Maintenance audi 100

Service. �

Maintenance

Audi 100 1991 >

Booklet No. 54: Audi 100 1991>

Edition 01.98

Booklet

Service Department. Technical Information

Service. �Maintenance

Audi 100 1991 >

Booklet No. 54: Audi 100 1991>Edition 01.98

Booklet

Technical Bulletins

Oil Change Service

Inspection Service

Lifting the vehicle

Tow-starting/towing

Technical Information should always be available to all foremen and mechanics, because their com- pliance withthe instructions given is essential to ensure vehicle roadworthiness and safety. In the normal safety precautionsto be observed when working on motor vehicles are also applicable.

All rights reserved.

No reproduction without prior agreement from publisher. Printed in Germany

Copyright © 1998 Audi AG, Ingolstadt 005.5251.50.20

Contents

Page- Survey of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Oil Change Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Inspection Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- Windscreen wiper and washer system and headlight washer system: adjust washer jet settings and check function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- Windscreen washer system: check washer jet settings and adjust if necessary . . . . . . . . . . . . . . . . . . . . . . . 15- Headlight washer system: check washer jet settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18- Wiper blades: check park position and check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18- Self-diagnosis: interrogate fault memory with fault reader V.A.G 1551 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- Service interval display: reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24- Door arresters and lock cylinders: lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- Sun roof: check function, clean guide rails and spray with lubricating spray . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- Removing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- Battery: check electrolyte level and top up with distilled water if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . 32- Removing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34- Engine (from above and below) and engine compartment: visual check for leaks and damage . . . . . . . . . . . . 38- Windscreen / headlight washer system: top up fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39- Cooling system: check antifreeze and top up coolant if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40- Coolant G11: Change (V8 petrol engines only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44- Air cleaner: clean housing and replace filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45- Spark plugs: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47- Hydraulic system: check for leaks, check fluid level and top up hydraulic fluid if necessary . . . . . . . . . . . . . . . 54- Fuel filter: replace (diesel and TDI engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56- Fuel filter: drain off water (Diesel and TDI engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58- Dust and pollen filter: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- Plenum chamber and water drain valves: check for dirt and clean if necessary . . . . . . . . . . . . . . . . . . . . . . . . 63- Noise insulation: remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64- V-belt: check for damage and check tension; adjust tension if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65- V-belts: tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66- V-belt (not ribbed belt) for alternator: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70- Ribbed belt: check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72- Ribbed belt: check tension; adjust if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73- V-belt and ribbed belt: replace (4-cyl. 5V engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74- Ribbed belt: replace (V6 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77- Toothed belt for camshaft drive: check for damage and measure toothed belt width (4-cyl. TDI engines) . . . . 81- Toothed belt for camshaft drive: check for damage and check tension (5-cylinder diesel and TDI engines) . . . 82- Toothed belt for injection pump: check for damage and check tension (5-cyl. TDI engines), tension toothed belt85- Toothed belt for camshaft drive: check for damage (2.6l 2V and 2.8l 2V engines only) . . . . . . . . . . . . . . . . . . 89- Toothed belt: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90- Manual gearbox/final drive: check oil level and top up if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93- Final drive (automatic gearbox): check oil level and top up if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100- Engine oil: drain or extract, change oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104- Brake system: visual check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107- Brake pads: check thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108- Underseal: visual check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112- Track rod ends: check play, attachment and protective boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112- Tyres: check and correct condition, wear pattern, tread depth and inflation pressures . . . . . . . . . . . . . . . . . . 113- Wheel bolts: tighten to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115- Engine oil: fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118- Engine: check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122- Automatic gearbox: change ATF (except 01N gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123- Idling speed: check and adjust if necessary (2.4 ltr diesel AAS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142- Brake fluid level (depending on brake pad wear): checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144- Brake fluid: change brake fluid (every 24 months) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146- Headlights: check settings and adjust if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150- Test drive: perform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154- Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155- Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158Lifting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164- Arbeitsabläufe Benzinmotoren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169- Arbeitsabläufe Dieselmotoren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

- Abgasuntersuchung Deutschland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171- Arbeitsabläufe Benzinmotoren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172- Störgröße vorbereiten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173- Prüfgeräte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177- Prüfablauf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179- Prüfung mit Fehlerspeicher-Abfrage (V.A.G 1551) zur Lambda-Regelkreisprüfung . . . . . . . . . . . . . . . . . . . . . . 189- Prüfung ohne Fehlerspeicher-Abfrage (V.A.G 1551) zur Lambda-Regelkreisprüfung . . . . . . . . . . . . . . . . . . . . 190- Arbeitsablauf Dieselmotoren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231- Prüfgeräte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232- Prüfablauf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Survey of engines

1 The order in which the individual operations are given has been tested and represents the optimum work-ing sequence. The sequence should therefore be followed to avoid unnecessary work interruptions.

1 The sequence of operations given is based on that specified for the Inspection Service, which is the typeof service most frequently required.

1 Always inform the customer if faults or defects which need repairing are identified during the InspectionService.

Code ADA ABB ADR AAE ADW AAD ABK

No of cylinders 4 4 4 4 4 4 4

Valves per cylinder 2 2 5 2 2 2 2

Capacity l 1.6 1.6 1.8 2.0 2.0 2.0 2.0

Output kW at rpm 746000

756100

925800

745500

795300

855400

855400

Torque Nm atrpm

1303200

1273700

1733950

1572750

1603200

1683200

1663200

Bore øin mm 81.0 81.0 81.0 82.4 82.5 82.5 82.5

Stroke mm 77.4 77.4 86.4 92.8 92.8 92.8 92.8

Compression 10.5 10.0 10.3 9.3 9.0 10.3 10.5

1

Code ADA ABB ADR AAE ADW AAD ABK

Injection/Ignition

Multi PointInjection

K-Jetronic/TSZ-h

Motronic Mono-Motronic

Digifant KE-Motronic

Digifant

RON at least 95(unleaded)

2)

98(unleaded or

leaded) 3)

95 1)

(unleaded)91

(unleaded)88

(unleaded orleaded)

95 1)

(unleaded)2)

95 1)

(unleaded)2)

Hydraulic valve liftersX X X X X X X

Self-diagnosis X - X X X X X

Catalytic converter X / - 4) - X X - X / - 4) X / - 4)

Lambda control X - X X X X X

Exhaust emission testafter3, 5, 7, 9 ... years X X X X X X X

1) Regular unleaded petrol RON 91 can be used but will cause a slight loss of power.2) Unleaded for vehicles with catalytic converter; unleaded or leaded for vehicles without catalytic converter.3) When using Premium unleaded petrol 95 RON adjust ignition timing to 3 ± 1° before TDC.4) Optional in some countries.

