Content

Maintenance

• Overview of engines
• Delivery service
• Description of work
• Type plate, vehicle identification number
• Lifting the vehicle
• Tow-starting/towing
• Vehicle tests carried out as part of inspection services and maintenance

Technical data

• Engine number
• Engine data
• Safety precautions
• General repair instructions

Removing and installing engine

• Removing engine
• Separating engine from manual gearbox
• Securing engine to engine and gearbox support
• Installing engine
• Assembly mountings

Crankshaft group

• Cylinder block
• Crankshaft
• Pistons and conrods

Cylinder head, valve gear

• Cylinder head
• Valve gear

Lubrication

• Oil pump, sump, balance shaft assembly
• Oil filter bracket and engine oil cooler

Cooling

• Cooling system
• Coolant pump and thermostat
• Coolant pipes, coolant temperature senders, coolant circulation pump
• Radiator and radiator fans

Turbocharging / supercharging

• Turbocharger
• Charge air cooling

Exhaust system

• Silencers
• Exhaust gas temperature control
• Exhaust gas recirculation system

Mixture preparation - injection

• Safety precautions and rules for cleanliness
• Injection system
• Engine control unit

Ignition system

• General notes and safety precautions
• Fuel supply system
• Fuel tank with attached components - vehicles with four-wheel drive
• Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive
• Supplementary fuel pump
• Fuel filter
• Bleeding fuel system
• Checking fuel system for leaks
• Accelerator pedal module

Glow plug system

• Anti-lock brake system
• General information on the anti-lock brake system
• Connecting VAS 505x and selecting functions
• Components and fitting locations on brake system ABS/ESP Mark 60
• Removing and installing parts of ABS/ESP system
• ABS/ESP Mark 60 control unit -J104- and hydraulic unit -N55-
• TFSI engine: ABS control unit -J104- and ABS hydraulic unit -N55-
• Vehicles with diesel particulate filter: Control unit -J104- with hydraulic unit -N55-
• ABS/ESP system components on front axle
• ABS/ESP system components on rear axle (front-wheel drive vehicles)
• ABS/ESP system components on rear axle (four-wheel drive vehicles)

Brakes - mechanism

• Servicing front brakes
• Servicing front brakes 17" FNR G57
• Servicing front brakes (TT RS)
• Pressing back brake piston in front brake caliper
• Vibration damper on brake caliper - front brakes
• Servicing rear brakes
• Handbrake
• Brake pedal

Brakes - hydraulics

• High-pressure and low-pressure tests
• Servicing front brake caliper FN3
• Servicing front brake caliper FNRG57
• Servicing brake caliper (TT RS)
• Servicing rear brake calipers
• Bleeding brake system - ABS/ESP Mark 60
• Brake servo/brake master cylinder - left-hand drive vehicles
• Exhauster pumps
• Brake lines and brake hoses

Front suspension

• General notes
• Subframe, anti-roll bar, wishbone, swivel joint, vehicle level sender
• Wheel bearing housing, wheel bearing unit
• Audi magnetic ride (AMR) - electronic damping control
• Suspension strut
• Drive shafts

Rear suspension

• General notes on rear axle
• Subframe, diagonal strut, lower transverse link, upper transverse link, track rod, vehicle level sender (front-wheel drive)
• Wheel bearing housing, wheel bearing unit, trailing arm with mounting bracket, stone deflector
• Shock absorbers, coil springs
• Anti-roll bar
• Subframe, lower transverse link, upper transverse link, track rod, vehicle level sender (fourwheel drive) - Coup?
• Subframe, diagonal struts, cross member, lower transverse link, upper transverse link, track rod, vehicle level sender (four-wheel drive) - Roadster
• Wheel bearing housing, wheel bearing unit, trailing arm with mounting bracket
• Shock absorbers, coil springs
• Anti-roll bar
• Drive shafts

Wheels, tyres, vehicle geometry

• Wheels, tyres
• Tyre monitor display
• Tyre pressure monitoring system
• Wheel alignment

Steering

• General repair instructions
• Steering wheel with airbag
• Steering column, mounting bracket with strut
• Electro-mechanical steering box

Starter, current supply, CCS

• Contact corrosion
• Battery
• Removing and installing alternator
• Checking and servicing alternator
• Removing and installing starter
• Cruise control system

