
C3
:E
15 15
0 0
Power Sunroof with Automatic Preselection
;, rne ;, -+. I
<O
I\) Q)
a
a
2000 m . y. -2
m
Fuse Panel
U ~ $230 L
1 230 (1)
Fu se Colors : (')
30
25
A
A
Green
White eT 230•T e
20A
8 ....+
~.
20
15
A
A
Yellow
Blue I I (')

~~.. ·~
0,35 0,5
10 A Red Ol
7.5
5
A
A
Brown
Beige r85 ~grlbl
J 21~32120
T1 5t14
:E
......
Starting with fuse pos1t1on 23. fuses 1n the fuse holder :::::J
are 1dent1f1ed with 223 in the wiring diagram 0,35 0 ,35 2,5 0,35 0,35 0,35 0,35
(Q

TI.
ro/br ro/br ro/li ro/gr ro/gr

0
Micro Central Electric Panel T 15v T 15tl3 T 3at T 15t T t5v/8

(Q

[LI]]].~"
......
0,35 0,35 2.5 0,35 0,35 Ol
ro/br

J .4294/19 I
ro/br

T6ad/ 3
rolm ro,/g r rolg,'
I T6ad/4 I T6ad/2
J 429
11 3
en
ws
sw
=white
= bl ack
11 :
:
© @I
ro = red I T6ad/1
br = brow n
gn =green
2,5 2 ,5 0,35
bl = b lue br br br
gr =grey
11 =violet
ge =yell ow
®8
13 14
l 91.51aa2I

E 139 - Sunroof Regulator Ground connection, on left A-pillar. lower part

J218 - Instrument Cluster Comb1nat1on Processor
J245 - Power Sunroof Control Module Ground connection. 1n sunroof wtring harness
J429 - Control module for central locking
S230 - Fuse 30 1n fuse holder
T3a t Connector 3 pin. grey. connector station A pillar, left Wire connection 158sl. 1n instrument panel wiring harness
T6ad Connector 6 pin, blue, on power sunroof control module
T6ae Connector 6 pin, on power sunroof control module Plus connection (301. 1n instrument panel wiring harness
T6u Connector 6 pin. grey, connector station A pillar, left
T15t Connector 15 pin, grey, connector station A pillar. left
T15v Connector 15 p111, orange, connector station A pillar. right Plus connection 1871. 1n power window/central locking
system and door contac switch wirin g harness
T32 Connector 32 pin, blue. on instrument cluster
W Front Interior Light Connection lclosedl. 1n wiring harness interior

Ed ition 10/99 Power Sunroof with Automatic Preselection Edition 10/99

W4 2.USA5602 06 2 1 W42 USA5602 06.2 1
Audi AG Wiring diagram No. 1/1 No. 1/2 Wiring diagram Audi AG

Standard Equipment 8 - Fold Relay Panel

Fuse Loca t ion :

m F JSP 101 Luggag~ Co1r:io•f111e1tSoLket.s18·1

2001 m . y.

Fuse Panel

Fuse Colors:
30 A G1een
25 A Whne
20 A Yellow
15 A Blue
10 A Red
75 A Brown
5 A Beige

Starting wn~ fuse pos,t1or 23 10ses n tne ·use holder

are 1den ,f,ed with 223 in "1e wring d agram

Micro Central Electric Panel

Relay Location :

II -Dua Horn Reiay JJ

fJ -LoacJ Reduc tion Relay J5
a- m
~
Fu I PuMp 1FP1 Relay, J17

El -W·p r/Wasner lntermment Relay. J31 CD

("')
I I I D -ll\1pe Vasner Reay
ne1n n 1 J31
.....+
~-
1

A B C
("')
Q)

~
13 - Fold Relay Panel ~-
Rel ay Location : ::::J
a- Sta rt ing Interlock Relay J207
co
(/)
D -Fog Light Relay J5 ti)" 0
:::l Q)
~ (Q

a. -I
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3
_gi CJ)
c::
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Edition 06/00
W42 USA5603 0121
Edition 06/00
W42 .USA5603 .01.21
- 0~
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--4.
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Audi AG Wiring diagram No. 1/3 No. 1I4 Wiring diagram Audi AG (J)
fir
m
~~ 30
:::l ~
x
15
x & 0
a.
31
~~ I
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l<P- ---- 81~

5/86 6/87 rn 00
I ..Q
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S 1f75 30
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53/15
-s·
~ Cf ~ '1
J 211

I ~ ap 3 m
ct>

I Ii II l l -
1.0 2,5 2,5 2.5 6.0 6,0 2.5 0,35 2,5 0.5
ge/sw CD

8
I I G
:::l (')
r-+
I\) ......
a (')
2.5 2.5 1,0 1.5 4,0 0.5
a
...._. Ol
ro ro

~
SW

rrfn aln cJn

-.!,,

j,,
I,_ ~
t
75

'" [LJ Jo,.

ro /sw
'f,. 'f·
ro/sw bl
l
~
4,0
'.:::j ID
r
0.5
~-
:::::l
{Q

t 9/4 T9/2
0
D
T9/6 {Q
......
1
IT9/8

I
0.5 0.5 2.5 0.35 0,35
~
0.5 Ol
br/ws br/ws ro/sw
ro ~ swl/ro
3
"~~ t"~
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Trn2 Tet14
R

t
w s = w hite WS w hite
sw =black SW blac
ro =red
br =brow n
ro
br
red
brown r2
0.5 0.5 0,35
gn =green gn = green br br/ws ro
6.o 4.0 2,5 2.5 4.o 4.o 16,o bl = blue bl =blue
~ ~ ~ ~ ~ ~ 1 9/B 1 4/13
gr =grey gr =grey
11 =viol et F 125 J 429
Ii = violet
ge =yellow ge =yellow
8
14 18 28
197-516331 197-51634 1