2

Code ACE AAN AAR AFM ACZ ABC AEJ



Capacity l 2.0 2.226 2.3 2.4 2.6 2.6 2.8


1695900

985500

1105800

1025750

1105750

1205400

Torque Nm atrpm

1854500

3501950...3000

1864000

2103300

2103500

2253500

2353000

Bore øin mm 82.5 81.0 82.5 81.0 82.5 82.5 82.5

Stroke mm 92.8 86.4 86.4 77.4 81.0 81.0 86.4

Compression 10.8 9.3 10.0 10.0 9.0 10.0 9.2

Injection/Ignition

KE-Motronic

Motronic KE III-Jetronic/

VEZ

Multi PointFuel

Injection

Multi PointFuel

Injection

Multi PointFuel

Injection


RON at least 95 1)

(unleaded)95 or 98

(unleaded)95 1)

(unleaded)95

(unleaded)88

(unleaded orleaded)

95 1)

(unleaded)88

(unleaded orleaded)

1) Regular unleaded petrol RON 91 can be used but will cause a slight loss of power.

3

Code ACE AAN AAR AFM ACZ ABC AEJ

CN at least - - - - - - -


Self-diagnosis X X X X X X X

Catalytic converter XX X X - X -

Lambda control X X X X X X X

Exhaust gas recircula-tion system

- - - - - - -

Turbocharging - X - - - - -


4

Code AAH ACK ABH AEC AHK 1Z AHU



Capacity l 2.8 2.8 4.2 4.2 4.2 1.9 1.9


1426000

2065800

2135800

2406500

664000

664000

Torque Nm atrpm

250 5)

30002803200

4004000

4004000

4003500

2021900 7)

2021900

Bore øin mm 82.5 82.5 84.5 84.5 84.5 79.5 79.5

Stroke mm 86.4 86.4 93.0 93.0 93.0 95.5 95.5

Compression 10.3 10.6 10.6 10.8 11.6 19.5 19.5

Injection/Ignition


Motronic Motronic Motronic Motronic Diesel(direct injec-

tion)

Diesel(direct injec-

tion)

RON at least 98 5)

(unleaded)95 1)

(unleaded)98 6)

(unleaded)98 6)

(unleaded)98 6)

(unleaded)- -

1) Regular unleaded petrol RON 91 can be used but will cause a slight loss of power.5) If premium unleaded petrol 95 RON is used, there will be a reduction in torque (245 Nm at 3000 rpm).6) Premium unleaded petrol RON 95 can be used but will cause a slight loss of power.7) Vehicles with an airflow meter: 182 Nm at 2300 ... approx. 2500 rpm

5

Code AAH ACK ABH AEC AHK 1Z AHU

CN at least - - - - - 45 45


Self-diagnosis X X X X X X X

Catalytic converterX X X X X

Oxidisingcatalytic

converter

Oxidisingcatalytic

converter

Lambda control X X X X X - -

Exhaust gas recircula-tion system

- - - - - X X

Turbocharging - - - - - X X


6

Code AAS AAT ABP AEL

No of cylinders 5 5 5 5

Valves per cylinder 2 2 2 2

Capacity l 2.4 2.5 2.5 2.5


854000

854000

1034000

Torque Nm at rpm 1642400...2500

2652250

2652250

2901900

Bore øin mm 79.5 81.0 81.0 81.0

Stroke mm 95.5 95.5 95.5 95.5

Compression 23.0 20.5 20.5 20.5

Injection/Ignition

Diesel(swirl chamber)

Diesel(direct injection)



RON at least - - - -

7

Code AAS AAT ABP AEL

CN at least 45 45 45 45

Hydraulic valve liftersX X X X

Self-diagnosis - X X X

Catalytic converter-

Oxidising catalyticconverter -

Oxidising catalyticconverter

Lambda control - - - -

Exhaust gas recirculation system - X X X

Turbocharging - X X X

Exhaust emission test after3, 5, 7, 9 ... years

X X X X

8

Oil Change Service

Work to be completed afterevery 7,500 km

only for vehicles with diesel engines (engine code AAS) Page

OIL 1) Work to be completed afterevery 15,000 km

only for vehicles completing over 15,000 km a year

Plenum chamber and water drain valves: Check for dirt and clean if necessary 63

Fuel filter: Drain water (diesel and TDI engines only) 58

Toothed belt for camshaft drive: check for damage and measure toothed belt width (4-cyl. TDI enginesonly) 81

Engine oil: drain or extract, change oil filter 104

Brake pads: check thickness of disc brake pads 108

Engine oil: fill 118

Service interval display: reset (Audi A6 / S6 only) 24

Audi service sticker: enter date for next service (and for brake fluid change) on sticker and affix on left ofdash panel or on door post (B-pillar)

1) Inspection due according to service interval display (Audi A6 / S6 only)

9

Inspection Service

Inspec-tion 1)

Interval Work to be completed Page

In 1 Every 12 months Jobs without -/-- positions

In 1 Every 30,000 km Jobs required every 12 months including -positions

In 1 One-off inspection after60,000 km

Toothed belt for camshaft drive: replace(5-cyl. TDI engines > 1994 only)

In 1 Every 60,000 km Jobs required every 12 months including -/--positions

In 1 Every 90,000 km In addition to Inspection Service:Ribbed belt: replace (V6 engines >1994 only)Toothed belt for camshaft drive and tensioning roller: replace (4-cyl.TDI engines only)

91

In 1 Every 120,000 km In addition to Inspection Service:V-belt and ribbed belt: replace (4-cylinder 5V engines)Ribbed belt: replace (V6 engines >1995 only)Toothed belt: replace (4 and 5-cyl. petrol engines)Toothed belt for camshaft and injection pump: replace(5-cyl. diesel engines)Toothed belt for camshaft and injection pump: replace(5-cyl. TDI engines)Toothed belt and tensioning roller: Replace (V6 5-valve engines only)Toothed belt and ribbed belt: Replace (V8 engines only)

91

10

Inspec-tion 1)

Interval Work to be completed Page

In 2 Every 24 months In addition to Inspection Service:Brake fluid: change 146

In 1 Every 36 months In addition to Inspection Service:Coolant G11: Renew (V8 petrol engines only)Coolant "G12" need not be changed, even after changing from "G11"to "G12" coolant