Gauges, instruments

• Contact corrosion
• Instrument cluster
• Cigarette lighter, 12 V electric socket
• Horns
• Data bus diagnostic interface

Windscreen wash / wipe system

• Contact corrosion
• Windscreen wiper system
• Windscreen washer system
• Headlight washer system
• Washer fluid hoses

Lights, bulbs, switches - exterior

• Contact corrosion
• Halogen headlights
• Bi-xenon gas discharge headlights with cornering light
• Bi-xenon gas discharge headlights with cornering light, LED daytime running light
• Automatic headlight range control
• Fog lights
• Checking and adjusting headlight settings
• Turn signal repeater
• Tail light cluster
• Exterior lights (rear)
• Steering column switch module
• Lock cylinder and ignition/starter switch with steering lock
• Parking aid

Lights, bulbs, switches - interior

• Contact corrosion
• Lights and switches in dash panel
• Lights and switches in front doors
• Lights and switches in centre console, luggage compartment
• Lights and switches in roof trim
• Immobilizer
• Ultrasonic interior monitoring

Wiring

• Contact corrosion
• Relay carriers, fuse carriers (engine compartment)
• Relay carriers, fuse carriers (vehicle interior, luggage compartment)
• Repairing wiring harnesses and electrical connectors
• Repairing connector housings and electrical connectors
• Releasing and dismantling connector housings
• Cleaning contact surfaces with contact surface cleaning set VAS 6410
• Repairing aerial wires
• Fibre optic cables
• Vehicle diagnostic, testing and information systems

Radio, telephone, navigation

• Radio system
• Radio system (USA)
• Sound system
• Aerial system (Coup?)
• Aerial system (Roadster)
• Telephone systems
• Telephone system (USA)
• Navigation system RNS-E
• Navigation system RNS-E (USA)
• Navigation system RNS-JP4
• Navigation system RNS-JP5
• Navigation system RNS-Low
• CD changer R41
• iPod holder R192
• Connection for external audio sources R199
• Multi-function steering wheel
• Steering column electronics control unit J527

Air conditioning system

• General information on air conditioning systems
• General information on refrigerant circuit
• Laws and regulations
• Problems with refrigerant circuit
• Connecting air conditioner service station
• Checking pressures
• Renewing components of refrigerant circuit
• Capacities for refrigerant R134a, refrigerant oil and approved refrigerant oils
• Test equipment and tools

Heating

• Notes on heater repair work
• Components for control and regulation of heater
• Heater components
• Dismantling and assembling heater

Air conditioning system

• Safety measures when working on vehicles with air conditioner and for handling refrigerant
• Notes on air conditioner repair work
• Servicing work on refrigerant circuit
• Replacing air conditioner compressor pulley
• Components for control and regulation of air conditioner not located in passenger compartment
• Components for control and regulation of air conditioner located in passenger compartment
• Air conditioner unit components
• Removing and installing heat exchanger of air conditioner unit (heater)
• Block diagram of air distribution system
• Checking cooling output of air conditioner
• Checking heat output of air conditioner
• Servicing refrigerant circuit
• Dismantling and assembling air conditioner unit
• Capacities

General body repairs

• Technical data
• Interior equipment
• Passenger protection
• Trim, insulation
• Seat frames
• Seat - padding, covers
• Body - front
• Body - centre
• Front doors, door components, central locking
• Convertible roof, hardtop, canopy
• Bumpers
• Glazing
• Exterior equipment

Clutch

• Overview - clutch mechanism
• Notes on removing and installing clutch master cylinder and slave cylinder
• Exploded view - pedal cluster, clutch master cylinder
• Exploded view - hydraulic system (LHD vehicles)
• Exploded view - hydraulic system (RHD vehicles)
• Exploded view - clutch release mechanism
• Overview - servicing clutch

Controls, housing

• Overview - selector mechanism
• Removing and installing gearbox
• Exploded view - assembly mountings
• Checking gear oil level and filling up with gear oil
• Overview - gearbox
• Exploded view - gearbox housing and clutch housing
• Exploded view - servicing selector unit
• Exploded view - selector forks

Gears, shafts

• Exploded view - input shaft
• Adjusting input shaft
• Adjusting output shaft
• Exploded view - reverse shaft

Final drive - differential

• Renewing flange shaft oil seals with gearbox installed
• Exploded view - differential
• Table of adjustments
• Adjusting differential

Current flow diagram