Ground suap, engine to body @ Ground connectior ·2 . 1n mstrumert panel vvn1ng harness D lgnr t1on/Starter Switch Ground connection. •n instr ment panel wirrng harness
F125 - Mult1-Funct1on Transn11ss10 Range iTRl Switch
@
e
Ground connect1on, in engine com partment. leh Ground connection, in rrght headlight w•f'ng harness F19-I Clutch Pedal Position iC PPI Swncr Plus connection t 151 rn instrument panel wiring harn ess
J59 Load Reductron Relay
Ground connec:1on, in engrne compartment, right Ground connec tion. 111 leh headlight wrring harness J207 Starting Interlock Relay Wire connection i86sl. rn instrument panel wmng harness
J217 Transmission Control Module 1TCMI
Ground connection, on righ t A- 1llar. lower par'
J<l29 Cor•trol module for central locking Plus co nee: OP -2- i30I 1n 1ns:rumenr panel Wifing harness
Ground connec tion. on le A-prllar, lower par: R Rad·o
TBf Connector 8 pin, blac>., connector radio Ill
T9 Connector 9 pin, brown, on s a rng interlock relay Vehicles wi th manua ly sh1hed transm1ssron
Ground connection -1- ,n instrument panel w1 rrng harness
Tl5r Connector 15 pin, blue. connec tor station A prllar, rrght Ve 1cles with automatic transmission
~~~~~~s conn ection -1-. 1n engine compartment wiring T17 Connector 17 pin, orange, connec tor stati on A pil lar. righ t

Ground connection - 1-. 1n rear wrnng harness

Edition 06/00 Ground Connections Ignition/Starter Switch , Load Reduction Rel ay, Edition 06 / 00
W42 USA.5603 01 21 Clutch Pedal Position Switch W42 USA .5603 .0121
Audi AG Wiring diagram No. 1/5 No. 1/6 Wiring diagram Audi AG
30 30 30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30
15 15
15 15
x x x x

f5 31 31

75 ~
~
31 31

51131 30

or
2,5
Of 2.5

Ef T T1

q. pfi
1.0 0.5 0.35 2,5

Lfe
b' bl bl ro/sw

i,.-
17
fe i 'L8L,I··· 'L8R
1 1
f, f f~.l.L
·uI 8
J 31 1,0
bl
2.5
ro/sw up
1,0 0,5 1,5 0,5
~
1.0 2,5 1,5 1,0 0,5

l~r J.
ge ws/ge gr/ws gr/bl
1Trnp11 I Trno/4 ~
u!ru ~
16,0

I 'i' ... 'i'

Of r
0,35

gd; ~ T
t:; ;J c, ;J 10/PR
0.35 1.0

·r
1,0

11 /R
1,0 2,5 2,5 2,5

m
CD
.. j. .
A ws = whi te ws while

C C1 B
sw
ro
br
gn
=black
= red
=brown
=green
sw
ro
br
gn
black
re d
brown
=green
I ... L E4 r6b h
(")
.-+
.......
2,5 6,0 25 .0 bl =blue bl =blue 1.5 1,5 1,5 0.5 (")
gr =grey ge/ gr ws ws br
br br gr =grey
OJ
Ii = viol et
ge = yellow
11
ge
=viol et
=yellow rrb ~ ~
30 33 36 37 38 41 42
197-51635 1
49 53 54 56
197-5 1636 1
~
~.
A Ba ery r;\ Ground strap, banery to body E1 Light switch Ground connection -1- •n instrument parel wrring harness
:::J
B Starter \.:._) E2 Turn Signal Switch
c Generator IGENI 8f::\ Ground connection. on le ft A-pillar, lower part E-1
E19
Head'•g Dimmer/Flasher Switch
Park Light Swi tch
Wire connection 1571), 1n instrument panel w111ng ha<ness (Q
Cl Voltage Regula tor (VRJ
Fog Light Switch (J)
J31
Tl
W•perf\/Vasher lnterm1 en Relay
Single connector, black, 1n engine compa rt ment. right
~
Q
Ground connection -1 n instrument panel wmng harness E23
K13
K17
Rear Fog Light Indicator Light
Fog Light Indicator Light
Wire connection 157rJ. 1n instrument panel wiring harness
ti)" 0
~ Ground connec tion -3, in ins trument panel wiring harness
T2cl Connector 2 pin, black. ,n engine com partment. right L9 Headlight Swi tch Light Wire connection 1561. •n rns rumen pane: wiring harness ::J OJ
Tl Oo · Connector 10 pin. brown, connector sta •On electronic box
plenum chamber
Q
~ Wire conn ct1on 161), 1n instrument panel wiring harness
L40 Fron t And Rear Fog Light Sw11ch Light
§- (Q
.......
Tl Op Connector 10 pin, black, connec or station electronic box
plenum chamber
Q
~ Plus connec tion (501 n 1nstrumen panel wmng harness
a. OJ
3
_gi CJ)
c::
-c·
:3 m
<D
Edition 06/ 00
W42 .USA.5603 .01 21
Battery, Starter, Generator Light Sw itch, Headlight Dimmer/ Flasher Switch,
Park Light Switch , Fog Light Switch
Edition 06/ 00
W42 .USA 5603 .01 21
::J
...... ~
I\) 0I
a
a
~
<.O
'- <.O
Audi AG Wiring diagram No. 1/5 No. 1/6 Wiring diagram Audi AG
30 30
15 30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30
15
x x 15 15

f5 31 31

75 ~
x
31 31
x

51 /31 30

er
2.5
er
2.5
T1,5

Cf T1 T
·~ .~:. "" "" f
1,0 0.5 0,35 2,5

Lf e
br bl bl ro/sw

fe
L•o

~
17
J 31 1,0
bl
2.5
ro/sw
fJL
0,5
gr/bl
tT1op11 tfoo/4 ~
16.0

er Cf
2.5 2.5

m
A .vs= white NS= Nh1te CD
B
ss = blac>-
rr = r d
or =brown
gn =green
S\'I =
'O
0 acv
= •ed
or =bro:."
gn = green
I... L b j.... ("')
.....+
~-
("')
25 ,0 b =blu e bl = b1ue 1,5 1,5 1.5 0.5
gr = grey gr =g rey ge/gr
Q)
11 = v1ole
ge = yellow
II = v101e
ge =yellow
ab ~ ~
32 33 35 55 56 ~
] 97-51636 1
--.
A
B
Ba ery
Starter
0 Ground strap, banery to body EI
E2
L·ght switch
Turn Signal Sw.tch
Ground connecrior -1 . n 1ns~rumert panel w1r ng I arn ss 1

:::J
c
Cl
Generator 1GENI
Vol tag Regulator IVRI
8 Grau a connection. on left A~1llar lower pari EJ
E19
rlead 19 t D1mn,er/l'lashe· Sw •ch
Par> L1gh Sw1 :cr
VJ1re connec~ or (571). tn 1nstrun-.en1 oane :. 1r rig harr ess (Q
(J)
131
T1
W1per/\/Vashe1 lnterm1 ent Relay
Single connector blac<. .n eng ne compartment, r•ght
0 Ground connec11on -1 . 1n instrument anel wiring harness E23
K13
Fog Light Swnch
Rear Fog Light Indicator L1gl.t
Wire connect.on 157rJ. 1 ins;rument panel w1r,ng harness
fir 0
T2cl Connector 2 p1r blac< 1n erg ne compartment, rig t @ Ground co nee ion -3- in 1nsuumen panel wir ng harness 17 Fog Light Indica tor Ligh t
W:re connec tion 1561. 1n instrument pan I wiring harness ::J O:>
e
L9 Headlight Switch Light
T10o

T10p -
Connecto1 10 p1r, brown. conr ec 01 station electronic bo\
plenum chambe1 Wire connection 16 11, in 1nstrumen panel wiring arness L·10 Front And Rear Fog Light Sw11ch Light
g. (Q
--.
a.
Conn ctor 10 pin. black. c0Pnecto1 sta11on electronic box
plenum chamber @ Pius connection 1501. ,n nstrur1ent panel wiring harness
O:>
ni
.Q
3
(J)
c::
-c·
3 m
-
ct)
Edition 06/00
W42.USA.5603 01 21
Battery, Starter, Generator Light Switch , Headlight Dimmer/Flasher Switch ,
Park Light Switch, Fog Light Switch
Edition 06/00
W42 USA.5603 .01 21
::J
~
f \) 0
a I
a <O
...._. <O
-.I..
Audi AG Wiring diagram No. 2/1 No. 2/2 Wiring diagram Audi AG ~ m
s· 0~
CQ

<D
(2,7 I - Injection Engine, 6 Cylinder), Code APB 8 - Fold Relay Panel I

~
.........
Fuse Locatio n:
.........
m( c .i 11 F.r· F ,-,c, s.17 :'.:}
0
2001 m . y.
m L1.)I tr I II 1(1!,il{~ r ISt! tur COO ii-!' t :nr 51<17
tl)
CQ
<D
Fuse Panel 3 m
<D
:'.:}
__........
Fuse Colors :
A
CD
30 G•et-n (')
25
20
A
A
Wht&
Ye!iow
!\) ..-+
15 A Blue 'J ~.
10
7.5
5
A
A
A
Red
Bro;vn
Beige -.
r-
CD"
(')
OJ
--"""
~
~
3 - Fold Relay Panel in E-Box plenum chamber
Sta1w'g with 'use pos111on 23. fuses 1n the luse holoer
are 1den;.f1ed with 223 111 the wiring diagram
Relay Locatio n:
CQ ~.
II ·Seconr1ary Air l1'1ec11on IAIRI Pumi: Relay J299 s· ::::J
<D {Q
II Fuse fm secor do•'/ dir p._,n-o S 130
(") 0
Micro Central Electric Panel 0

a -Fuel Pu111p IFPI Relay. J 17 :b.

"tJ
tn
•m~
llllll!ifl I\)
a
a
A B C Rela y Pan el behind Instrument Panel left, on central girder
..._
-.A.

Relay Locati on :

II Brake Booster Relay. J569

II -Fis" fo1 Hvdraul1c Pump Rddy, S279

13 - Fold Rel ay Panel

Relay Location :

a Starting lnterloo, Relay, J207

~rm GJJ 18
A c
4 1 2 3 4 5 6
B D I A97-0127 I

8 9 10 11 12

Edition 01 /01 Edition 01 /01

W42 USA.5603 02.21 W-42 USA 5603 02 21
Audi AG Wiring diagram No. 2/3 No. 2/4 Wiring diagram Audi AG
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~-30

15 15
x x
31 31

~ ~
~2,5
8 1t 0,3 5 0.35

~
1229 "'t swllg r

r·
Es1
5 229
T 15u/3

D D ***
J 554

T1 f° T1 rn . .0

Lfle
0,5 0.5 0,35
**
~ '~f
2. 5

i'rs lf. ~
0.5

brt•~'"
ro/gn

I --- I J 207

r © ·:: :

l.~
1,0
bl
2.s o.s **
I **** ** 0,35 0,35

f.'
0,5 0.5

tT10p11 r~

jr. .,.
0,5
bl
T 10n11

fr...,
l""
o.s ** 0.35 0.35
gi
(Q
:s·
n .., m
1,5 16.0 br/ws ro/gn
CD
'f e_ ·t
bl

t . 9/B
F 125

~ <D
()
A = white \\'S = wh te
v\S
::J
.
r-+
C Ci B
sw
ro
=black
=red
sw =black
'O =red OJ
(Q
.....
or = brovm or = hrov. 1
"'
0.5 0.35 0,35 (")
gn = green gn =green CD
6,0
br
bl
gr
= blue
=grey
ol = olue
gr =grey
br

(§ rrb
bl/Ii bl/II

lA3 3 ro
Es1
CD
lo
11 =violet 11 =violet --~------- 023
ge =yellow ge =yellow ::J
~- ~
13 14
1 97-520541
15 18 20 22 24 28
1 97-52055 1
!\) ~.
'-J :::J
A
B
Ba~ery
Srarter
8 Grounu strap, ba::ery to oody D
E87
'Ol'1t101 /Starter Switch
A/C Control Head r-
;:;:
cc
c Ge~eraror tGEl"l
Cl
D
Voltage RegJ:ator tVRI
lgn1i1or/Starter Svv1tch
8 Ground connection on ler;. A-p lar ov1er part Fi25 ·
Fl9..!
J207
lv1u 1-FunC'.101 Transm.ss·on Range t~RI SN :ch
C,utcl Pedal Pos1t1on tCPPJ Swl!CI'
S:arting lrterloc> Re:ay
Corr-ector rC 15. A/Cl n •1str~roer i" oa•1el \\ 111ng harness
CD
~°"""'I
0
Tl~
T2cl
S.ngle conrector black, 1r engine con·par·.men· rig"t
Conr ector 2 p11· blac' 1n engine corr pannie111. rig111
Ground cor rect1on -3- ir instrume~t panel w1nng tiar r1ess J220
J55--l
Motron1c Eng ne Control Module 1~CIVl1
4-Low Range Control Module
Connector 1eng1re overheat .vari-1ng 1gt-tl 1n mstrur1en·
panel w11 1-9 harness ro
gi cc
TIQo Connecto1 10 p11 brown, co.-nector sta11on elec1ro1 c bO\
plenu1·1 chamber
Wire cornec11or (61 J. n nstrurre11t nar 1 el wring harness 5229 .
T9
F-1se 29 111 fuse holder
Connector 9 pin, b1owr on sta 1ng interlock relay
Connec:or lover tuse 2291, 111 'N1'111a ha11•ess fror · rigl-t
(Q .....
TIOn Connector 10 pin biacl'-., connector stat1or electron1 !1ox
pen um c~1ambe1 Plus conr~eu1on (501, 1n 111s;,n,mer;: pa'lel \\ :r1r9 1-rarress
TIOn Connector 10 p n, orange. connector station elect10111c box
plen rrr challlber Vehicles w·th ·11anuallr sh1f1ed trans1111ss1on :s· ro
Tl5r
Ti5u
Connecto1 15 pin. bll! connector s1a11on A pilla1 right
Cormecto1 15 pin. red. connector s1a1101· elect10111c box
Vehicles with automatic. transmission CD 3
plenum chamber Vehicles all road w1t11 sh1i;ed liar sn11ss1on 01 E (") (/)
0
~ m
~

Edition 06 / 00
W4 2.USA 5603 01 21
Battery, Starter, Generat or, Igniti on Starter Switch Motroni c Engine Control Module, Starting Interlo ck Relay,
Clutch Pedal Position Switch
Edition 06 / 00
W4 2 USA. 5603.01. 2 1
d5 0~
I\) __..
I
C)
C)
__..
-.I. __..
"-
Audi AG Wiring diagram No. 2/9 No. 2/10 Wiring diagram Audi AG gi m
:s· ~
(Q
30~~~~~~~~~~-<ll>--~~~~~~~~~~~---=========~~
30------
~
15

~1=============:::;;=====::i========~~~~~~~~~~~~-31
x

J~
~5----

31 ===================== 3~~1 CD 0 I
n22

r·
21/31

~==~
~:. .:. _=__t~-.l===;--r----===
~ ~ ::J~ ~

tl:l ~
S3/50A SJ/1 SJ/LA I SJ/67a r67l
F/OTI (Q
2,5 1.5 CD
@Zl gn/sw gn/ro
3
ro/br
I

I r1
~

~-
S
1 23•

i ~340 ~ 122~ .·fa

15 34
u
gn
~
1220
S
I~
I
u
ro/bl

~~
uI
sw
G ;9.
@

rl
I
G 10

®
rr fe
Q
I .~i~n
CD
::J
"'.......
~
m
CD
()
,.....+

0.35
ro/br
1.0
gnfge
2.5
gn/ge
1,5
ge
0,35
ro/bl
0.35
br/gr
0.35
gn/sw
0.35
gnfbr ~
0,35 0.35

gin
0.5

;be
0,35

l~,gr
0.35

s w,/gn
"J
r-
'
()
t ~ cAi rrfID ts J 220 c& c& t ~- Ol
~ ~
! 29 \ 53 1 21 J 220

®
~ ~ "'~

r l' irt:Jr J~ ~
t •5 - 15 i 51 110 . 32 - ___ [_1_2 .. I1 J _ 14
®

Fl 'Ii__ 1 1 1 v rr
0.35 0.35
~-

T""" 1
I
200

8
-=---------- - - - - 200
8 I 1· I :t' :::J
(Q

0.35
ws/ge
1,5
ro/gn
1,5
ro/ge
0,5
ge/gn
0,35
ge
0.35
gn
0,35
'f
0.35 0.35
br
0.35
ws
0,5
ge/bl
0.35

ge/ro
0.35 0.35

bl
0,35

sw
0.35 0.35 0.35 0.35

µ
gr

~ - -" t: t: ~ (Q
Ol
h
T•u121i! T•udlJ T4u/4 T4vl3 ffi T4v/4ffl T•vl2 T•s12ffi T<sl3ff1 T4s14 T•v2 l:1J T<v3 ffl T•v• '
LJ Ol
OJ 3
Es *Jss9Ill 'i'a1a1~"'1
I ---ii M I 2
• •

w I gTr •

2.5
I LW ~ I \'VS w hite ws = w hite
I &-=wll 2 WI l'f
r1 G 23s
~ Wf ~I
G 235 1 1
t\) CJ)
a
1
v .~
21 I SW black sw =bla ck
30 Z 19 G 39 G10a Z 30 G 13 1 2 3 3 2
a
I