44

After the first 36months, then every 24months

Exhaust emissions test 169

Work to be completed 5

1) Inspection due according to service interval display (Audi A6 / S6 only)

Work to be completed Page

Front and rear lights, turn signals, hazard warning lights, luggage compartment lights: check func-tion

Interior lights and glove compartment light, warning lamps, horn: check function

Windscreen wiper and washer system and headlight washer system: adjust washer jet settingsand check function

15

Wiper blades: check park position and check for damage 18

Self-diagnosis: interrogate fault memory with fault reader V.A.G 1551 21

Service interval display: reset (Audi A6 / S6 only) 24

Door arresters and lock cylinders: lubricate 30

- Sun roof: check function, clean guide rails and spray with lubricating spray 31

Battery: check electrolyte level and top up with distilled water if necessary 32

11

Engine (from above) and engine compartment: visual check for leaks and damage 38

Windscreen / headlight washer system: top up fluid 39

Cooling system: check antifreeze and top up coolant if necessary 40

-- Air cleaner: clean housing and replace filter element(every 60,000 km or every 2 years, whichever comes first) 45

- Spark plugs: Replace (vehicles > 1993) 47

-- Spark plugs: Replace (vehicles 1994 >, every 60,000 km or every 3 years, whichever comes first) 47

Continued 5

- Hydraulic system: check for leaks and check fluid level, top up hydraulic fluid if necessary (vehicles >1991 only)

54

-- Hydraulic system: check for leaks and check fluid level, top up hydraulic fluid if necessary (vehicles >1992 only)

54

- Fuel filter: Replace (diesel and TDI engines only) 56

Fuel filter: Drain water (diesel and TDI engines only) 58

- Dust and pollen filter: replace(Audi 100 > 1992 with 2V1 => vehicle data sticker, Audi 100 1993 > 1994 without air conditioner,Audi A6 1995 >) 61

Plenum chamber and water drain valves: Check for dirt and clean if necessary 63

V-belt: check for damage and check tension; adjust tension if necessary 65

-- V-belt (not ribbed belt) for alternator: Replace (vehicles > 1993 only) 70

- Ribbed belt: check for damage (vehicles > 1994 only) 72

- Ribbed belt: check tension; adjust if necessary(4-and 5-cyl. 1993 engines only) 73

Toothed belt for camshaft drive: check for damage, measure toothed belt width(4-cyl. TDI engines only) 81

12

- Toothed belt for camshaft drive: check for damage and check tension(5-cyl. diesel and TDI engines only) 82

- Toothed belt for injection pump: check for damage and check tension (5-cyl. TDI engines),adjust tension of toothed belt - Additional job 85

Continued 5

-- Toothed belt for camshaft drive: check for damage (2.6l 2V and 2.8l 2V engines only). 89

Engine (from below): visual check for leaks and damage 38

Gearbox, final drive, steering and protective boots: visual check for leaks and damage

- Manual gearbox/final drive: check oil level and top up if necessary 93

-- Final drive (automatic gearbox): check oil level and top up if necessary 100

Engine oil: drain or extract, change oil filter 104

Brake system (from below): visual check for leaks and damage 107

Brake pads: check thickness 108

- Underseal: visual check for damage 112

Exhaust system: visual check for leaks and damage, check that parts are properly secured

Track rod ends: check play, attachment and protective boots 112

Ball joints: check protective boots for leaks and damage

Tyres (incl. spare wheel): check condition and wear pattern 113

Tyres (incl. spare wheel): check and record treaddepths

FL FR RR RL Spare 114

Tyres (incl. spare wheel): Inflating to correct pressures 114

Engine oil: fill 118

-- Automatic gearbox: change - ATF (additional job) (every 60,000 km or every 4 years, whichevercomes first)

123

13

Idling speed: check and adjust if necessary (2.4 ltr diesel AAS only) 142

Continued 5

Brake fluid level (depending on brake pad wear): check 144

- Headlights: check settings and adjust if necessary 150

Audi service sticker: enter date for next service (and for brake fluid change) on sticker and affix onleft of dash panel or on door post (B-pillar)

Test drive: perform 154

14

Windscreen wiper and washer systemand headlight washer system: adjustwasher jet settings and check function

Note:

If the wiper blades judder or make a noise whentested, check the contact angle of the wiper blades=>Page 19.

Windscreen washer system: checkwasher jet settings and adjust if neces-sary

Special tools required

♦ Windscreen wiper jet adjusting tool 3125 A withneedle 3125/5

Note:

Never use pins or other sharp objects as these willdamage the water channels in the jet.

Windscreen washer jet settings

- Mark the four points on the windscreen with wa-ter-soluble ink.

15

Setting dimensions:

♦ Dimension a = 230 mm ♦ Dimension b = 280 mm ♦ Dimension c = 160 mm ♦ Dimension d = 480 mm

Note:

The setting dimensions are calculated from the outeredges of the windscreen.

- Use the special tool 3125 A to aim the individualjets at the points marked.

Notes:

♦ The setting dimensions give the values for thevehicle when moving. The spray from the jetswill be slightly offset when stationary.

♦ If the jet of water is irregular or cannot be adjus-ted to the specified setting, replace the jet (re-pair measure).

16

Rear window washer jet setting

- Adjust the washer jet using special tool 3125 Aso that the water jet is directed onto the rear win-dow within the dimension a = 280 mm above thewiper arm pivot mounting.

17

Headlight washer system: check washerjet settings

The headlight washer jets are set by the manufac-turer and therefore do not require adjustment.

Wiper blades: check park position andcheck for damage

Park position for windscreen wiper blades

- Switch windscreen wipers on and off and allowto return to the park position.

- Check that the wiper blades are in the correct po-sition on the windscreen.

- A - End of wiper blade on passenger's side atupper edge of dotted pattern.

- B - Wiper blade on driver's side: a = 10 mmbelow upper edge of dotted pattern.

Note:

The positioning is symmetrically opposite for right -hand drive vehicles.

- If necessary, loosen the wiper arm, align andtighten fastening nut.

- Actuate flick wipe switch and check settings.

Tightening torque Nm

Wiper arms to pivot mountings 16

Park position for rear window wiper blade

18

- Switch rear window wipers on and off and allowto return to the park position.

- Check that the wiper blade is on upper edge ofthe dotted pattern on rear window.

- If necessary, loosen the wiper arm, align andtighten fastening nut.


Wiper arm to pivot mounting 16

Contact angle of front wiper blades

Note:

Only check the contact angle when the wiper bladesjudder or make noises.


♦ Wiper arm adjusting tool 3358

- Switch windscreen wipers on and off and allowto return to the park position.

- Remove wiper blade.

19

- Insert wiper arm -2- in wiper arm adjusting tool3358 and secure with locking screw -3-.

- Compare angle indicated to specified value intable.

Contact angle (specifications)

Driver's side - 4°

Passenger's side - 2°

Tolerance ±0°

- If necessary, adjust the contact angle to the spe-cified value as follows:

- Place open ended spanner -1- (24 mm A/F) overadjusting tool and adjust angle of wiper arm -2-(arrows) according to specified values.

- Release wiper arm -2- from adjusting tool and re-secure with locking bolt -3-.

- Check set value against table. If necessary, re-peat setting and checking procedure until spe-ci-fied value is achieved.

- Remove adjusting tool and fit wiper blade. - Check that windscreen wiper system operates

without juddering.

20

Self-diagnosis: interrogate fault memorywith fault reader V.A.G 1551

Connecting V.A.G 1551:

- Apply the handbrake. - Move selector lever to position "P" or "N" on mod-

els with automatic gearbox. - Remove cover from additional relay carrier I on

left of plenum chamber. - Ensure that ignition is switched off, then connect

black connector to black diagnostic connection.

V.A.G Indicated on display:1) appears alternately

Note:

If the display remains blank:

=> Fault Reader Operating Instructions

- Connect white connector to white or brown dia-gnostic connection (blue connector not required).

21

- Switch on printer with PRINT key (indicator lampin key illuminates).

- Enter "1" to select "Rapid data transfer".

Interrogating fault memory

- Start engine and run at idling speed. - Briefly press brake pedal. - Enter "00" for address word "Automatic test se-

quence" and confirm entry with Q key. The V.A.G1551 transmits all known address words in se-quence.

If a control unit answers with its identification, thenumber of faults stored or "No fault detected" ap-pears on the display.

Any system faults stored will be displayed in se-quence and printed out. The V.A.G 1551 will thentransmit the next address word.

V.A.G The automatic test sequence has ended when thefollowing appears on the display:

1) appears alternately

- Switch ignition off.

If faults have been stored, they must be rectified.The fault print-out is required for carrying out the re-pair work.

Notes:

♦ It may be necessary to leave V.A.G 1551 con-nected in order to carry out the exhaust emis-sion test.

22

♦ On vehicles with 5-cyl. 2V engine (engine code"AAR") it is also necessary to interrogate thefault memory for engine electronics in "Flashcode output" mode.

Interrogating fault memory for engine electronics(engine code "AAR")

- Start engine and run at idling speed. - Press key "2" for "Flash code output". - Press ⇒ key.

Any faults (flash codes) stored in the fully-electronicignition control unit will appear in sequence on thedisplay and on the print-out.

Flash code: 4444

No fault detected

If no faults have been stored in the memory, thismessage will appear on the display:

Flash code: 0000

Output ends

After the last fault or "Flash code 4444 No faults re-cognised" has been displayed, this message will ap-pear on the display:

Notes:

♦ With the printer switched on, V.A.G 1551 willnow advance to the next step and interrogatethe fault memory of the KE III Jetronic controlunit.

♦ The idling speed will be increased while the faultmemory of the KE III Jetronic control unit is in-terrogated.

Any faults (flash codes) stored in the KE III Jetroniccontrol unit will appear in sequence on the displayand on the print-out.

23

Flash code: 4444

No fault detected

If no faults have been stored in the memory, thismessage will appear on the display:

Flash code: 0000

Output ends

After the last fault or "Flash code 4444 No faults re-cognised" has been displayed, this message will ap-pear on the display:


If faults have been stored, they must be rectified.The fault print-out is required for carrying out the re-pair work.

Service interval display: reset

Audi A6 / S6

The service interval display must be reset (usingfault reader V.A.G 1551) after each Oil Change Ser-vice or Inspection Service.

When a service is due, the type of service requiredwill be indicated by a flashing message on the triprecorder display when the ignition is switched on.The message will continue to flash for up to 60seconds after the engine has been started.

Display Type of service due

OIL Oil Change Service

In 1 Inspection Service

In 2 Inspection Service with additional jobs

The service due will be indicated either 1,000 km or10 days in advance.

24

- Connect V.A.G 1551 => Page 23. - Switch the ignition on.

V.A.G Indicated on display:1) appears alternately

- Enter "1" to select "Rapid data transfer".

Rapid data transfer HELP

Enter address word XX

Indicated on display

- Enter "17" for address word "Dash panel insert"and confirm entry with Q key.

4A1919033HGC4-INSTRUMENT CLUSTER D20 ⇒Coding 00040 WSC 12345

If following display appears (example):

- Press ⇒ key to continue. - Enter "10" to select the "Adaption" function and

confirm with the Q key.

Adaption Q

Enter channel no. XX


- Enter the required adaption channel according tothe following table.

25

Type ofservicedue

servicedueto becan-celled

Adap-tion

channel

Input value

OIL OIL 05 00015

In 1 OILIn 1 (dis-tance)In 1(time)

050607

000150003000036

In 2 OILIn 1 (dis-tance)In 1(time)In 2

05060708

00015000300003600073

Resetting SID in adaption channel 05 (OIL):

- Enter "05" to select "Adaption channel 05" andconfirm entry with Q key.

Channel 5 Adaption 1 ⇒

(-1 3-L

Indicated on display:The figure displayed indicates the number of kilo-metres remaining until the OIL Service is due (e.g."1" for 1,000 km).

- Press ⇒ key.

Channel 5 Adaption 1 Q

Enter adaption value XXXXX


- Enter "00015" for "15,000 km until next OIL Ser-vice" and confirm with Q key.

26

Note:

Always enter the distance in kilometres even forvehicles that are calibrated for miles.


(-1 3-L


- Confirm entry with Q key.


Store changed value?




Changed value is stored


- By pressing the ⇒ key complete resetting pro-cedure for SID in "adaption channel 05".

Resetting SID in adaption channel 06 (In 1):



(-1 3-L

Indicated on display:The figure displayed indicates the number of kilo-metres remaining until the next Inspection Service 1is due (e.g. 1 for 1,000 km).

- Press ⇒ key.




- Enter "00030" for "30,000 km until next InspectionService 1" and confirm with Q key.

Note:

Always enter the distance in kilometres even forvehicles that are calibrated for miles.

27


(-1 3-L














(-1 3-L

Indicated on display:The display will show the number of days remainingbefore Inspection Service 1 is due. In this example, 1 =10 days).

- Press ⇒ key.