Z 2a ro red ro =red
iT4u/1 TT10n/8 br brovvn br = b row n
IIfl ..._
-.A.
TT4v/1 T4s/1 T4V1
1111
r e
gn =green gn =g reen
0.35 1.5 1.5 0.5 2,5 0,5 bl =blue bl = blue
a
I@ I@
u u u ubr u u
~ ~b,rgr gr =grey gr =grey ~
gn/ge gn/ge gn/ge gn/ge gn/ge br
gr
0 22
11
ge
= viol et
=yel low
Ii = VIOiet
ge =yellow I I I 0 I I
@ 022 022

86 90 96 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112
I 97 .52060 I 1 97-52061 1

G39 Heated Owg"n Sensc.r 1H02SI 2

0 connt,Cl1Cn I·-. r- fln~y--1-.~ c:ornp;:irtrrer1! -..vir;ng
G70
G130 0 Ground connection -1· 111 sn91ne compartmtn t w1rir:g
harness
(j108 H<Jatod Owg>!r Ser,sor 1H02S1 ?
@ \::>hio id1nq), 1n engine cornp,ir11-ner t
G29·l
J17
Brake Boos ~ or PressL.re Sensor
Fue' Pvrn IFP1 R'Jluy @ Grour;d corHwi:t,~:'1 , .... t11eid: · i~J1 r1c1,r·.~~ C\:1T1n..,r · ri>:nt
G13 1

J2CO Mc'<•on1c Enqi:1" Contro' iv10du'e IEClvt1

w1r:PCl ~1amess
G235 @ Connect0r love! fuse 234) n v..u1na harr~es:::: fr or-t. 11ght
J5b9 Bra'e booster •elav @ Cor,r,eu01 \Q\1f:H 1 .!Sf:: ?::HI. iP ':~1 1r nq r:dff'•:s..::. 'rt_wt. ~;gt1!
G236
sna
S23-1 ·
Fuse 28 1r 1._,se l•o•de1
Fuse 34 1n Lis~ I olde1 tJrilv V~~~•Clf!S \".'ltl"1 -:!l i!Olll,1t1C trar· S!!llS~, or
J/20
T<ls
0 \f\J; 1 e t:onnec.t1on 1-. 111 en~11 ne compartment w1rm~1 ;iarne:ss

T3au Connec:or 3 j) ! red, Ci.J!lf;(lCfor Sta1•0fl ..:...t-:'.:'.;fror fl br_Jx

pienurn c~<nmt:>r Tjt
T1_, Connector .1 p ri 1
hcatel'.J oxyger Sf;:nsor
T.lv Connec!or 1 01n0
:1ea:ed OAygen srjrsor 2 Z29
TIOr Connector 10 pn1, r1range connector s:cP-···n elF.:ch."'IJliC ho:-. Z30
plenum chamber
TlOp Cor111e;cwr 10 p:n black. c0nnec to1 stat1r;r e~er.tron1c bo ...
pli? r1u111 d,nmber
T151.1 ConrPc!Or 15 nm. 1ed connector sta tion f\ei: trorH:: t;o·<
plen1,1r chamb.:-.r
\.192 Brake Vacul!'n Pump
Zl9 Oxygen Sersor 102SI Heater
228 O• ygen Si;nsor 102SI 2 Heater
Edition 01 / 01 Motronic Engine Control Module, Fuel Pump Relay, M otronic Engine Control Module, Mass Air Flow Sensor, Edition 01/01
W42 USA 5603 02.21 Oxygen Sensors Heater, Brake Vacuum Pum p Heated Oxygen Sensors W42. USA 5603 02 21
Audi AG Wiring d iag ram No. 2/11 No. 2/12 Wiring diag ram Audi AG
30 30 30
15 15 15
x x x
31 31 31

~ ~ ~
I I I I ot* 18 I.
ns~
4 ,0 0,5 0.35 2,5 2,5
l¥J
1.5 6.0

..
ro/gr

I 15
D
l ~ ct l In7 S 5
10A
S 1
10A ~ S 219
15 A * 40A

r f r f
el-1 '0.35
swtro
1,0
sw/ro
1.5
WS

rrb
J 220
j
1.5

e
4,0 2.5
ro/sw

~ ®
~ ~ ®

r r r r rr i39
0,35 *
i55 i56
0 ,35 0.35

r <olg~15e/13 I :1J:15e/11
BjID
0.35 1,0 1.0 0 ,35 0,35 0.35 0,35 2,5
bl/gn br/gr br/gr gn/ge 11/ws gelgn bl/gr ro/sw

t. f f 11 2

-QI J~
w•~mo
0 .35 0.35
I

4,0
ro /ge
ef le 0.35 1,0
~
(Q
:s-
([) m
~ N15
r 1"~ 1"'"' 1"·
0.5 0.5 0 .5 0,5
~r
0.5
N ao
~
N112 r
0.5 0.5
4f !

4.0
V 101
:,s =
S.'. =
r)
GI
=
=
gn = greer
,\'$
$".\

(1(
=
=
=
gn = green
/,r-- !8

°1
F•1

1,5
1-T 1r
rr
0.5 1.0
F
~
::J
Q)
(Q
([)
CD
()
r-+
......
()
Q)
gn1ge gnlge gn/ge gn/ge gnlge gnige gn/ge b< bl =blue o! =blue
gr =grey
rol ge

~
3
I I I I I
gr =grey
I I
022
8
11 6 118 119
b
126
197-520621
'l = ·11olet
ge = yelb1.
II = 'IO'e:
ge = '{El O·i,

133 134 135 137 138 140

j s1-52os 3j
([)
::J
~-
~
~
~.
:::::l
'.J

G
0
0
r ..
F i7
n

'.dc-_iur· \'";_,.
Ttircnk:- p, is t c'
~~e-=:nsD'.
Ti1ro t1l e
1 1/:1 ,,..
1TP1 <;pr·:-:-cJ'
-:'- tor ;.:ic1 elm .:pr,; ;);o.;rfal
r11
pr-1~;1! r-r
G
0
0
·~'\

p ,
"'

~JI rt; t
110' S..fl

~ 301
r 1 :-; 11

'1 If
1

':'i·r
•~·

·~
t:

r;r.
~-:·

h:H el~·
~"'- "~

'•
;,"

11 r
n•,

C1'')t!'·
-
t:
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0
Q)
~J
W05
112 8 G ~ ......(Q
mos
S5
0 G1:3f

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S 1 30
S:?7q
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S13
fhrott~e
Fuse
\ nl\e Cont1ol ~..1lo.J1~,e
1
Th1otrle Po ..... 1111·11TP1 Se11sor 1,\1!! out ,::1dctp1er N1
or(1d,11 \l(i!' Uid'i9PI
t 1r 1 .n.•1;·~p ([)
3
T3rJC1
Tfjy,
115,,
Co1 I ·<'~tor
B:tor
6 .-, front footwtil1 let1
p;n, \.\•n1:t? connBctor stoi1c1r e'c:crror-1r.: bo-.:
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Edition 01101
W42 USA.5603 02 21
Motron ic Eng ine Control Module, Valves,
Secondary Air Injection Pump Motor
Motron ic Engine Control Modu le, Brake Light Switch ,
Throttle Valve Control Module, Vacuum Vent Valve Bra ke
Edition 01 / 01
W.'.12.USA 5603 02 2 I 0
!\) I

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a --'"
--4.
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 n m
Audi AG Wiring diagram No. 4/5 ~ m l
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30~--------------------------~30 3·
15
x
31
15
x
31
(1) ) 0I
I
=-~
~
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) --L.
I\)
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t:l) 0 ) 00
(Q l
CfJ
0.35
(1) )

3 m ~
m
~ G ies Gi a1 G iaa

.... (1) )

y,_JG•2 J,,.1 r=i~~ri:- --- n 1 ::J

~- CD ..l CD
r
0,35 1.0 1,0 0,35 0,35 0.35 0.35
~x~~
!'V
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(')
.....+
~-
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:)
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~-

T LI.TI Tl ~ -
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l)
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J220 (1)
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r ~""'
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1
la2 Igo
CfJ I 106 lio1 l -...
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T @ gt
o.35 035*

eJg"t
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s· ::J
!
;· ::J
cc
,.__.------~--,---,---,----,----
;-------, I .0 11
(1) cc )

)
0,35
gr
0.35
bl
~ ~
SW
~ ~ ~ ~ ~ ~
gn
~
ge
I 1,
~ 0 I
0
,- c!J cAi -c L OJ
H ~ cc
OJ
-~
;1
- ~
cc
-...
l 3wf3! 1 l 3w/2 13w/1 T 3ax T 3a• T 3a• T 3av l T 3ay T 3ay11
II )::. -... ~

T81,:=:,_
13 /2 /1 13 /2

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-- ~
~
r --
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-- ~ II
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3
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o.5
brf/ge
o,s
br.ge
[DJ
G26
[a CJ

G s1
~ CJ

G ss
ws
sw
= white
=black
ro = red
[@] br =brown
T 1op/5 gn =green
bl =blue
0.35 gr =grey
11 =violet
ge = yellow

32 35 36 42
1 97-520701

G2 ~!i~Jine C":i01Li~ltTt')nipi::.o1ature iECT) Sensor Ground connect;or· !sensor qround). 1n eng1n0 cr1rnp;w-n~nt
G28 [•1[Jll <: Sor,ed 1RDfv11 Sensor \\'Hing 11arness
C.t2 !r.rn· e A:r TG-rnpern:L.~0 !IATJ Se~1sor (Ormcctor f"-ensor grouncll 1·. n ·rVi1runwnt prrnol
G6i Knv~ SePsor IKS1 I
G62 Er1;;11 e Cool,;:rit Ten1pe1ar·_ire iECTI Sens:)!
Sensor Ground Conrec11on 2 r eng:r~~ ..,., ·u~g t'lc.irncs~)
G66
G186 ·
~rucf' Sen'O' 1KS1 2
Ti"•onie drive.!-'..... ~"'!~-~ ......... ,""'-'' :ict:1rJ'1m 1 ~
::,
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G187 - r\r:qpl sen~rJr q··OW!·:r riCc o:ern'nr
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...,~;1 e!erdlt)r

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actuatron)
JC20 . Motronrc Ergrne C0mro' Modulr; 1ECl\J1
,1338 Tnrot!'E' Vaive Control Module l> o.
T3w Connector 3 pin, grev. on engine speeci 5ensor Li ;+ l:n" I
I ~. I
T3ax Connector 3 pin. brown, on Knoc> sensor 1
60'
T3av ·
T10D
Connec•or 3 P'n browr, on knocl< sensor 2
ConnPct1Jr 10 P'n b!ach.. connecto·· s1?.t1on l-"''ectron1c bo<
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plenum d 1aniber
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Edition 01/01 Motronic Engine Control Module, Knock Sensors,
W42 USA.5603 02 21 Throttle Valve Control Module

I
 Audi AG Wiring diagram No. 417 No. 4/8 Wiring diagram Audi AG
30----------------41---------------~30

t 30~----------------------------30

n I lffi --+f~1-918_6
15 15
15 15 x x
~, ~ ~ 1 31 31

~ ~
17130 ____

22 21 131 I~
T24 T 1BILA 201B7a •2-1J1_a1_Ft+1""6/B~s=-----+-----~I

E a1
53/SOA 5311 53/L A I 53/B7a n 7F/DTI 53/5 52/87 F

2,5

CT. T
0,35 0,35 0,3 5
gn/sw

~34 25 15 0,5 0,5 rJ21- G 10

~~ I
'fd' "F·~ r1
0,35 0,35
~i34~34a ~ ~
1,0 2.5
mf/bl

0,35
T 1op1a

0,35
I
ge
0,35
rr
bl/g n
®

0,5
gn/ge
h
0,35
gn
I

0,35

~
g~e ~e
L~
sw/ge ws/bl

'40 t J 220
<Ol/bl

HS L J 220 t 3

0,35
r r rT rrr Tr r
b</sw
0.35

,g~ -
0,35

-bL
I J
SW
0,35 0,35

b</ge
0,35

ws
0,35

b<
0,35

sw
0.35

]~10n/6
0,35
9
I~10nn
1,0 0,35 0.35 0,35
@
0,35 0,35 0.35 1,0 r ~ -- l r

l~tT~~ ·~T~l·l~
' ~ -- ' ~ -- 0.35 0.35

w, ~61 1
9 9

T 4s/2l T 4s/J T 4s/4 l T 4V2 l T 4v3 T 4v4 i~61 2T

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I en: 42JJ T ILW 5 1 ws = whne ws = whi te I ~ LQJJ I I'--'-- 2--=~=---.J,,I v... t 4~
': 1 ·":~"' ~
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r r
2.5
I r-+
l sw =black sw = black

"l~·~· ' -
G 39 G ioe Z 2a ro = red ro = re G 13o
(t)
br = brown br = brown (")
T 4u11 lT4vl1 T::o

~
gn = green gn = green T 4s11
ffiJ 0,5
I OJ
1,0 2,5

8
1.0
bl
gr
= blue
=grey
bl
gr
=blue
= grey 1,0 1,0 0 .5
ro/gn
-
8 "r_·_____ i
-------~~-- :::s
gn/ge 9
".1_·___________~•~,·---- 022
gn/ge 9 9 9 9 9
= violet Ir = viol et
I
.___ _ _ _--"._ _ _ _ 11
ge = yellow ge = yellow 022 I .. ". .-·- - - - - - - - - - - D22 ru
(Q ~
' (t)
~.
59 63 64 65 68 69 70 71 79 BO 81 83 84
( 97-52072 1 ( 97 -5 2073 1
:3
(t) :J
G70 Mass Air Flow IMAFI Sensor
Heated Oxygen Sensor (02Si Behind T ree Way Ca talytic
@ Connector lover iuse 234), rn wrnng harness from. nght
:::s (Q
G130 -
E87 A/C Control Head Ground connection lsh1eldingl. 1n engine compartment Converter ITWC) ~-
G39 Heated Oxygen Sensor IH02SI 2 wiring harness G13 1 - Heated Oxygen Sensor i02SI 2 Behind Three Way Cataly11c 0
G108 -
J17
Heated Oxygen Se 5or IH02SI 2
Fuel Pump (FPI Relay
Connector lover fuse 2341, in wir ing harness from. right
J220
Converter ITWCI
M otronrc Engine Control Module IECM)
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T4s Connector 4 prn, green. near oxygen sensor, behind Three

-.
J220 Motronic Engine Control M odule IECMI
S234 -
T4u
Fuse 34 1n fuse holde r
Connector~ pin, black, hea1ed oxygen sensor
Vehicles wi th fron t wheel dri ve
Vehicles with all whee l d11ve and manually shifted T4t
Way Cataly 1c Converter (TWCI
Connector 4 pin, brown, near oxygen sensor 2, behind r- (Q
T4v
TIOn
Connector 4 pin, black. healed oxygen sensor 2
Connector 10 pin, orange, connector sta ti on elec1ro111c box
transmrssron
T6f
Three Way Catalytic Converter (TWC)
Connector 6 prn, dark brown, connector station A pillar, nght (!)'
OJ
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Tl On Connector 10 prn, orange, connector station elect10111c box
TlOo -
Plenum chamber
Connector 10 pin, brown, connector station electronic box
plenum cham ber
3
~
V144 - Leak De tection Pump ILD Pl
Plenum chamber Z29 Oxygen Sensor (02SI Heater CJ)
TIOp Connector 10 pin, black, connec tor station elec tronic box Oxygen Sensor 102SI 2 Heater
Z30
Plenum chamber (Q
T15u Connector 15 pin, red, connector station electronic box
Plenum chamber s·
Z19
Z28
Oxygen Sensor 102Sl H ater
Oxygen Sensor (02Si 2 Heater
(t) m
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Mass Air Flow Sen sor, Heated Oxygen Sensors Edition 06/ 00
~ 0I
Edition 06/ 00 Motronic Engine Control Module, Fuel Pump Relay,
W42 USA5603 0121 Heated Oxygen Sensors Behind Three Way Catalytic Converter W42 .USA .5603 0121

)::a ........
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AudiA6 Wiring diagram No. 4/9 No. 4/10 Wiring diagram AudiA6 gi m
s· 0~
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30 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~-3 0

15 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~- ~

x (1)
31 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~-31