- Enter "0036" for "365 days until next InspectionService 1" and confirm with Q key.


(-1 3-L










28





(-1 3-L

Indicated on display:The display will show the number of days remainingbefore Inspection Service 2 is due. In this example,12 = 120 days).

- Press ⇒ key.




- Enter "00073" for "730 days until next InspectionService 2" and confirm with Q key.


(-1 3-L











29

Door arresters and lock cylinders: lubric-ate

- Only grease the door arresters at the pointsshown in the illustration -arrows-.

- Lubricant: "G 052 778 A2" - Lubricate the lock cylinder.

- Lubricant: "G 052 778 A2"

30

Sun roof: check function, clean guiderails and spray with lubricating spray

- Check the sun roof for leaks. - Clean the guide rails. - Spray the guide rails.

- Lubricant: "G 052 778 A2" - Check function of sun roof.

Removing plenum chamber cover

- Pull plenum chamber cover - 1 - out of retainingclips -arrows- and lift up at the front.

- Detach plenum chamber cover to front.

Note:

When installing the plenum chamber cover, insert itcarefully under the water deflector on the bottomedge of the windscreen to prevent water from enter-ing the dust and pollen filter or the heating system.

31

Battery: check electrolyte level and topup with distilled water if necessary

Fitting location of battery:

♦ Vehicles without jump lead connection in enginecompartment:below plenum chamber cover on right

♦ Vehicles with jump lead connection in enginecompartment:below rear seat bench on right

♦ Vehicles with auxiliary heater:additional (2nd) battery on left of luggage com-partment behind cover in side trim

Vehicles without jump lead connection in enginecompartment:

- Remove plenum chamber cover => Page 31.

32

Vehicles with jump lead connection in enginecompartment:

- To remove rear seat bench, unscrew cross-headscrews on left and right.

- Raise rear seat bench slightly and take out to-wards the front.

Additional (2nd) battery on vehicles with auxili-ary heater:

- Open cover in side trim on left of luggage com-partment.

All models:

- Checking electrolyte level: - The electrolyte level should be between the

MIN and MAX markings. - If necessary, top up battery cells to max. mark

with distilled water.

Notes:

♦ For batteries with clearly visible min and maxmark, the electrolyte level can be checked visu-ally from the outside of the battery.

♦ If the electrolyte level is not visible from the out-side unscrew the battery caps.

♦ The electrolyte level must align with the markinginside the battery - plastic web - . This corres-ponds to the outer max marking.

33

Removing engine cover

- Loosen bolts and nuts -arrows- and take off en-gine cover.

4-cyl. 5V engines

V6 - 2V-engines:

34

V6 - 5V engines:

V8-engines > 1994:

35

V8-engines 1995 > :

4-cyl. TDI engines

36

5-cyl. TDI engines

37

Engine (from above and below) and en-gine compartment: visual check forleaks and damage

Perform visual check as follows:

- If necessary, remove engine cover => Page 34. - Check engine and engine compartment for leaks

and damage. - Check the pipes, hoses and connections of the

following systems for leaks, chafing, porosity andbrittleness.

- Fuel system - Cooling and heating system - Brake system

- Perform a visual check of the same areas frombelow with the vehicle raised on a lifting platformand the noise insulation removed.

Important

Faults found must be rectified (repair meas-ure).

38

Windscreen / headlight washer system:top up fluid

- Fill container in engine compartment to the topwith washer fluid.

On Avant models, the container for the rear windowwasher is at the back of the luggage compartment,behind the side trim on the right.

- To fill container, swivel filler pipe on container in-to luggage compartment -arrow-.

Note:

The washer fluid must always contain a pH-neutralscreen cleaning fluid (antifreeze in winter).

Intensive washer system

The fluid container for the intensive washer systemis on the right of the plenum chamber, next to thecover.

- Fill container right up to the top with intensivecleaning fluid "D 005 100 10".

Note:

To avoid damaging the paintwork and causing discol-ouring, do not use any other intensive cleaning fluidthan "D 005 100 10".

39

Cooling system: check antifreeze andtop up coolant if necessary

Notes:

♦ The cooling system is filled all year round with amixture of water and antifreeze/corrosion pro-tection agent.

♦ Coolant additive "G 011 A8 C" (green) is used upto vehicle identification no. 4AVN 002 872.

♦ Coolant additive "G 012 A8 D" (red) is used as ofvehicle identification no. 4AVN 002 873.

Important

The two different coolant additives "G 011 A8C" (green) and "G 012 A8 D" (red) must not bemixed together. Otherwise, this can result inserious damage to the engine.

♦ If the fluid in the expansion tank is brown, thismeans G 012 A8 D has been mixed with anothertype of coolant. In this case, flush out the cool-ing system and fill with fresh coolant. To flushthe system, fill it with clean water and run theengine for about 2 minutes. This should removeas much of the old coolant as possible.

40

♦ "G 011 A8 C" and coolant additives "conformingto TL VW 774 C" or "G 012 A8 D" and coolant ad-ditives "conforming to TL VW 774 D" preventfrost and corrosion damage, scaling and alsoraise the boiling point of the coolant. For thesereasons the cooling system must be filled allyear round with the correct anti freeze and anticorrosion additive.

Checking coolant level and topping up if neces-sary

- Check coolant level on expansion tank while theengine is cold.

♦ Coolant level between MIN and MAX marks

- If coolant level is too low, add required amountaccording to mixture ratio.

Mixture ratio

Frost protec-tion to

Coolant additive Water

- 25 °C approx. 40 % 1) approx. 60 %

- 35 °C approx. 50 % approx. 50 %

- 40 °C approx. 60 % approx. 40 %

1) For V8 engines 40 % concentration of coolantadditive is not sufficient to give adequate protectionagainst corrosion.

Notes:

41

♦ Because of its high boiling point, the coolant im-proves engine reliability under heavy loads, par-ticularly in countries with tropical climates.

♦ Protection against frost must be assured toabout - 25 °C (for V8 engines and in countrieswith an arctic climate to about -35 °C).

♦ The coolant concentration must not be reducedby adding water even in warmer seasons and inwarmer countries. The proportion of anti - freezemust be at least 40 % (50 % for V8 engines).

♦ If greater frost protection is required in very coldclimates, the amount of "G 011 A8 C" or "G 012A8 D" can be increased, but only up to 60 % (or54 % for V8 engines). This gives frost protectionto around -40 °C), as otherwise frost protectionis reduced again and cooling effectiveness isalso reduced.