I

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--1..
(\)
:::s (\)
ru
(Q
(1)
8 3
T T I I at T T1 m
I
4,0

t
I I I 1.. 1
2,5

l l
0.5 0,35 0.35

~
2.5

l
0,35 0,35
I ® I
0,35
sw/g r
0 ,35
sw/g r
lfo•w gn/br
0,35
sw/li

tr..~
0.35
ge/br

fr,- - .,
(1)
:::s
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rrr
I C1 5 035
D
rr1
f f
I :1J :15e/11 E 81 gn/br
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113
t"'"'
112
0,35 0,35
Co
0 .35 0 ,35 0.35
(")
ws/ro ro/sw 0,35 J 104 0.35 0,35 0 ,35
r-
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t t ;::;: Q)
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0.35
ge/ws
1.0
brfgr
1,0
br/gr
r r
0,35
Ii
0.35 *
ro/gn
. 45
0.35
wslge

fr'~
r r
0,35
ro/ge
0.35
bl
r
0 ,35
rolgr
r
0 .35
sw/ws
rrr
0 ,35
sw/ro
~ 0,35
ro/gr
gi .,
-. co
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(1)
:::J

T1 5•
/13
T 3au/ 1
1.5
ro/gn
0,35
ws/ge l T 15e/9 T 15e18
1
T 15en T 15e110 T,n" ... ·- ~ 0
CB- w
,0

T1 co
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0,35 0,35 0 ,35 0,35 0,35 0 ,5 0,5 ~
Q)

. rr d
rolge bl sw/bl ro/gr sw/ws sw/ro ro/gr

tt
.~~ ~·~ ~~ '
·· a /87 6/85 3
en
-
ws white ws =wh ite 1J""" -- ~~ I ' © jJG
,..
J~ sw black
ro
br
red
brown
sw
ro
br
=black
=red
=brown
f1 oqn I T10q/4
I E 45

gn =green

·r
gn =green 0.35 0,5
0,35
1,5 0,35 bl =blue bl =blue swfws b<

~~
gr =grey gr =grey
11 =violet
ge =yellow
11 =violet
ge =yellow
8 I
D
86 87

lgn1t1on/Starter Switch
89 90 91 97 98
197-52074 1

Ground connection -1-. 1n engine compartment wiring

99 100 101 102 103 104 105 106 107 108 109 110 111
'®
112
197-52075 1

E45 Cruise Control Switch Ground connection -1-. 1n engine compartment wiring
F36 Clutch Vacuum Vent Valve Swnch harness
E87 A/C Control Head harness
G294 - Brake Booster Pressure Sensor Plus connection 1151. 1n instrument panel wiring harness G266 - 011 Level Thermal Sensor ISRIJ Wue connection (cruise control), 1n instrument panel wiring
J220 - Motronic Engine Control Module IECMI J104 ABS Control Module lw/EDLI harness
J569 - Brake booster relay
Connector lover fuse 234), 1n wiring harness lront, right J220 Motron1c Engine Control Module IECMJ Connector IC 15, A/Cl. 1n instrument panel wiring harness
N80 Evaporative Emission IEVAPI Canister Purge Regulator
Valve T10o Connector 10 pin. brown. connector station electronic box
plenum chamber
N156 - Intake Change-Over Valve Vehicles with manually sh1hed transmission
N205 - Valve -1- for camshah ad1ustment * only Vehicles with au tomatic transmission
T10q - Connecto1 10 pin, black, on cruise control switch Vehicles with ABS 5 3
N208 - ** T15e - Connector 15 pm, white. connecto1 station electronic box
Valve -2- for camshah ad1ustmen1
plenum chamber
T3au - Connector 3 pm, red. connector station electronic box
plenum chamber T15u Connector 15 p111, red. connec or sta ion electronic box
plenum chamber
T15e Connector 15 pin, white, connector station electronic box
plenum chamber T17f Connector 17 pm, black, 1n 8-Fold Relay Panel behind the
T15u storage driver's side
Connector 15 pm, red, connector station electrornc box
plenum chamber
V192 - Brake Vacuum Pump

Edition 09/02 Motronic Engine Control Module, Valves for Motronic Engine Control Module, Cruise Control Edition 09/02
W42 USA.5603.09 .21 Camshaft Adjustment , Brake Vacuum Pump W42 USA.5603.09 .2 1
Aud i A6 Wiring diagram No. 4/ 11 No . 4/ 12 Wiring diagram AudiA6

I
4.0

~
i1
s~
lSA **
12
1,5

~
l
s~
,46 40A

0.35
i44 0,35
f
4.0

m
~
(Q
CD
(")
s· ,.-+
:::::!.
ws =white ws =white CD
(") -
~
sw =black sw =black
ro
br
=red
=brown
ro
br
=red
=brown
OJ
gn = green gn =green ::J
~
bl =blue bl =blue tu
gr = grey gr = grey (Q
Ii =violet Ii =violet
ge =yellow ge =yellow CD .......
3 :J
113 115 120 123 124 126 127 135 138 140 CD
197-52076 1 I 91-s2on I ::J (Q
~-
E3 Emergency Flasher Switch 0 Ground connection . in engine compartment. left !\) 0
G79 Throttle Posit ion (TP) Sensor
e Co OJ
-r-.
G185 - Sensor -2- for accelerator pedal pos1t1on Ground connection -1-. 111 engine compartment w1nng
J220 - Motronic Engine Control Module (ECM ) harness E87 NC Control Head
- Ground connection . on left A-pillar. lower part (Q
J234 - Airbag Control Module Q Plus connection (30). in instrument panel winng harness
F18 -
Coolant Fan Control (FC) Thermal Switch
.......
J299 - Secondary Air Injection (AI R) Pump Relay ~ F54 -
Coolant Fan Control (FC) Thermal Switch Ground connection -1-. in coolant fan winng harness
N112 - Secondary Air Injection (AI R) Solenoid Valve Q Connection (crash signal) in instrument panel w1nng harness
F129
J293
NC Pressure Switch
-
Coolant FC (Fan Control) Control Module
-
CD"
~.......
OJ
~
S130
S279
-
-
Fuse for secondary air pump
Brake Booster Relay Fuse 542 - Coolant Fan Fuse
Wire connection (75al), in NC winng harness
3
T3au - Connector 3 pin. red. connector station electronic box
plenum chamber
Connector 3 pin. white, connector station electronic box
new Throttle Pos1t1on (TP) Sensor without adapter wire.
running change
S142 - Control module fuse for coolant fan
S225 - Fuse 25 in fuse holder
T2by Connector 2 pin. on Coolant FC (Fan Control) Control
Wire connection -1 - (NC Pressure Switch). 1n Climatron1c
wiring harness
gi CJ)
T3bg - only Vehicles with automatic transmission Module (Q
T6an -
plenum chamber
Conneclor 6 pin . in front footwell. left T2bz Connector 2 pin. green , for After-Run Coolant Pump s·
T10n - Connector 10 pin. orange . connector station electronic box
plenum chamber
T4av
T6ao
Connector 4 pin, red , 1n engine compartment. left
Connector 6 pin , on Coolant FC (Fan Control) Control CD m
~
T15e - Connector 15 pin , white. connector station electronic box Module
plenum chamber T10c - Connector 10 pin , grey. connector station A pillar. left CJ
V101 - Secondary Air ln1ect1on (AIR) Pump Motor V7 Coolant Fan 0
~ 0
V51 - After-Run Coolant Pump
V177 - Coolant fan -2-
I
Edit ion 06/01 Motroni c Engin e Control M odule, Secondary En gine Cooling Ed it ion 06/ 01 ~
W42 .USA.5603.05.21 Air Pump , Throttle Position Sensor W42.USA .5603 .05 .2 1 h
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AudiA6 Wiring diagram No. 4/13 No. 4/14 Wiring diagram AudiA6 ~ m
:s- 0~
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30 30 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~­
30
15 ~5~~~~~~~~~~~~~~~~~~~~~~~~~~~~- 15
x x
31 3 1 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
31 CD
I

~ ~ ~::J
_J,,,

I\)
tl:> ~
~
0,35
'1
0,35
Cf
0.35
ITjID
0.35
llfl
0.35
ge/br
er-r !
ws/bl wslbl ro/gr
(Q
CD
3 m
ge swlli ro/br

' T32/25 , T32/6 '~;211 ' T32/13

' T32a/14 @ I T32/3 ' T32a/15
CD
-
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~
..........

~
) © K2 J218 © © K s3 © Km 0 G 5 J218© ()
0 G 1
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r,,
r+
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1,5 T32/9 OJ '
-.
T32/24
T32a/12 T32/7
()

g~[~"'
T3 2/5 T32a/28
61 # K
31 31
r-
o.>
0,35 <D -
..-..
~
gn/bl

r· ~
20A

~ -·
2,5 0,35 0,35 0.35
(Q '
s· {C
:J
ct
ge li/sw gn/bl

CD
(') 0
J T 1oba14 T 10113 0
r ct ).LJ

~. rl..
{C
I )::i.
0.35

L ~
0,35
'
o.>
~ T16a!7 d 3
CJ)
ws =white ws =white
sw =black sw =black
0.35 ro =red ro =red
br br =brown br =brown
gn =green gn =green 0,35 0,35 0,5
bl =blue bl =blue br br brfg e

Is le.le· ~
gr =grey gr =grey
Ii =violet Ii =violet
ge =yellow ge =yellow
@l @l
141 142 143 144 145 146 147 148 149 150 151 15 2 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168
197-5 2078 1 1 97-52079 1

G
G1
Sender for fuel gauge
Fuel Gauge
@ Ground connection -1-, 1n rear wiring harness Fl
F66
Ori Pressure Switch
Engine Coolant Level !ECU Warning Switch
Ground connection -1-, 1n engine compartment wiring
harness
G6
G169 -
Fuel Pump iFPI
Sender 2 for fuel gauge
@> Ground connector (sensor ground) 1-. in instrument panel
wiring harness
G3
G5
Engine Coolant Temperature !ECTI Gauge
Tachometer
Ground connection -2-, 1n instrument panel wiring harness

G237 -
J218 -
Sensor -3- for fuel supply
lnstrumen1 Cluster Comb1nat1on Processor @ Connector IK-<11agnos1s wire), 1n instrument panel wiring
harness
G21
G22
Speedometer
Speedometer Vehicle Speed Sensor iVSSI
Ground connection -3-, 1n 1nstrumen panel wiring harness
K2 Genera or (GEN! Warning Light J218 Instrument Cluster Combination Processor Q
K83 Malfunction Indicator Lamp !MIU K3 Ori Pressure Warning Light ~ Connector (speed srgnal), 1n instrument panel wrnng harness
K132 - Vehicles with front wheel drive
Fault light for power accelerator activation * K28 Engine Coolant Level(Temperature iECUECTi Warning Light
S228 - Fuse 28 1n fuse holder
** Vehicles with al l wl1eel drive T10p Connector 10 pin, black. connector station electronic box * both are possible
T10f Connector 10 pin, brown, connector Station A pillar. leh Wiring 111s1de fuel tank plenum chamber
T10ba - Connector 10 pin, blue, connector stauon A pillar, leh ***
# Exit Sensor ground
T32 Connector 32 pin, blue, on instrument cluster
T16a Connector 16 pin. data link connector T32a Connector 32 pin. green, on instrument cluster
T32 Connector 32 pin, blue, on ins trum ent cluster
T32a - Connector 32 pin, green. on 1nstrum nt cluster

Edition 09/02 Instrument Cluster, Fuel Pump Instrument Cluster, Speedometer, Oil Pressure Warning Edition 09/02
W42 USA 5603 09.21 Light, Engine Coolant Level/Temperature Warning Light W42 USA5603 09.21
AudiA6 Wiring diagram No. 4/15
30~~~~~~~~~~~~~~~~~~~~~--~~~~~~-30
15 15
x x
31 31

~ l a I
~s,oe; 6,0

m3 ~231 m S
7 1
.l--..,_S_1__,,-'-; '---1-3l
'L
l4j ~
5

r· r 0 rr
15A 10A '---'_1_0A__,_1_0A_./

2,5 1.0 1,5 1,0

swlbl sw/ro ws ro/ge

t.e te T.i
ll l l
0,35 0 ,35 0 .5 0,5

WS

rC::±:i
F41~ F Ms
I r M
io
THIS SPACE INTENTIONALLY
m
0.35 1.0 1.0
LEFT BLANK
~
ws/ro ro/sw ro /sw

8 CD
et ~ 0 .35 0.35
(Q
:5"
(')
.....+
~.
I 'I ws
sw
ro
br
gn
= white
=black
= red
=brown
=green
(t)

~ m
(') -
bl =blue :::i

-~·
gr =grey tb
Ii =violet (Q
ge = yellow (t)

169 170 171 172 173 174 175 176 177 178 179 180 181 182
3 ':::J
(t)
1 97-5 1632 1
:::i co
F Brake Light Switch Wire connection 1541, 1n instrument panel w1r1ng harness ~-
F4 7 Vacuum Vent Valve. Brake
~
0
M9
MlO
Leh Brake Light
Right Brake Light
Wire connection i15a). 1n ins trument panel wiring harness
Q)
-·
m
-.r-- co
SS Fuse Plus connection 115a 11), 1n instrument panel wiring harness
S7 Fuse
Plus connection -2-1301. 1n instrument panel wiring harness
S13
S231
Fuse
Fuse 31 1n fuse holder
Connector 1541, in wiring harness 1nterio1 CD' '
m
Wire connection 1- l15al. 1n ABS wiring harness
~""" 3
* Vehicles with front wheel drive ~
(Q
CJ)
** Vehicles with manually shifted transmission
s·
(t) m
CJ
0 ~
Edition 06/00 Brake Light Switch , Vacuum Vent Valve Brake
~ 0I
~
W42 .USA.5603.01.21 h
l\J
d 01
Audi AG Wiring diagram No. 5/1 No. 5/2 Wiring diagram Audi AG ~ m
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(4,2 I - Injection Engine, 8 Cylinder), Code ART 8 - Fold Relay Panel

CD 0I
Fuse Location : $:
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EI!J ·Coolan• Fan Fuse. S-\2 ::J m
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2001 m . y. EIJ Control module fuse for coolant fan. Sl-l2 (Q
CD
Fuse Panel 3 m
CD
Fuse Colors : ::J
30 A Green
"'........ CD
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25
20
A
A
White
Yellow ~ r+
15 A Blue I\) ~-
10 A Red (")
7.5 A Brown r- Q.)
5 A Beige ;:::;.·
CD
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3 - Fold Relay Panel in E-Box plenum chamber