Checking antifreeze and topping up coolant ad-ditive if necessary

- If the degree of frost protection is too low, drainoff the required quantity as specified in the frostprotection table (=> Page 43) and add coolant ad-ditive:

- Up to vehicle identification number 4AVN 002872"G 011 A8 C" orcoolant additive "according to TL VW 774 C"

- From vehicle identification number 4AVN 002873"G 012 A8 D" orcoolant additive "according to TL VW 774 D"

42

Note:

Observe environmental requirements for disposal.

Frost protection table

Frost protec-tion to °C

Required quantity in litres

Actualvalue

Spe-cifiedvalue

4-/5-cyl.

petrolen-gine

4-/5-cyl.

dieselen-gine

5-cyl.4V

6-cyl. 8-cyl.

0 -25 3.0 3.5 4.0 5.0 -

-35 3.5 4.0 5.0 6.0 6.0

-5 -25 2.5 3.0 3.5 4.5 -

-35 3.5 3.5 4.5 5.5 5.5

-10 -25 2.0 2.0 3.0 3.5 -

-35 3.0 3.0 4.0 4.5 4.5

-15 -25 1.5 1.5 2.0 2.5 -

-35 2.5 2.0 3.0 3.5 3.5

-20 -25 1.0 1.0 1.5 1.5 -

-35 2.5 1.5 2.0 2.5 2.5

-25 -35 2.0 1.0 1.5 1.5 1.5

-30 -35 1.0 0.5 1.0 1.0 1.0

-35 -40 0.5 0.5 0.5 0.5 0.5

- Check coolant additive concentration after testdrive.

43

Coolant G11: Change (V8 petrol enginesonly)

To prevent corrosion damage, the coolant must bechanged at regular intervals in vehicles with V8 pet-rol engines up to vehicle identification no. 4AVN 002872 if coolant additive "G 011 A8 C" (green) has beenused.

- Draining and filling cooling system

=> 8-cylinder Engine, Mechanical Components; Re-pair group 19; Removing and installing parts of thecooling system; Draining and filling system withcoolant

Notes:

♦ Observe environmental requirements for dispos-al.

♦ When changing the coolant it is also possible touse coolant additive "G 012 A8 D" (red) insteadof coolant additive "G 011 A8 C" (green). Ifswitching to "G 012 A8 D", always follow the rel-evant instructions:

=> 8-cylinder Engine, Mechanical Components; Re-pair group 19; Removing and installing parts of thecooling system; Draining and filling system withcoolant

♦ After switching to coolant additive "G 012 A8 D"(red) it is no longer necessary to change thecoolant (system is then filled for life).

44

Air cleaner: clean housing and replacefilter element

Engines without mixture control unit on air filtercover:

- Loosen hose clamp on air intake pipe/hose anddetach pipe/hose.

- Release clips -arrows- around air cleaner housingand press cover to the side.

- If necessary, unplug connector for air massmeter/air flow meter.

- Remove old filter element.

Note:


- Clean filter housing and install new filter element.

Note:

On vehicles with V6 - 5V-petrol engines renew thespark plugs and fit the spark plug connectors beforerefitting the top section of the air cleaner.

45

Engines with mixture control unit on air filtercover:

- Remove air intake hose above mixture controlunit.

- Release clips around air cleaner housing -arrows-. - Pull out mixture control unit with upper section of

air cleaner housing from above. - Remove old filter element.

Note:



Audi S4 (V8):

- Unbolt upper section of air cleaner housing. - Remove old filter element.

Note:



46

Spark plugs: replace


♦ Spark plug socket, A/F 20.8(4-cyl. 2V and 5-cyl. 2V engines)

♦ Spark plug socket 3122 B(4-cyl. 4V, 4-cyl. 5V, 5-cyl. 4V engines, 6- and 8-cylinder engines)

Notes:

♦ The spark plugs must be renewed every 15,000km if the vehicle is run on leaded fuel.

♦ Spark plug designation

=> "Exhaust Emission Test" binder


4-cyl. 2V and 5-cyl. 2V engines:

- With ignition switched off, unplug connectorsfrom spark plugs.

- Remove spark plugs with spark plug socket. - Screw in new spark plugs.

- Check ignition cables and spark plug connectorsare correctly seated.


Spark plugs in cylinder head 30

47

4-cyl. 4V engines:

- With ignition switched off, unplug connectors -ar-rows- from spark plugs.

Note:

Use the special puller fitted on the spark plug con-nector of cylinder 1 to detach all the spark plug con-nectors.

- Remove spark plugs using spark plug socket3122 B.

- Screw in new spark plugs. - Check ignition cables and spark plug connectors

are correctly seated.



4-cyl. 5V engines:

- Remove engine cover => Page 34.

48

- With ignition switched off, unscrew and unclipconnector and earth wire from ignition coil withoutput stage -arrows-.


- Fit spark plugs and ignition coil with output stage. - Check ignition cables and spark plug connectors


Tightening torques Nm


Ignition coil with output stage to cyl-inder head cover 10

49

5-cyl. 4V engines (turbo):

- Unscrew mountings of ignition coil carrier -arrows-and pull carrier evenly off towards the top.


- Screw in new spark plugs. - Install ignition coil carrier; replace gasket if dam-

aged.



Ignition coil carrier to cylinder headcover

10

50

V6 - 2V engines:

- If necessary remove air intake pipe -1- betweenair cleaner and throttle valve unit.

- Remove engine cover => Page 34. - With ignition switched off, unplug connectors -ar-

rows- from spark plugs. - Remove spark plugs using spark plug socket

3122 B. - Screw in new spark plugs. - Check ignition cables and spark plug connectors




V6 - 5V engines:

- Remove air intake pipe between air cleaner andthrottle valve unit.

- To unscrew rear left spark plug, remove coolantexpansion tank and connected hoses.


51

- Detach spark plug connector -arrows-. - Remove spark plugs using spark plug socket

3122 B. - Screw in new spark plugs. - Check ignition cables and spark plug connectors




V8 engines (206 and 213 kW):


- Remove engine covers => Page 40.

- With ignition switched off, unplug connectorsfrom spark plugs.

Note:

Use the special puller -arrow- fitted on the spark plugconnector of cylinder 1 to detach all the spark plugconnectors.


- Screw in new spark plugs. - Check ignition cables and spark plug connectors




V8 engines (240 kW):

52


- Remove engine covers => Page 40. - With the ignition switched off, pull the retainer

clips for the ignition coil connectors upwards andunplug the connectors.