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Starting with fuse pos111on 23. fuses 1n the use holder
Relay location:
are 1dentif1ed with 223 1n the wiring diagram (Q
El -Secondary Air ln1ect1on (AIR) Pum p Relay, J2 99 5·
El -Motron1c Engine Control M odule IECMI Power Supply Relay, J27 1 CD
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Micro Central Electric Panel II -Fuse for secondary air pump . S 130

a ·Fuel Pump (FP) Relay. J17

co
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El -W 1per/l!Vasher lntermment Relay, J31
3
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D -W 1per/l!Vasher Inte rmittent Relay, J31
CJ)

I I I
A B C

13 - Fold Relay Panel

Relay Location :

a -Starting l nterloc~ Relay, J207

Edition 06/00 Edition 06/00

W42 .USA.5603 .01 .21 W42 USA 5603 .01 21
Audi AG Wiring diagram No. 5/3 No. 5/4 Wiring diagram Audi AG
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=====================
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15 15
x
31
x
31 ~5
31
30

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I I I I I I
8.
SH31 W30

D 4.0 G 0,35 2.5 0.5 2.5 2 .s

o131

1,0
br T
0,35
1 50
0.5
16,0
er2.5
Is ;& ~ ~ ~.. 232 swflbl

ef
bl bl

J 3117 I He ~~32
232a
T 1on/S

DIP
1

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1,0 0,5 2,5 2,5
~
0,35 2,5
bl bl
sw/bl ~ swfb l sw/bl

I e I I
T 1op11
J 22ol
ro © ~
l "'
l.1 J,2 r s

r'I.
0.35 0,35

"F-
1,0

l~·o~
2.5
bl

0.35 0,35

IT••"
l"'
L!J S,., 200A
br/ws

TT"" T1
. 918
1,5 16.0 16,0 35,0 2.5 F ,2s
0.5 0,5 1.0

m
bl

T T
gn/ge

L .,., ~ CD
A ·\t.;5 = vvs = ·t\'f-)1 te
sw = blac~ F1~4BJ ii &-jlv1•4 Tsfls ~
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..-+

r
=

r
5'.'.·
c C 1 B ,.")-:;:_ ro = ierJ Cl) ~-
= uro'.\"1
i br = br

~ £
:~ 0 l0
gn =green gr' =green 0.5
4 ,0 0,5 4,0 1.5 1.5
2,5 35,0 bl =blue bl = olue
br br br br/ws br/ws
ro/gn
br
gr = grev gr =grey
I =violet Ii =violet :::J
~·
11
ge = yellow ge = veliow tb
@ @18 @18 1@ ® I® (Q
-
10 14
1 97-518401
15 23 25 28
1 97·518411
Cl)
:3 ~ .
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0 G:rvu: op. :G nndv D
F125
·-i,/S:ane· S·v".'1'r'
Rc.rqe ITRi S·.v•IU
8 Grour cl C:O" 'lCC: C·" in t'-:'~{j::lf: C(1!l:P-1' 1 rr~~nt 1t.:.f·
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0 (Jrour".r~ s·1,=ip. i:-rrq:rt'.> ![; hi:jdy F19·l Sv·.·n. ~1 @ -1 11 pr:g I' P r_orrpc;nr· er· i \.VII rq
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J3 1 C0 Gro•_:n.j crjrnect1on 1- 11 irst::Jn-i..;:pt pa,..,e1 -.-.:1r1rg r-1a·-rc.ss J220
S2J'.?
Mi:ltrnn1c Er 19 1 0 Control rv1001~ ~~ IE.C!'vll
1

32 11~ tu~~c holoer ~

Gro1nui
CON·i?CtlOr-1 2-,

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lr1 PrlU1n1 C0 r1WCYtP·,e'1t ';Vlrfng

ifl<.:truner,J Pi1!lOI w 1r r,g t'arness

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S20•l
T3i1•,, oli.ld w eng1w: Cflrrpart~11t:nt. r10rit 8 Vv1rt=> l:Or,r,p(.t!O'l 1Gl1, 'r 1r;sfr;.J1flt)r't pcff.1_•1 ·~\'If ·19 l,'1lrtP'•S
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T9
('·_'.Of G rnn d~urbrov\'Tl, (..on r,pcwr 5 ' i:lt1011 A. pd!w ;1gl·t ~
CGnr1e>ct0r 9 p1r .. nrov\iii, ·1P ~idrt;r1g 1r~tpriod rdc1y
C0Pn(:1.·tor 10. oir= orcm~Jt? connec.:10• Sl. tittor oi.ec;·un1c uci>. .l..-.
i:O r ne1,;10q.

Pil,s connGc1on 115! :ri 1risi11xnenr pare! \V ·1nq h;Jmess

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T'Q,1 bro•.v1~. r.:011r=ee;1~1r stat1or o!er.tiO'llL' ho;.. '!On
P!us cc•nnei ' 1e1 ibOl. ;r .nstrur·-1et1 l uanel w1r11"'p t~arress
r;lc1ur•1 r::hcJrrioer _
Ti Op \)lac!-., connector stnti0r1 el1)t:tron1c hiJ'if Tl~r
VI J·l
Cvnn8ctor 1t> p'n. olue connc:ctor stut1or' ,A, p1i!a1, rigt1t
Lt1 a~ Detection Purno !LDP!
1' >
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Co'1nector (15at, 111 ·.·v111r'g

vv ;p CC)Cflr~Cll1:i:1 l15l. OVt-·t fUSP

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;P .:->ng-·1e C(•rr pi!! ii \t'l1t

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Edition 01101
W42 USA 5603 02 21
Battery, Starter, Generator Motronic Engine Control Module,
Starting Interlock Relay
Edition 01 / 01
W42. USA 5603.02.21 g. 0 I
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Audi AG Wiring diagram No. 5/5 No. 5/6 Wiring diagram Audi AG ~ m
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30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30 ~~ ~~~~~~~~~~~~~~~~~~~~~~~~~~~~­ 30
15 15 15
x x ~!~~~~~~~~~~~~~~~~~~~~~~~~~~~~- x
31 31 31 CD

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I
1,0
I
1,0
I
1,0
I
1.0 8 C4jJ
0.5
Cf
0,5 CD
swlbl sw/bl sw/bl sw/bt ro/gn ro/gn ro/gn
:3 m
~r ~ ~ ~r ~r "™~
I, CD
T 3o 912
Tm S 229 :J
CD
r r ~-
N 31 N 32 JOA
N 33 29• N 205
N 3o
()
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0.35 0,35 0,35 0,35 2,5 2.5 1.0 1.0 I\) ~.
swtro gn gr/gn Ii ro ro/gn br/gr br/ge
()
~ ~ t: Ol
L L L L J 220 L L ........
CD
~ ~ ~
~~

1 '°2 13
r7
®
r1 " 1 94 r1 03 r1 10
®
fa 1 95 ~
.....,.
0.35 2,5 0.35 0,35 0,35 0.35 0,35 0,35 0.35
ws/gn roJgn ws/bl gn/br gr/ws
8 ws/br gn/gr bl/ge g r/sw
8
t t t
I
:J

t®
N 10
I
2,5
rolgn
11 t I
2,5
ro/gn
1 1 t I
2,5
ro/gn

1 1
I
2,5
ro/gn

• 1
I
2.5
ro/gn

fr.~
t I
2,5
ro/gn

•1
2.5
I
ro/gn

• 1
I
2.5
ro/gn

• 1 t I
2,5
ro/gn
1 1
I
0,5
rolgn

c&
(Q

ro gn

p p p ws = whi te ws = whr te p
sw =black sw =black
a a a ro =red ro =red a
br = IJrown br =brown
gn =green gn = green
bl =blue bl =blue
2,5 1,0 2,5 1.0 2.5 1,0 2,5 1,0 2,5 ~ ,0 2.5 1,0 2.5 1.0 2,5 1,0
br/ws br/ge brtws br/ge br/ws br/ge br/ws br/ge gr =grey gr =grey br br/ge br br/ge br br/ge br br/ge
Ir = violet Ii =violet
ge =yellow ge = yel low
@ @ @ @ @ @ @ @)
30 33 37 40 42 •6 49 53 56
197-51842 1 j97-51843 j

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J220
D,stritJutor !yn1 ,on .DI) C.:1oac1tor
1

Jlotronrc Er191ne Ccntroi fv1odu!g !ECtvll 8 G•oi.1nd cr.innect1on 1 1n engirH~ co•T'Pd'trne0t ·/-.1H1r~1
harness
Cu
J220 -
D1strii)l;tor lnnit1on 1DIJ Capaci t or
lvlot 10111c E1~11re Control lv1orJu!e 1ECMI
8 Ground cor.nect1or -2. 1n engwe Cl1rrpartrne11t v-.•1r1n g
harness
1

N30
'J31
Cyr,1 uer I Fut>I lnwc :or
Cylinder 2 Fue1 ln1ector 8 Ground conriec11on .3 1n e11q1r:P con'Da::rT1er.t /1Ming
harness
~I~::.
N8·1
Cyl1nd<;1 5 Fuel lo1ector
Cvlwd,>r 6 Fuel 1111.:>ctor
@ Grouno di .,er.t1n1 -3
harness
11 er1g1r ~ cornpaitment vV!'lng

N32
N33
rno
Cy111.der 3 I uel ln1ector
Cyltricie .t Fuot !niector 0 ConriectOI love fuse 2291, !'"1 ,,._, r ng 'l(Hr'ess front r1giY N85
N86
CylrrcJer 7 Fue ln1ector
Cylinder 8 Fuel l111ec101 6
1"127
1<291
!gn1t1011 Coll 1 v\.'1 ~ h P01.'\'er Outp11!
lgnrt101 Cod 2 w11h Power Output
lynit•on Coil 3 w1tt1 Po\-ver Output
StriCJf:
S1agr-
Std9''
0 ;,1205
n200 -
Va 1ve 1- ~or can1shatt ac.J1ustrr1ent
Vn1ve -2 fo~ c.amshdrt cldjUStrne·1 · 0
N292
p
lgn1t1on Cod i ~~.,.1 · 11 Po \r1;er Output
Spar ' Plug C0rir:t~cto1s
Stag(
0 \·V1 ·e
w1r,ng
i 15) ovc~ 1 1 ;<;t 232, r i::1~q·1e comprntn~P.iit N323
~J324 -
f\1325
Coil 5 wr·'' Power Q_r'.p•H Staqe
Coil 6 vvllh Power Outpu · Stdge
lgn111or· Cr;,I 7 .v1'11 Power Ou;µcH Staqe
0 \·~'J;re conneCi1on
\.\<If 119 ha rnPSS
115J. eve· fuse:' 23/ ri er·g·'":e cornnan·ner·t
0 Sparl Plugs
S229 Fuse 29 111 fuse holder f'J326 lqr '1011Coil81·.·rt~ Power Outpu' Stage
T3bo - Connecto1 3 oir, v .. h1te connectN stn11or, e1eci101 <.. h•:..' p Sp;ir>, Pi,ig Conr·ectors
olenum chamber 0 Spilrr Plugs
T101 Connecto; 10 pin. orange. corinecto·· Sl?.t1on e:er.tron1c ho-.
plenurr-1 chrimhcr

Edition 01 /01 Motronic Engine Control Module, Motronic Engine Control Module, Edition 01/01
W 42 USA .5603 02 21 Fuel Injectors and Ignition Coils Cylinder 1 - 4 Fuel Injectors an d Ignition Coils Cylinder 5 - 8 W '4 2 USA 5603 02 21
Audi AG Wiring diagram No. 5/7 No. 5/8 Wiring diagram Audi AG
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30 30~~~~~~~~~~~[~~~~~~~~~~~~~~~~-30
15 15 15 15
x x
31 31

;, ' I " " ·1- --1-a---- 1- -1 ;,

0,35 2.5 2.5 0,35 ~ 2.5 0.5

ot 8 ot I
G ies

lffPTf1
G1s1 G las

J ..
r.... i;
0,35

T
J 234/69
l,, , bJ
0.35
M~,
2.5 0.35
0,5 0,5 0,35 0,35 0,35 0.35 0.35

~w
ro!U br/li ge/sw swfbl swlbr br/ws /Ubl

LLLLLt J 220

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t 7
T3ffl J 220

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62 [
r r
0.35
br
f9
035
t1 07

0.35
gn
rr
0,35
bl 0.35 0.35
br/gr
r j93

ge/0.3511
- - -1-- -1-- - - -1--
8
-1-- - - -1-- -1-- - - = - --1-- 8 - - -I-- 220
tfoe/2 0.35 0.35 0.35 0,35 0,35

0.35

l~""'
0,35
T 3kl3 I
0.5
Ie I
0,5 0,35 0.35 0.35
m
brt/ge ~ bt
'l: btJ
fg: gi : gi CD
~'·.'$ ~ v'/t°'I
s·t-
·o
= !)lac~
rr=:d
~
1;· = r·J. r
€' \'v'S
s .".
ro =reel
= 'd11t8
= blac>
b• =Lero·.
g1 = yre:8n
~
Gss
T1op1s .1
11

r u

Gs2 G2
I
.
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<D
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gr. = greP1
b! = lut bl = blue
0.35
br
0.3 5
bllb r OJ
gr ::::: grev
= JiOlet
gr = grev
=violet uL ::J
~
11
ge =yellow ge = yeilo Q)
CQ
60 62 63 65 66 70 75 78 80 83 84 <D ~
I s1.52210 I
Js1-522ss l
3 ~
E3
G7D
Er· r..;rger 'i FJ::;5·~s· s......
T"'Ottle Pos tior TP1 S~·1so·
.. G G2
G28
Er':O:"t- Coo an Ternrerat..1re ErT1 S'e,.,sor
Eno r"
SDP80 i RPf" 1 St>nso· 8 G~:,._1n0 cr;r·101 ·.or (Ser<;c r Grci.r10·
F •e n1ect,or· lvl" '""'·' rg ~ ..,·ress
·· \101'·0 ... c ',.1 J po .. <D (Q
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Gi85
G186
Sr;risor -2 ror ar:ceieraro~ r.,eaa DOS tior
T"ron!e dr VP. !pm\er ar:ceierator ac.tuat10i')
0
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G'U 1•10
rar1,es.:-
r;n · ·r~c · ,., . ~- r-r 1 re .orr 1 r.1f'1"·n et ~':ir g G61
G62
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E'1q:rif: Coe ar: Ter""f"pi=.rtiure 1.EC. Tl Se·-s r G G1 yo car· er:.: 0 1ser _, .. ff'1 i,..:::::1 ., ·•1(11-:e c0rrpc.utr-- e=..,.
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G ' 87 A"gff se'"lsor - ·- ior thrc... ,t? tjr•ve tpmver ac elei~ir::,t O· _ (or1PF.C. rJI \r'T;S~ ~1pnal! 1r1 r1Stri.Jff•€r 1 t panf1 \\1r ng !'111 055
G6 <n06 SPnsor 1KS! 2
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11c·1~a~ on .1270 w.r iig harr·ciss - I\) OJ
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.-h tudt1onl
itt.f: dr~vo

rvlot10•11c Engine Con1rol lv1odu1e IECl\/11

A"liilg Cor.1rol lv1od,,le
Thonle \!•,Ive Control Moou'e
t.pO\\·er 6C< e!err1l1l~ J271
T31-..
T3bc
T3bd
Tl On
Motror"c Engw<. Cr'r'!'ol Moad e ffCM.1 Pow~· 5,,polv Reidy(.'."'\
Corn t•Ct \" 3 ~i.r grey. i1· E!"1g11 c~ Speed (RPtvlJ 5, 1br·
Connector 3 nr. gree or Kno -i... Sor s0r 1
Conrecll11 3 pw grcrn ori Knoc~ ~or1sm 2
1

Connec.t01 10 pw hro·..vr' connector sta11or· elert:on1c bo"X

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T3au Ccnnec1or 3 Pd\ rerl. conriec.tor stat;on electronic rJO),
µll?nurn chamber Tl Op
1...ilen 1r-1 t.:har'"'!Lie~
Cori 1 ~Ltor 10 p1fl blac .. cv:inenor Stdt on elPct1on11.. box ~'""" 3
16r•
T15~
Cor1nector pin 01 11 ierior light fror11
Cor.·wr:tor 15 p1r-1 wrnte. . 0111e1 ~01 i;;.1:=won e!et 1ror1c. tJO'-<.
t:ff!! Ur" c~1ar1'rn~r
o Pf'l 1r1 c.l 1an be•
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Edition 01 /01 Motronic Engine Control Module, Throttle Valve Motronic Engine Control Module, Knock Sensor 1, Edition 01/01
W42 USA 5603 02 21 Control Module, Throttle Position Sensor Engine Speed Sensor, Engine Coolant Temperature Sensor W42 USA5603 02.2 I
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Audi AG Wiring diagram No. 5/9 No. 5/10 Wiring diagram Audi AG ~ m
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3o~~~~~~~~~~~~~~~~~~~~~~~~~~-.~3o
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~ 1:4
30
15 15 15
x x x
31 31
31
(1)
__..
I

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30
Q.) 0
Cf I CQ

N
25
w
6,0 G I
'C5/6.o 6,0
I I I I I I
0,5
I 0,5 0,5 0,5
e 1,0 1,0 0.5
022
(1)
3

ef ~f ~r
gnlge gn/ge gn/ge gn/ge gn/ge gn/ge

al.~

r ~f ~f
5 7
,, (1)

N 156 N 261
N ao ~ N145 N1 44
:::l
.............

I
N 112
2 ~

L L L®flJ
4.0 0,35 0,35 0.35 1,0 0,35 i\)
ro gn/ge gnJro lilws bllro bl/ro blfro li/ge

~ t:
L L L .........
(1)
®
~
rr
0.35
gnfsw
0,35
gn/li
r r
0,35
btlli
0,35
rr
0.35 0,35
r
0,35
ro/gn
~
4,0
r rrr r J 22o
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~
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rot/•: ,5ewts/r~15e/12
ro/b1 0,35 0.35 0.35 0,35 0,35
bl/gr sw/ws ro /ge bl ro/gr
M9
T 15e/13
(1)
M 10

I '" L,85
1,0 0,35 0,35
15efl
ro/sw ro/sw

0,5 0,5 0,5 0,5

T 10n14
8 1,0 0,35
61 31

4,0
T 3b9 13
r
4,0
gnlge
0.35
swlws
0,35 0,35
CV1
0.35 0.35
co
'
tu

~v,,,
gn/sw br/gr gn/sw brlgr

1lr 11 Tr
~
L L L L
II®
12
0 I II®
12
0 I F1l "k, w s = w hite ws =white
3
(/)

r
G 4o Gm sw =black sw = black

1,0
Cf I I
1.5 1,0 0,5
ro = red
br =brow n
ro =red
IJ1 = brown E•s
gn =green gn =green

I I J; I bl = blue
gr =grey
11 = VIOie
ge = yellow
bl =blue
g1 =g rey
11 = violet
ge = yellow
4,0
br
0,35
sw/ws
0,35
sw/ws

85 BB B9 92 95 9B 100 102 103 104 105 106 107 109 110 111 112
197-518461 I 97·51B47\
F Brake Light Switch Ground connecuon !sensor groundl, 1n engine compart ent .is C 11S• Cor~tr I S\.v•11 r,
F36 Clutch Vacuum Ven1 Valve Sw1 ch wiring harness J220 f1,lo11ori1c E"9'"' Co1•tro1 Modu'e 1ECll/11
F47 Vacuum Vent Valve. Bra'<e ,1299 Se1·ond,1ry Air 'rqe( t1on !AlRJ P~Hl'O Rnlay
Wire connection 1541. 1n instrument panel w11111g harness Vv',r~ CGf"·PC!lOr !c1u1se lOl"!l!nl/, in .ns:rurr~1 t pa··.~1 w+r1r~g
G40 Camshaft Pos1t1on ICMPI Sensor '180 Ev•1pora1 ve Ern1sS1tH1 :EVAPI C11 !.Ster Pura0 Reg .., :i·o· harr.::ss
G163 - Camsha ft Pos1t1on ICMPI Sensor 2 Vi=!vt"
Plus connect.on -2- 1301. in 1nstrul1"ent panel wiring harness Pu·· c.or • Pc'1or t30J 111slr_11110rit can~-:..: ·~vn 119 hr11r-1P5S
J220 - Motron1c Engine Control Module IECMI Ser.1.Wdory· Air 1!1je '0n ~r\IR Sc. erc1d \d Vf:
M9 Left Brake Light Len Ul'""cro-H-yrJraultc f:_!-;g ~· e Ml11 ;nt So;en01d \lCJ;ve
MIO Right Bra'<e Light Connector 1541, 1n w111ng harness interior R'gl 1 Electro-HyrJroul1c E··1f:w'e lvlount Soleno":l l/"lve
S5 Fuse h1·-1!--e Cho::ir10~ -Ov1--r Vflive
S7 Fuse Plus connection (5 Vol sl. 1n Mo ron1c Mui 1po11 Fuel
l~l.1!-'(• r'vleiri< lei TiJn1ng 1lMT1 VOW· 2-
S13 Fuse ln1ect1on IMFll wiring harness Fu ... e f(1 sec0Pdc1:v ,,.~ p1.j11=p
Tl On Corr 1.;lC'-.1~ 3 n r v· ...r11te c011nf.-L tor c_;tat10l' eler•ronc
1
bO'<
Connec or 10 pin. orange, connec tor station electronic box ( ; \ Wire connection -1- 115a). 1n ABS wiring harness p!e111uT .;hrmd)er
plenum chamber \::::J Corr·,~cto~ 15 r··1
A·t ~te C01''1E:·~·or Stallt,,_""lf1 F''C!('rorq Qr;'\
T15e - Connector 15 pin. whi te. connector station electronic box p!er-un, ch('H eer
plenum cham ber Vehicles wnh manually sh1f ed transmission "t01 Sec·ircla v .'.\1r i•111-c' on 1..\IR1 Pumr- lvlotor

Edition 06/00 Motronic Engine Control Module, Camshaft Motronic Engine Control Module, Secondary Air Edition 06/00
W42 .USA.5603 .01.21 Position Sensor, Brake Light Switch Injection Pump Relay, Cruise Control Switch W.+2 USA 5603 0121
Audi AG W iring diagram No. 5/11 No. 5/12 Wiring d iagram Audi AG
30~---------------------------30 30 30
15 15 15 15
x x x x
31 31 31 31

~
17130 + 19/86

01Ft; --+I
J 11 '
20/878 23/87 F ,t 16/85
I
022--<- - - - - - - - , , - - - - - - - ---<>---<>--- - - - - - - - - - - - 022 02 2
I I I
S3 87F/OTI
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S2/87F I S3/S S3/15

8
/87a
022

l. ~
0,5 0,5 0.5 0.5
gnlge gn/ge

~ ~
® I

r r r rh
L·1~ l L ;&
0.5 0.35 0,35 0,35 0,35 0.35 0,35

J no
gn/ge
'[

l.ru-u-J lruu.J l.ru-u-J 42Y l.ru-u-J 42Y

42Y I 42Y I
Z 2s G i3o
I
Z 3o G 131
I m
gi
Z 19 G 3s Z 28 G 108

CD
·,-.s = ,•,n ·e
CQ ()

0.35 0.35
fijfil
0.35
\VS= \N/lrte
svv = olac>
ro =reel
s-.•. . ,
ro
= 0 .::ick
=red
1

0.35 0.35
s·
Ct)
.....+
......
er = bro ·,r ':J r = brOv\'n ()

.L 0·1 = oreer
bl = blue
g·
01 = i)lue
= ;:;re"3~

~ PJ

L
gr = grey gr =grey

11 3
la 121 122
la
123 126
197-51848 1
11 = violet
ge = yeliov,
11
ge = vellow
=violet

128 130
Ia 134 136 138 140
i s1-52275 1
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tu
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Ct)
3
~
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r;:o [',lass
Ser S1/ • H02S 2
1rvi11F1 Ser 1 5c• ::J co
G108 Hea1ed s~1'sor iH02Si 2 G' lO - Hea:.e(i O-..y·qr;'"' Ser sor 1 025 Be· ·"'Id - i..,.ee VVav
8 G,.c r1d or'li;~· on 2 ,... erg·re CO'T'p?.rtrie,."il -..~.-iring ~-
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~
0
T4t.,
T.1,.
Z19
Cocr1ecto: t1la(k. l--;t:-:a1ea o<voen s""n"or
Connector .l prr t_1la-:k. he::ned ox~·9e!"J sensor 2
Q,yge1' Sensor 10251 Ht>ater
G!31 ·

J 17
Heat~d Oxyge'l Sensor 10251 2 Ber.r-o -:-1ri::e Vv:a 1
Catalvt1c Corn,e~ter T'..:i/C!
Fe.el Pu,,·p 1i'P1 Re-w
G \',It[ ng
tsh1t~!cl 1ngl. in r3 ...·£cr ·e cornpartrwnt
I\) PJ
Z2b Oxvge 1 Sensor 102s1 2 Hearer J220
5228 .
f\lotroi;1c E"oine Con ' "' Mcdu!e 1ECMI
Fu"e 28: m h~c..e holrjei
(§) Conr.ec!or !Over ~use 23-1!. r .,\··flnQ ha:rie~s f nnt. nor ·
r- co......
Fu .... e 34 r~ tt.se I 1ol0Hr ~·
S23·1
T4s ConriPctor ..i ptn. gree1 . near Q"ll;ygen ~ensQ1 Of·l1ir1d Truee
Ct)
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Way Cata;y;,c Converter ITVVCI
Conr:e::ctor .1 01n, mow . near oxyqen serir-or 2. behira 3
TIOn
Three Way Catalytic Converter iTVVCI
Cur-:r;ector 10 pm, orange connecto: stat1or e1ect10r 1 1c bo\
n!e1 :um chcw1ber
gi U>
1 tQp Conr :ecr,v 10 pr. hlacJ.. connector stat:or· eleciron11... h1•x CQ
?29
plt'lriury, clian 1oer
0\ygen Sw1so1 (0251 Ht?atcr
s· m
Ct)
no Oxvgen Scnso1 1025) 2 Ht>att:1

Ed it ion 01 / 01
CJ
0 ~
~ 0
Edition 01 / 01 Motronic Eng ine Control Module, Heated Oxygen Motronic Eng i ne Control Module, Fuel Pump Relay, Heated
W42 USA 5603 02 2 1 Sensors, Mass Air Flow Senso r Oxygen Sensors Beh ind Three Way Catalytic Converter W~ 2.USA 5602.02 21
I
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J 0
J J 0J 00 0~ Cl~
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om J J Cl ro ]
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0 :: !!t
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mJ 6
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:s· :::J
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m~ m J <D
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m CJ 0
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n 2 a
~ PJ
::!
(J J
o ~ - ii T1oc12 (Q
x "~ )::,. -t
JJ PJ
....,
*'
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0,5
br/ sw
0.5
br/gn en
. B12
g~ 0J 0J 0J 0 0 0
3g
-· z' J J J a·m
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w,
ws =white
E s1
dm"
1

r
F 1sl
-ro m ro m
(") J sw =black
(/) c Q Q 0 0 ~ 0. ro = red
~~ 6
::-.:0 J
i5 Q
J m J
0 s (") br =brown
gn =green
:r w ~ TI !2 0J bl =blue 6,0 0.5
wiii 0

Is
~ tB" .Ul i5 !2 gr =grey
c '
-(J) :r J Ii =violet
i5
f0
0 c (J
(J ~ J
3~ c ge =yellow
!!t ~ !E,
c
D Ul
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ii" 3 J s· 155 156 157 158 159 160

~J
s 3 s· 3 m 3 161 162 163 164 165 166 167 168

!'! !'! (/) ~- J 1 97·51852 1

(/) 2 22 fO
E87 A/C Control Head
3
~·
3 3
m m 3 3 m
3
F18 Coolant Fan Control (FC) Thermal Switch
Ground connection , on left A-pillar, lower part
(/)
:!. :!. :!. m 0 F54 Coolant Fan Control (FC) Therm al Switch Ground connection -1-. in coolant fan wiring harness
i5 :!. F129 - A/C Pressure Switch
J w \)w \)w \) \)3
\)
J293 - Coolant FC (Fan Control) Control Module
J J J w Wire connection (?Sal) , in A/C wiring harness
!!. ~ !!. J :iw S42
S142 -
Coolant Fan R.ise
Control module fuse for coolant fan
~
!!. 3 W ire connection -1- (A/C Pressure Switch), in Climatronic
~ ~ S225 - R.ise 25 in fuse holder
s: s: ~
:;·
ro Q~ = ~ g:~~a~ ~ T2by - Connector 2 pin, on Coolant FC (Fan Control) Control wi ring harness
J J 3 :!.
fO
fO fO s
fO ~
11111111111111111111
T4av -
M odule
Connector 4 pin , red , in engine compartm ent , left
:r :r :r
~ w w :r 3
J 3 3 3 fO n~~~~m ; T6ao - Connector 6 pin. on Coolant FC (Fan Control) Control
M odule
m ©
(/) m © ~~~'< ©~ ~ ~~ T10c Connector 10 pin. grey, con nector station A pillar. left
(/)
(/)
(/)
(/)
(/) (/) m< J V7 Coolant Fan
(/)
V177 - Coolant fan -2-

Engine Cooling wi th Coolant FC Con trol M odule Edit io n 06/01

W42. USA. 5603.05.2 1
AudiA6 Wiring d iagram No. 5/15 No. 5/16 Wiring diagram AudiA6
w w w w
15 15 15 15
x x x x
31 31 31 31

~ ~ ~
~~
~
~
~
n
81 0.35
wsfb1

~- ~ ' T32/3

\T__l I
/ef K 2

r--
0 G 1 ® J 21a
~ ~ 0

I
G 5 ® Ks3ef K m ® J 21B 0

I
G 3 0 G 21

I
Q<f/ K3

I
0/ K28

i.T32/5 J:~2i7 i~32a/26

0.35
rm•
gnfbl
rW"
0.35
ro/gr
l"T"'"
0.35
bl/br
0.5
br/ro
r..
0.35
ws/gr
rm·
0.35
bl/ge

~
T~, TT'""" tT'"" ©foe>

8 0.5

efi 0,35 0,35 0.35 0.35 0,5 l·I " 0.5

L J'.;
gn/bl

~ ~ T m
~ T16an

~
G

lF. ~ CD
cg (")
r
/'VS-= te \'\•5::::
F1

r
5\', = 5,·, = G 22
::J' .....+
ro :::: CD :::! .
:::rc·::r ::: ur""'I·: . •

~ £
t·." :::
gri = gree• 9'1 = 0,5 0.5
t.r = bll:e bl =

169
8 le - L 179
18
0
181 182
j 97·51853 j
gr =grey
r
ge
= v10ltl
= ·,ellovv
gr =grey
11 = volet
g'3 =yellow

186
le J
J;
195 196
j s?-5185•1
~CD -~
:3
CD
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~
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G'
•or
F.r;;, G.1,,uc
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Instrument Cluster, Fuel Pump, Instrument Cluster Edition 01 /01
~ ~
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Edition 01 /01
Wl2 USA 560:': 02 21 Fuel Gauge W42 US.i\ 5603 02 21

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Audi AG Wiring diagram No. 10/1 No. 10/2 Wiring diagram Audi AG -
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Driver's Information System 3
(1) --L.
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2001 m . y. J 220 ::::J
I Q
Fuse Panel 0,35

CJ m
-
Fuse Colors :
30
25
20
15
10
A
A
A
A
A
Green
White
Yellow
Blue
Red
-a
0
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r-+
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7.5
5
A
A
Brown
Beige
r\) OJ
a
~
a
~
@ J 1a9 -.i..
"-
Start.ng with fuse pos1t1or 23. fuses 1n the fuse holder
are 1dent1f1ed wi th 223 in the wiring d1ag1am

0.35
gr
0,35
bl
0.35
gn
Im~·
0,35
br/ro
j,,,.,,
Clock

0,35
gr/ro I"""'
0,35
ro/br
Data
j,,~,
0 ,35
rolge
En able
~

::::J
(Q

13 - Fold Relay Panel

0
110x/9 ~ I 10x/7 l 1ox110
OJ
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D -Lamp Control Module. J123 0,5 0,35 0,35 0,35 ~

l1lJ -Lamp Control Module. J123

OJ
3
CJ)
ws = whne
sw =black
ro =red
br =brown
gn =green
bl =blue
gr =grey
11 =violet
ge =yellow

13 14
1 97·516151

E91 Board Computer Function Selector Switch Ground connection -1-, 1n instrument panel w1nng harness
E92 Board Computer Reset Bunon
F77 Windshield Washer Fluid Level Warning Switch Ground connection -2-. 1n instrument panel wmng harness
J189 - Auto Check System
J220 Motron1c Engine Control Module iECMl
Ground connection -3-. in ins;rull'ent panel wiring harness
R Radio
T6x Connector 6 pm, green. connector radio I 2
TIOa Connec tor 10 pin, pink, connector station A pillar, leh Ground connector (sensor ground) -1-. 1n instrument panel
w1nng harness
T10b Connector 10 pin, red connector station A pillar, leh