- Unscrew ignition coils -arrows-. - Remove spark plugs using spark plug socket

3122 B. - Install new spark plugs using spark plug socket. - Install ignition coils. Replace seals if damaged.



Ignition coils to cylinder head cover 10

53

Hydraulic system: check for leaks, checkfluid level and top up hydraulic fluid ifnecessary

Note:

In the case of vehicles with self-levelling suspension,the vehicle must be in its unladen state when check-ing the fluid level.

• Cold fluid:

- Do not run engine and set front wheels tostraight-ahead position.

• Fluid at operating temperature (from approx. 50°C):

- Run engine and set front wheels to straight -ahead position.

- Unscrew filler cap -arrow- with dipstick. - Wipe dipstick with a clean cloth. - Screw in cap hand-tight and unscrew again.

54

- Check fluid level:

• Cold fluid:

- Level must be around MIN. mark (up to 2 mmabove or below mark).

• Fluid at operating temperature (from approx. 50°C):

- Level must be between MIN. and MAX. mark.

Notes:

♦ The definitive fluid level is the one measuredafter screwing in the cap.

♦ Fluid must be drawn off if the level is above thespecified range.

Important

If the fluid level is below the range specified,the hydraulic system must be checked forleaks (repair measure). It is then not sufficientto merely top up the fluid.

- If there are no leaks in the hydraulic system, topup with "G 002 000".

- Screw in cap hand-tight.

55

Fuel filter: replace (diesel and TDI en-gines)

Notes:

♦ Please ensure that no diesel fuel contactscoolant hoses. If necessary, clean hoses imme-diately.


4-cyl. TDI engines:

- Loosen hose clamps on fuel hoses -1- and -2- anddisconnect both fuel hoses.

- Loosen nut -arrow- on filter bracket and pull filterout of bracket without disconnecting the two fuelhoses.

- Using a 17 mm open-ended spanner, counterholdupper part of fuel filter at flats on boss for bleedscrew. Unscrew filter using strap wrench if ne-cessary -arrow-.

Important

Do not use pliers to hold the fuel filter. Thiscan damage the head of the filter and causeleaks in the fuel system.

- Unscrew filter from upper part of fuel filter. - coat new rubber seal lightly with diesel fuel. - Fill new filter with clean diesel. This will enable

the engine to start more quickly.

56

- Screw filter onto upper part of filter flange (hand-tight).

- Push plastic insert onto new filter.

- Insert fuel filter into bracket and secure withclamping nut -arrow-.

- Connect fuel hoses -1- and -2- and secure withnew hose clamps (use correct type - same as ori-ginal equipment).

=> Parts List

- Start engine and check fuel system for leaks(visual check).


Clamping nut on filter bracket 10

5-cyl. diesel and TDI engines:

- Unplug connector for water level sender.

- Hold filter in place using a strap wrench, unscrewbanjo bolt -1- and remove filter.

Note:

Do not turn filter.

- Moisten new seal and new rubber seal with dies-el.

- Transfer water level sender (if fitted) with new O-ring onto replacement filter.

- Fill new filter with clean diesel. This will enablethe engine to start more quickly.

- Fit a new O-ring and tighten banjo bolt hand-tight.

57


- Press the accelerator pedal several times - withthe engine running at idling speed the fuel shouldflow through the transparent pipe with nobubbles.

Fuel filter: drain off water (Diesel andTDI engines)

Notes:

♦ Please ensure that no diesel fuel contactscoolant hoses. If necessary, clean hoses imme-diately.


4-cyl. TDI engines:

- Release hose clamps on fuel hoses -1- and -2-and disconnect both fuel hoses.

- Loosen nut -arrow- on filter bracket and pull filterout of bracket without disconnecting the two fuelhoses.

58

- Open water drain plug and drain approx. 0.1 litreof fluid into a drip tray.

- Close water drain screw. - Coat rubber seal on fuel filter lightly with diesel

fuel.

- Insert fuel filter into bracket and secure withclamping nut -arrow-.

- Connect fuel hoses -1- and -2- and secure withnew hose clamps (use correct type - same as ori-ginal equipment).

=> Parts List



Clamping nut to filter bracket 10

59


- Release vent screw -2-. - Fit hose onto water drain screw or breather valve -

3-.

Note:

Vehicles > 1994 with engine code AAT and ABPhave a water drain valve instead of a water drainscrew.

- Unscrew water drain screw or press drain valveupwards and drain off about 0.1 litre of fluid.

- Tighten water drain screw or release drain valveand tighten vent screw.


- Press the accelerator pedal several times - withthe engine running at idling speed the fuel shouldflow through the transparent pipe with nobubbles.

60

Dust and pollen filter: replace

The filter is located below the plenum chamber cov-er on the right.

Vehicle Page

Audi 100 > 1992 without air conditionerwith M-Nr. 2V1 61

Audi 100 1993 > 1994 without air condi-tioner

61

Audi A6 1995 > without air conditioner 61

Audi A6 1995 > with air conditioner 62

Audi 100 > 1994 without air conditioner:


- Unscrew both nuts -A-. - Turn filter cartridge and take out of bracket.

Note:


- Install new filter element. - Before fitting plenum chamber cover, check plen-

um chamber and water drain valves for dirt =>Page 63.

Audi A6 1995 > without air conditioner:

- Remove plenum chamber cover => Page 31. - Depending on the size of the battery, either

loosen battery retainer and push battery towardswing panel or remove battery completely.

61

- Push clamp -A- up and remove dust and pollen fil-ter -B- from filter holder.

Note:


- Install new filter element. - Before fitting plenum chamber cover, check plen-

um chamber and water drain valves for dirt =>Page 63.

Audi A6 1995 > with air conditioner:


- Unscrew the three bolts -A-. - Remove cover -B- and pull dust and pollen filter -

C- out of evaporator.

Note:


- Before installing dust and pollen filter, checkevaporator for dirt and clean if necessary.

- Insert dust and pollen filter (ensure that filter isthe right way round).

- Arrow on filter element points towards evaporat-or.

- Before fitting plenum chamber cover, check plen-um chamber and water drain valves for dirt =>Page 63.

62

Plenum chamber and water drainvalves: check for dirt and clean if neces-sary

- Remove plenum chamber cover => Page 31. - Check plenum chamber for dirt (leaves, etc.) and

clean as necessary. - Check that water drain valves are functioning

properly, and clean and replace as necessary.

Note:

Ensure that water drain valves close properly and arenot blocked by wax or underseal.

- Observe note on installing plenum chamber cover=> Page 31.

63

Noise insulation: remove

On vehicles with diesel and TDI engines the noise in-sulation consists of two parts.