T10o Connector 10 pin, brown connector station electronic bo'
plenum chamber Both are possible
Tl Ox Connector 10 pin, green, connector station A p11ia1 nght
T32 Connector 32 pin, blue, on instrument cluster
T32c Connector 32 pin, grey, on instrument clus ter

Edition 06/00 Board Computer Function Selector Switch , Edition 06/00

W42 .USA.5603 .01 .21 Windshield Washer Fluid Level Warning Switch W42 USA.5603 012 1
Audi AG Wiring diagram No. 10/3: No. 10/4 Wiring diagram Audi AG
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30 30~~~~~~~~~~~~~~~~~~~~~~~~~~~~- 30

15 15 15 15
x x x x
~ ~ 31 31

I 8
4.0
I
2.5
SW 8 ' 8 •µ·------------------....
2,5
ge
A51 1,0
~
1.0
~

k
L ~
SW
0

ri·r
t/56
r,;.
Es1 s 21 s 2
5 5

r~·'°
107 15•
10A E1
0.35 1.0
D
T
sw/ro
1,5 1,5
·1T32a/29 ge/gn ge/br

I I
TT32a/3 1 TT32c

I 11 /S6bL
o m
J 123 14/S6b R

Vs G 1os~ ® J199
i 13/S6bL1 1 2131 j 15/56bR 1

811 I l ~
T32c/ 1 T32c/23 T32c/24
II
T32/20
T32c T32c T32c
14
I
J, T32c
0 ,5 1,5 1.5 0.5

l-T- f,. ,. l···

5Bs 12 /3

0.35
gr/bl

e+ 0,5 1,5 1,5 0.5

ws
sw
=white
= black
ws =white
sw =black
'Ll T10an/7
M1
¥T10an/8
¥T10an/S
M29
IT10an/10
l 'L
¥T10ao/5
M 31

T10ao18
~T10ao/7
M3
ITlOao/10
m
CD
(")
......+
ro =red ro =red
br =brown
31 31 31 31 :::::! .
br =brown (")
gn =green gn =green I I
1,5 1,5
bl = blue bl =blue
gr =grey
1.5
br
1,5
br OJ

le la
gr = grey

I@ le
11 =viole t 11 = violet
ge =yellow ge = yellow
~
16 20 23 25 26 28 37 38 39 42 -o;

D
E87
lgn111on/Starte• Sw,tch
A/C Control Head wiring harness
1 97 -5 1616 )

Ground connector !sensor grounal -1 . rn instrument panel E1

J123
L ght sw.tch
Lamp Control M odule
1 97-51617 1

Ground connection -2-, 1n instrument panel wiring harness -

::J
Ci)
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E272 -
G106 -
J123
Board Computer Function Selector Sw11ch II. 1n console
Outside Air Temperature Display
Lamp Control M odule
Plus connect ion 1151. 1n instrument pane1 w'rrng harness
MI
M3
Leh Parking Light
Right Parking Light
Ground connection. 1n r'ght headlight wiring harness

Ground connection, 1n left headlight wiring harness

2 0
J189 Auto Check System Wire connec tion 158sl, 1n instrument panel wiring harness
M29
M31
Leh Low Beam Headlight
Right Low Beam Headlight 3 OJ
J217 Transm1ss1on Control Module iTCMI S20 Fuse Ground connection -3-. rn instrument panel wiring harness ct> (Q
S5 Fuse
Wire co11nec 11on (15al. 1n instrument panel wiring harness S21 Fuse ::J
T15r
T32a
T32c
Connector 15 pin. blue. connector station A pillar. righr
Connector 32 pin. green. on instrument cluster
Connector 32 pin, grey, on 111strument cluste1
T10a
T10an
Connector 10 pin. pink, connector station A pdlar. leh
Connector 10 pin. on headlight, leh
Wire connection 1561. 1n instrument panel wiring harness
Ci)' '
OJ
tb
Y6 Transm1ss1on Range (TRI Selector Lever Display - Vehicles with automatic transmission 01 V
T IOao -
T'IOay -
Connector 10 p111, on headlight. right
Connector 10 pin. pink, connector station A pillar, right both are possible
::J 3
CJ)
Q.
(")

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0
::::s

C3
Lamp Control Module, Outside Air Temperature Display, Lamp Control Module, Parking Light Edition 09/02 Ci)"
Edition 09/02
W42 .USA 5603 09 21 Board Computer Function Selector Switch II W42 .USA. 5603 09 21 0
~ I

a ~

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Audi AG Wiring diagram No. 10/5 No. 10/6 Wiring diagram Audi AG -
::J
(/)
m
2 0~
.......
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30 30~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
30
15 15 15~~~~~~~~~~~~~~~~~~~~~~~~~~~~­ 15
x x x ~~~~~~~~~~~~~~~~~~~~~~~~~~~~- x
31 31 31~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
31 3
([)
I
.........
::J
(j)" w
tl:l
en
F
::J
I
1.0 8 I
0,5
... 2
1.0
I o
v
0.5
I
1.0 Q.
m
frok-1enoT
gn/sw gn/sw gn/ro gn/ro
()
~
~ 22

~r a
l 13/58 L l 14/58R
5 223 E, E l S 22
SA SA @) ::J
.......
(l)
r l 223a r l 22a

I I a"G)" ()
.......
0,5
gr/sw
0.5
gr/ge ~w 0,5 0.5 0,35 0,35 :::!.
~gr ()
br/ws br/ws

~ f\)

!Tm~
DllJlll I A12 Q)
t 8/58L ! 5/5 4 t /54HE J 123 10/58R E a1 a
~
a
...._ ~
r"'
-.-4,
t 17/58BL1 :
r 4L r 4H r 4R
--.
1,0
ro/ws
0,5
gr/sw
1,0
ro/sw
1,0
ro/ge
0,5
gr/ro
0.5
brfws :J

T 10ba18 T 10111 T loba/2 T 1oba16 T 10112

t (Q

0
Q)
1.0 1.0 0,5
I (Q
--.

I. ro
L ~'L
0.5
br/ge
Q)

M 10 M2 ws = whi te ws = white
,,,_ 3
CJ)

I2 r/31 sw
ro
=black
= red
sw
ro
=black
=red
br =brown br =brown
0,5 1.0 gn =green gn =green
br 0,35
bl =blue bl =blue br/ge
gr =grey gr =g rey
11 =violet Ii =violet
las

45 46 48
I® l® 56
ge =yellow ge =yellow
E a1

62 65 67 70
J97-51618J [97-51a55J

El Light switch Ground connection -1-. in rear wiring harness E87 - A/C Control Head Ground connection -2-, 1n A/C wmng harness
F Brake L.ght Switch G 17 Outside Air Temperature Sensor
J123 Lamp Control Module Wire connection (541. 1n instrument panel wiring harness T10b - Connec tor 10 pin, red. connector station A pillar. left
M2 Right Tail Light
M4 Len Tail Light
M9 Leh Brake Light Wire connection 15711. 1n instrument panel wiring harness
MlO Right Brake Light
M25 High-mount Brake Light Wire connection 157rl. 1n instrument panel wiring harness
S22 Fuse
S223 - Fuse 23 1n fuse holder
T10f Connector 10 pin. brown. connector station A pilla1. lefi
T10ba - Connector 10 pin. blue. connector station A pillar. len
Wl8 - Leh Luggage Compartment Light

Edition 06/00 Lamp Control Module, Brake Light, Tail Light Outside Air Temperature Sensor Edition 06/00
W42 USA 5603 0121 W42 USA.5603 01 .21
AudiA6 Wiring diagram No. 13/1 No. 13/2 Wiring diagram AudiA6
Daytime Running Lights with Fog Light and Rear Fog Light 30
15
- 30
15
x x
(Canada) 31 31

1£ §1 ~
5

El
J 59
6 16/87

S1/75 30 15
2001 m. y.

0,5
8 1 I I I I 0.35 0,35 0,5 0.5 0.5
Fuse Panel

Fuse Co lo rs:
1.0
ge/sw
or T T
2.5 2.5 2.5 6 ,0
SW

cL I l .f
gn/gr

~ c!i
gn/gr

-i3'v21
gn/gr

3R2/26
gn/gr gnlgr

II 'I 'I J 21a J 21a

30 A Green
25 A White
20
15
A
A
Yellow
Blue
2,5 2.5
8 ~
1,5
10 A Red
,0

L
~5 A Brown 9'
5 A Beige
1 30 D I
Starting with fuse position 23, 'uses n the fuse hoider
are 1dent1f1ed with 223 1n the wiring diagram

Micro Centra l Electric Panel

Relay Lo cat ion :

EJ -Load Reduction Reay J59

~
CD
ws = white ()
..-+
sw
ro
=b lack
=red ......
I I I br
gn
=brown
=green
()
A B C
bl =blue 0)
gr =grey
II = VIOie
ge =yel low
~
~-
12 13 14
197-519651
13 - Fold Relay Panel ::J
Relay Locatio n:
B
Cl
Starter
Voltage Regu lator IVRI
Ground connection -2-. 1n rear wiring harness
CJ co
D lgn1t1on/S arier Switch tl)
Ill -Fog Light Relay. J5 J59 Load Reduct ion Relay
Plus connection 1151. 1n instrument panel wiring harness
......... 0
Iii -Lamp Control Module. J 123
J218
S3
Instrument Cluster Com bi na ti on Processor
Fuse Wire connection (86sl. 1n instrument panel wiring harness """§" 0)
ll!J -Lamp Control M odul e. J123
S4
T5a
T10f
Fuse
Connector 5 pin , black. behind instrument panel, right
Connector 10 pin, brown, connec tor station A pillar. left Plus connec tion -2-1301. in instrument panel wiring harness
Ct) co
......
m -Fog Light Circuit Breaker, S28
T32
W6
Connector 32 pin, blue. on instrument clus ter
Glove Compartment Lig ht Connection 2 (daytime running l1 ghtsl , in instrument panel
J:J
c:: 0)
X License Plate Light wiring harness
:::::J
:::::J
3
CJ)
s·
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Ignition/ Starter Switch , License Pl ate Light , Ed ition 06 / 00
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Edition 06 / 00
W 42 USA.5603 .01 21 Load Reduction Relay W42 .USA 5603 01 21 0I
t\)
a .....L
a-.... (,.)
-.._. ~
 Audi AG Wiring diagram No. 13/3 No. 13/4 Wiring d iagram Audi AG m
~
0I
~

c.u
co
LfJ
2,5
°11 LJJ
2,5 2.5
~1,5
C¥J
1,5
Ofl
1,0
~
1,0
~
0,5
ro ws/ge ge/sw gr/gn ge ge gn/gr

E1
. .
, 15/30 1 5/56 0 ' 1/XZ E 23 ' vxR K13 K11 L9 L 4o L ~ 1 223 m
I ' ?~ S19
10A
S 21
15A
~ 5A
S223

2,5
/56
1
I

1,5
8/N L
r

1,0
/NSL
'r 7/58s

0,5
I
10131
r 1 19a

0.5
ws/sw
1.5
ws/sw
h r
1,5
ge/gn
0.5
grlge
0,5
gr/sw

~
et om l ~"'-' ~'-"'
ge/ro ws/ge gr/ws gr/ bl

f""~· ,J °f
r~
0.35 1.5 1,5

TT
J 123
gr/b l

cp cp l 5as
T32/20
1'58 BL1 8 ~­
2,5 2,5 1,0
J 21a
1,5 0,5 1,5 1.5 :J
ro ro gr/ws ge/sw gr/sw
cc
"J:. ~ l-~
E4 1156 '1 130 , 2130 1 1
I
~ T' T -~ I~~ L 46
I T 1oa14 T 1oa15 M4 T 1oa12 0
~

I
1,5
w s/gn

~
ws = whi te ws =white

T
1,0 1,0
br
0,5
br
sw
ro
br
gn
=black
=red
=brown
=green
sw =black
ro =red
br =brown
gn =green

I 8
I@
bl
gr
Ii
=blue
=grey
= violet
bl =blue
gr =grey
Ii =violet

20
I®
24 25 26 27 28
ge =yellow ge =yellow

33 35 36 40 41 42
197-51966 1 197-51967 1

El Lrght swrtch Ground connection -1-, rn instrument panel wrring harness J5 Fog Light Relay Ground connection. rn right headlrght w111ng harness
E4 Headlight Drmmer/Flasher Swrtch J123 Lamp Control Module
E23 Fog Lrght Switch Ground connection -2-, 1n rear wiring harness L22 Leh Front Fog Light Ground connection, in leh headlight wrring harness
J218 - Instrument Cluster Combination Processor L23 Right Front Fog Light
K13 Rear Fog Lrght lndrcato1 Light Ml Leh Par ing Light
W11e connection 158sl, 1n instrument panel wiring l1arness Connection 3 ldayt1me running lights), 1n instrument panel
K17 Fog Lrght Ind icator Lrght M4 Leh Tail Lrght w111ng harness
L9 Headlight Switch Light M29 Leh Low Beam Headlight
Wire connection 1561. 1n instrument panel wiring hamess M30 Leh High Beam Headlight Connector -1- 156bl, 1n wiring harness headlamp
L40 Front And Rear Fog Light Switch Light
L46 Leh Rear Fog Light S19 Fuse
S28 Fog Light Fuse Connector (dayn1me running lights), 1n instrument panel S21 Fuse
S236 - w111ng harness S223 - Fuse 23 1n fuse holder
Fuse 36 1n fuse holder
TlOa Connector 10 pin , prnk. connector station A pillar, leh
T10ba - Connector 10 pin, blue. connector st tron A prllar. leh
TIOb - Connector 10 pin, red, connector station A pillar, leh
T32 Connector 32 pin, blue. on instrument cluster TIOan- Connector 10 pin, on headlight. leh
TlOaz - Connector 10 pin. red, connector station A pillar, right

Edition 06/00 Light Switch, Headlight Dimmer/ Flasher Switch Lamp Control Module, Front Fog Light, Edition 06/00
W42.USA5603 0121 Left Beam Headlight W42.USA 5603 0121
Audi AG W iring diagram No. 13/5
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30

15 15
x x
31 31

LljJ
1.5

T 10ayt4 T 1oay/2

THIS SPACE INTENTIONALLY

LEFT BLANK m
CD
ws = wh ite
()
.....+
sw =black
ro
br
gn
=red
= brown
=g reen
'
()
bl =blu e Ol
gr =grey
=violet

~
11
ge =yellow

46 51 52 54 56
1 97-51968 1 '::::J
J 123 Lamp Control Modu1e Ground connection. 1n 'g~· neadl1gl t w1'lrg harness (Q
Kl Headl1gh : H1gn Beam Ind cator Light CJ
M2 R·gh1 Tail Light tu
M3 R-ght Parnng Light 0
M31
M32
s18
R ght Low Beam Headlight
R Qht High Bearr Headlight
Fuse
""".........
§" Ol
S20 Fuse (1) {Q
S22 Fuse
T IOao Connector 10 pin. on headligh t. r1ght
lJ '
T IOay Connector 10 prn. pink connector station A pillar, r1glil
c: Ol
T32 Connector 32 pin blue, on instrume nt clus ter
::::J
::::J
3
(J)
s·
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ca·
Lamp Control Module,
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Edition 06/00
W 42 USA.5603 01 2 1 Right Beam Headlight 0
!\) I

a .....L.
a
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Audi AG Wiring diagram No. 19/1 No. 19/2 Wiring diagram Audi AG $::J m
~
Power Windows
2- 0
~ __..
I

1\3 ~
a 0
2001 m. y. ~ 30 a
2.5 2.5 ...._.
-.I.

Fuse Panel
l lm m
m
5 37 CWJ
.
Fu se Colors:
CW) 5 43
(1)
r12 h
30A 30A
30 A Greer ()
11
25 A Whrte
......+
20
15
A
A
Yellow
Blue 2.5 2.5 2.5 2.5
......

ro,-~,.:01·~..ll. ,.
10 A Red ()
7.5 A Brown
5 A Beige OJ

~
S:art1ng wrtl fuse positron 23. fuses 1n :he fuse holder
are 1dent:f1ed W'th 223 in the wiring diagram 2.5

ri
2.5

r~
"ll
2.5

';&; ';i;
2.5
~
0.5
~
0.35
ro/gr rofbr
C?jl
0.35
Cif
0.35
Ii
cp2,5
rofgn
~
0.35
rofgn
......
:J
(Q

Micro Central Electric Panel T 3n11 T 15k T 15k T 15k

0
/10 /11 f7

(Q
......

·
p ·
0.35 0.35 0.35 0,35 0,35 0.35 0,35 2,5
OJ
3
~
(J)

A B C
ws
sw
ro
br
gn
=white
= black
=red
=brown
=green
4.0
R
2.5 2,5 0,35
I ®
J 295 r
2,5
511
V 1.

bl =blue br br br ro/gr br
gr
Ii
=grey
=v iolet
I
L1os
ge = yellow

10 14
1 97-518731
8 - Fold Relay Panel
E-10 Left Front Wrndow Switch Ground connection. on left A-pillar, lower part
Fu se Location : J295 - Le Front Power Wrndow Control Module

m Power Wrndow Circur Breaker Front. 537

L 108
537
S-1 3 -
Door opener l1ghtrng, driver srde
Power W111dow Circuit Breaker Front
Power Window Crrcurt Breaker Rear
Ground connection -1-, rn power window wrrrng harness

Ground connection, n driver's door wiring harness

Ii Power Wrndow Crrcurt Breaker Rear. SJ3
T3n -
T5b
Connector 3 pin. red. connector station A pillar, lefl
Connector 5 pin, black. in driver's door
Plus connection 130I. in power window wiring harness
T10ag- Connector 10 pin, red. connector station A pillar, rrght
T10ah- Connector 10 prn . red 111 B pilla r, left
T10a1 Connector 10 prn, red, 1n B pillar. right
T15k Connector 15 pin. red. connector stati on A prllar, left
V 14 Le ft Wrndow Motor

Edition 06/ 00 Left Front Power Window Control Module, Edition 06/00
W42 .USA.5603.01 .21 Left Front Window Switch W42.USA 5603 01.21
AudiA6 Wiring diagram No. 19/3 No. 19/4 Wiring diagram AudiA6
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~3 0 30~~~~~~~~~~~~~~~~~~~~~~~~~~~~-30
15 15 15 15
x x x x
31 31 31 31

~ ~
E 53

0,35 0,35

T0,5
·1~""'
0,5
fr. ~
0.5
T
0,35 Cf
..
0,35

1~·-~ 'f~ ~
ro/gr

'"'"" l~'"'"'"
T l oag/3

0.35 0.35 0,35 0.35

0. 35

~s:=r=6
ro/gr

E'"' t:j ·~~..I .

1/3 1

0.5
~
0.35
I I I
0,35 0,35 0,35
er
0.35

·: :' ·: T ~· E;]) I
rolgr

11

J~ rf ws = wh1 e
T 5c/3 WS=Wle

0,35 0,5 2.5

r v..
2.5 0.35
r,:::J
1·;,u-"I
2.5 2.5
sw =black
ro
br
gn
=red
=brown
=green
sw = black
ro = red
br = orown
gn =green
ro/gr br br br bl = blue bl = blue
I ~ blr
gr =grey gr =grey

lsI@Is
L1os Ii =violet 11 = violet
ge =yellow ge = yellow
8
19 20 23 28 32 33 40 42
1 97·5 1874 1 1 97-51875 1

E41 - R1gh1 Front Window Switch Ground co11nect1on 1 ,n oower vv1ndow w1r1rlg harress E52 Le" Rear Window Switch. !In LR Doorl Ground conrec ron -1-. 1n powec w.ndow wiring harness
E107 - Sw11ch for window regulator, n passenger door E53 Leh Rear Window Switch. lln Console)
J296 - R1gh Front Power W1 dow Control Module Ground connec~1on. in passenger's door wiring arness J245 - Power Sunroof Control Module Grou•1d connection. 1n le rear door wiring harness
L 109 Door opener lighting passenger side J297 Leh Rear Power Wrndow Con rol Module
T5c Conn ctor 5 pin, black, 1n passenger's door J429 - Control module for central locking Plus connec11on 1871, in pow r window/central locking
T10ag- Connector 10 pin, red, connector station A pillar right L48 Left Rear Ashtray Light system and door contact switch wiring harness
T15k Connector 15 pin, red. connector sta11on A pillar, !eh L 110 Door op ner l1ght1ng, left rear
V15 Right Window Motor T4 c Connector 4 pin, black. 1n leh rear door
T6u Connector 6 prn grey, connector station A prllar. leh
T6ad Connector 6 pin, blue, on power sunroof con trol module
T10ah - Connec1or 10 pin. red. 1n 8 pillar, leh
T15k Connector 15 pin, red connec!or s1a11on A pillar. leh
Tl7b Connector 17 pin. blad., connector station A pillar, right
T17d Connector 17 prn, grey, connector statron A prllar. le
V26 Leh Rear Door Window Motor

Edition 09 / 02 Right Front Power Window Control Module, Left Rear Window Switch , Left Rear Power Edition 09/ 02
W42 USA 5603 09 21 Right Front Window Switch Window Control Module W42 .USA5603 .09.21
Audi AG Wiring diagram No. 19/5 No. 19/6 Wiring diagram Audi AG $::J m
~
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30
15
x
31
15
x
31
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~-30
15
x
31
15
x
31
2- 0
~
I
~

t\) ~
a I'\)
a
-.l.
E 55 D '-'
('5
4,0
m

ef 0,5
CD
()
...+
~

()
OJ
-
T
0, 35
gr/bl ~
~
f T1oau10

0,35
::J
(Q
n
"!·"~I
113 1
OJ
(Q
ot ! 15 15 15
~

Tr~:~I
0,5 0,5 0,35 0.35
OJ
gr/bl

~ ~ ~
3
V 21

Fl
ws
sw
ro
br
gn
=white
=b lack
=red
=brown
=green
ws
sw
ro
br
gn
= white
=black
=red
=brown
=green 0,35
ef 0,35
CJ)

l~ ler®
0.35 2,5 2.5
bl =b lue bl =bl ue b< gr/b l

~ '~ I
Is
gr =grey gr =grey
58s
bl' Ir = vrole t Ii = violet T32/20
ge =yellow ge =ye llow
8 J 21s

45 46 48 49 51 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
1 97 -51876 1 1 97-51877 1

E54 Right Rear Window Switch, (In RR Door) Ground connection -1-. in power window w1rrng harness D lgn1t1on/Starter Sw1tc Ground connection. 1n drivers door wirrng harness
E55 Rrght Rear Window Swrtch. !In Console! E39 Window Lockou t Switch
J298 - Right Rear Power Window Control Module Ground connection. rn righ rear door w1r.ng harness E150 - Switch for interior lock. driver side
L49 Right Rear Ashtray Lrght Plus connection ( 151. 1n instrument panel wiring harness
J218 Instrument Cluster Combination Processor
L111 Door opener "ghting. right rear
T6u Connector 6 pin. grey, connector station A pillar. leh
T4d Connector 4 pin. black. in right rear door Wire connection (58sl. in instrument panel wiring harness
TlOa1 - Connector 10 pm red. 1n B pillar, right T10ag- Connector 10 pin, red. connector station A pillar. right
T15' Connector 15 pin, red. connector station A pillar. leh T10ah - Connector 10 pin. red. 1n B pillar le
T10a1 - Connector 10 pin. red. 1n B pillar. right Plus connection 1581. 111 power window wiring harness
V27 Rrght Rear Do01 Window Motor
T15k Connector 15 prn. red connector sta ion A pillar. leh
T32 Connector 32 prn, blue. on 1nstrumen cluster Plus connection 175sl. 1n power wrndow w1rrng harness

Edition 06/00 Right Rear Window Switch , Window Lockout Switch Edition 06/ 00
W42 USA.5603 01.21 Right Rear Power Window Control Modul e W42.USA.5603 0121
Audi AG Wiring diagram No. 19/7
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30
15 15
x x
31 31

T6a d/3

1
0.35

I I I I I I
l.. . l·~ l:··
0.35 0.35 0.35 0,35 0,35

fr..~ tr.... fr...

J;
Ii

o!J THIS SPACE INTENTIONALLY

LEFT BLANK
0,35 0.35 0,35 0,35 0,35 0,35

~ ~ ~ j; ~ ~ ws
sw
= whi te
=black
ro = red
br =brown
gn = green
bl =blue
gr =grey
Ii = vi olet
ge =yellow

72 75 78 81 83 84
1 97-51878 1

J 245 - Power Sunroof Control Module Connection (openl. 1n wifing harness ·ntenor
J429 - Control module for central locking
T6u Connector 6 pin. grey. connector station A pillar. left Connection lclosedl, 1n Wifing harness interior
T6ad Connector 6 pin. blue, on power sunroof control module
TlOag - Connector 10 pin, red. connec tor station A pillar. right
T10ah- Connector 10 pin, red 1n B pillar, left
T10a1 Connector 10 pin. red . 1n B pillar. right
T17 Connector 17 pin, orange, connector station A pillar. nght
Tl7d Connector 17 pin. grey. connector station A pillar, left

Edition 06/00 Power Windows

W42 USA5603 .0l21
AudiA6 Wiring diagram No. 23/1 No. 23/2 Wiring diagram AudiA6 (J)
ct>
m
30
o:i
Ci)"
~
Heated Seats
15
x 0
31
I\) __,.
I

~ a
a ~
~
--l.
"-"
2001 m . y.

Fuse Panel
m
Fuse Colors:
CD
30 A Green ()
25 A Whi te ....+
20 A Yellow ~
15 A Blue
10 A Red ()
,5 A Brown
5 A Beige
Q)

Starting with fuse pos1t1on 23 . fuses 1n the fuse holder

are 1dent1 f1ed wi th 223 1n the wiring diagram .
:::::J
(Q

Micro Central Electric Panel

0
T11c111 (Q
2.5 t ~

r~s
rn z, OJz32 Q)
3
~ ws =white
sw =black
ro = red
0,5
'T2af/2
1,5
I
1,5
CJ)

I I I br = brown
br/sw br br

A B C gn =green
bl =blue
gr =grey
T11c1J 'Tss11 ~
fefe
0 ,5
Ii =violet
ge =yellow

10 14
197·5 15351

E94 Adjuster for heated driver's seat Ground connection - 1-, in heated seats w1nng harness
G59 Driver's Heated Seat Temperatu re Sensor
J218 - Instrument Clus ter Comb1na t1 on Processo r Wire connection (58sl. in instrument panel w1n ng harness
S244 - Fuse 44 1n fuse holder
T2a Connector 2 pin. black, below driver's sear Wire connection (15al , 1n instrument panel w1nng harness
T6s Connector 6 pin. g1een, below driver's seat
T17c Connector 17 pin, green. connector stat ion A pil lar. right Plus connection (301. 1n instrument panel wiring harness
T32 Connector 32 pin. blue, on instrument cluster
Z6 Driver's Seat Heating Element
Connector (30a.S2441, 1n instrument panel w1nng harness
Z7 Driver's Backrest Heating Element
Z31 Driver's Seat Side Bolster Hearer
Z32 Driver's Seat Backrest , Side Bols ter Hearer

Edition 06/00 Adjuster for Heated Driver's Seat, Edition 06/ 00

W42 USA5603 0121 Driver's Backrest Heating Element W42.USA.5603.0l21
Audi AG Wiring diagram No. 23/3 No. 23/4 Wiring diagram Audi AG
30~~~~~~~~~~~~~~~~~~~~~~~~~~~~30 30~~~~~~~~~~~~~~~~~~~~~~~~~~~~-30

15 15 15 15
x x x x
31 31 ~ ~

~
15
~
0,5
~
0.35

~ Cfl
~·r:
== f'lem
1,5 0,5

btl/g~17cblt/w~17c/5
/16
b~~. 17
0.5 1,5 0.5
tT•

fe rl~·l·
912
0.5 0,5 0.5
sw/ws br

2.5 1.5 1.5 0.5

l T TT
~.~! ,,rn Z.ct::!JG.
rnI rnb·g
T•911
1.0

sw/ro
Z3• Z9
m
I
1.5
IT~g
1.5 0.5
ws
sw
ro
= whrte
=black
=red
ws
sw
ro
= whrte
= olack
=red
0.5
br
' T2ad12

1.5
br
' T2ae/2

1.5
br br
CD
()
......+
:::::!.
~T6u3b,~6U1
br =bro\!\ n br =brown ()
6,0
br
1.5
br
0,5
br
2,5
br
4,0
br
gn
bl
gr
Ir
=green
=blue
=grey
= vrolet
gn
bl
gr
11
= green
=blue
=grey
= violet
0,5
br
UT41 3
1.0
br
t=-1
1,0
br
tu

15 20
8 @
25
8 8
28
ge =yellow ge =yellow

30 31
@
32 33 34
e 35 36
e 38 39 42
197-5 1536 1 ) 97-51537 1

E95
G60
Aa1ust 'for hea:ed oassenger's seat
Passenger's Hea:ed Sedt Temperature S nsor
G Gro1.nd conni;ct1or or pf! A·p1 lar ov.·er part E77
E78
Let: Rear Hea:ed Seat Sw11c
Right Rear H8<i:ed Seal Swr tch
e Gm 1r;a conn ct1or -I . n f·P.ated sea'.s v\'tring harriess
co
::::J

S5 F.i e 0 Ground conn ct1on 1 ·n heated seats vwrng l1arr.ess E 128

E129
Leh Rear Hea ed Seat Reg-J.at1ng Switch
R1gh · Rear Heated Seat Re ula•.ng Sw11ch 0
T2ag Connector 2 pin b1ack. below assenge1's seat
@ Ground connect1or -3-. •1 1nstrun1en1 pan I w.r,ng harness G 4
G 5
Leh Rear Hea ea Seat Ternpera ure Sensor
Rrght Rear Heated S dt Temp rature Sensor
T6t Connector oin. gr en. below passenger's seat
T2ad Connector 2 pin, IJlack, lielow rear seal, le tu
T17c Connector 17 pin green. connec1or station A p1I a• ngn1
0 T2ae Conneco• 2 pin black elaw 'ea1 seat righ: co
ZS
Z9
Z33
Passenger's Seat Heating ElemerH
Passenqer's Backres1 ar111g Eleq1en
PassMger's Sea1 Side Boister Heat r
e Plus connection ( 151. 1ri 111sirumen1 panel w11n1g harness
T-lf
T-lo
Tllc
ZIO
Connector .J p111, black l1Plow rear seat. Jen
Connector 4 pin, blac•. elow rear seat rig!•t
Connector 17 pin. green. connector statro1 A p liar rigl·t
Len Rear Seat Heating E·Pmer1t
.......
tu
Z3·1 Passenger's Seal Backrest, Side Bolster Hcoter Zll
Z 12
Len Rear Backrest Heatrng E1ernem
Right Rea1 Seat Heating Element
3
CJ)
l13 Rrght Reilr Bac•rest Heat 119 E1enier r

(J)
<ti
m
Heated Seat Regulating Switch, Edition 06/00
!l)
Ci)" ~
Edition 06/00
W42 USA 5603 01 21
Adjuster for Heated Passenger's Seat,
Passenger's Backrest Heating Element Heated Seat Temperature Sensor W42 USA 5603 01 21 0I
f\) .....L.
a
a ~
...._.
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AudiA6 Wiring diagram No. 24/1 No. 24/2 Wiring diagram AudiA6 :r: m
<D
Headlight with High Intensity Gas discharge Lamps and 30
15
30
15