- Turn quick - release screws - arrows - in an anti -clockwise direction.

- Pull front noise insulation off bumper towardsrear of vehicle and remove.

- Pull rear noise insulation (on diesel and TDI en-gines only) towards rear of vehicle and remove.

Note:

When installing ensure that the noise insulation ispushed in over the bumper cover at the front.

64

V-belt: check for damage and check ten-sion; adjust tension if necessary

- Check condition of V-belts along entire length ofbelt:

- Cracks, fractured core, cross-sectional breaks - Layer separation (base, cord strands) - Base break-up - Fraying of cord strands - Wear on sides of belt (material worn down,

sides of belt frayed, surface cracking or sides ofbelt hardened - indicated by smooth, shiny sur-face)

- Traces of oil and grease

Important


- Check tension of V-belts: - Press in the ribbed belt firmly with the thumb at a

point half-way between the two pulleys which arefarthest apart.

The amount of yield should be as follows:

65

V-belt for alternator Belt yield (max)

- New V-belt 2 mm

- Used V-belt 5 mm

V-belt for PAS vane pump

- Petrol engines 10 mm

- TDI engines 5 mm

V-belt for air conditionercompressor

- All models 5 mm

V-belts: tensioning

Note:

With the 4-cyl. 5V-engine it is not possible to adjustthe tension of the V-belt for the coolant pump.


♦ V.A.G 1410 Torque wrench ♦ Ring spanner attachment V.A.G 1410/2 (22 mm

A/F)

• V-belt for alternator

66

- loosen all bolts securing alternator and tensioningbar -A- at least one turn.

- Loosen clamping bolt for tensioner nut -B-. - Using torque wrench V.A.G 1410 and ring span-

ner attachment V.A.G 1410/2 (22 mm A/F), applythe following torque to the tensioner nut:

- Used V-belt:4 Nm - New V-belt: 8 Nm

- Maintain this torque on tensioning bolt, and tight-en clamping bolt to 35 Nm.


Clamping bolt for tensioner nut to ten-sioning bar

35

Tensioning bar to lifting eye 20

Alternator to bottom mounting 35

Note:

If the V-belt has been replaced:

- Start engine and run at idling speed for 5minutes.

- Switch off the engine and re-adjust the belt ten-sion as described above.

- Apply a torque of 8 Nm to tensioner nut.

• V-belt for PAS vane pump

- Remove noise insulation => Page 64.

67

- Loosen bolts 2 ... 6. - Adjust belt tension with tensioner nut -1-.

- The amount of yield should be as follows: - Petrol engines:10 mm - TDI engines: 5 mm

- Tighten securing bolts on vane pump.


Vane pump to bracket 25

Vane pump to tensioning bar 25

• V-belt for air conditioner compressor


- Unscrew the 4 nuts -1-. - Detach hub -2- from belt pulley. - Take off front section of belt pulley -3-.

Notes:

♦ Belt tension is adjusted by adding or taking outshims -5- between front section -3- and rear sec-tion -4- of belt pulley.

♦ To reduce tension, add shims between two sec-tions of belt pulley.

♦ To increase tension, remove shims betweentwo sections of belt pulley.

68

- Place remaining shims between hub -2- and thefront section of belt pulley -3-.

- Loosely bolt together the two sections of the beltpulley.

- Tighten the bolts securing the two sections of thepulley in stages while turning the crankshaft.

- As the bolts are tightened, the V - belt shouldgradually move outwards until seated on thecontact surface.

- Tighten nuts to 25 Nm.

- The amount of yield should be as follows: - Used V-belt:5 mm - New V-belt: 2 mm

- Start engine and check belt running. - Check the belt tension again and re-adjust if ne-

cessary.

69

V-belt (not ribbed belt) for alternator: re-place



A/F)

4-cyl. petrol engines

- Remove noise insulation => Page 64. - Remove V-belt for air conditioner compressor:

- Unscrew the 4 nuts -1-. - Detach hub -2- from belt pulley. - Take off front section of belt pulley -3-. - Remove V-belt.

70

- Remove V-belt for PAS vane pump: - Loosen bolts 2 ... 6. - Remove V-belt.

- Remove V-belt for alternator:

- loosen all bolts securing alternator and tensioningbar -A- at least one turn.

- Loosen clamping bolt for tensioner nut -B-. - Fit new V-belt for alternator. - Re-install the other V-belts. - Tension the V-belts => Pages 68.

71

Ribbed belt: check for damage

- Check condition of ribbed belts along entirelength of belt:

- Cracks, fractured core, cross-sectional breaks - Layer separation (base, cord strands) - Base break-up - Fraying of cord strands - Wear on sides of belt (material worn down,

sides of belt frayed, surface cracking) - Traces of oil and grease

Important


72

Ribbed belt: check tension; adjust if ne-cessary



A/F)

- Press in the ribbed belt firmly with the thumb at apoint half-way between the pulleys.

- The belt should yield 5 mm

- Loosen the alternator securing bolt -1- and clamp-ing bolt -2- at least one turn.

- Using torque wrench V.A.G 1410 and ring span-ner attachment V.A.G 1410/2 (22 mm A/F), applya torque of 6 Nm to the tensioner nut -3-:

- Maintain this torque on the tensioning bolt, andtighten clamping bolt to 25 Nm.


Clamping bolt for tensioner nut to ten-sioning bar

25

Alternator to bottom mounting 25

73

V-belt and ribbed belt: replace (4-cyl. 5Vengines)


♦ Mandrel 3204

Removing

• Ribbed belt for air conditioner compressor

- Unbolt torque reaction support from engine andcross member -arrows-.

- Loosen bolts -arrows- of tensioner for ribbed belt,slacken belt and remove.

• Ribbed belt for PAS vane pump and alternator

74

- Remove ribbed belt for air conditioner com-pressor => Page 74.

- Loosen ribbed belt for hydraulic pump and altern-ator, secure tensioner for ribbed belt using man-drel 3204 if necessary -arrows-.

- Remove ribbed belt between hydraulic pump andalternator at alternator.

• V-belt for coolant pump

- Unscrew pulley for coolant pump. To prevent pul-leys from turning, insert a pin -arrow- in the vanepump pulley.

- Remove V-belt.

Installing

Installation is carried out in the reverse order; notethe following:

- Fit ribbed belt for PAS vane pump and alternator. - Fit V-belt and assemble two sections of pulley on

coolant pump without tightening bolts. - Tighten the bolts securing the two sections of the

pulley in stages while turning the coolant pump. - As the bolts are tightened, the V - belt should

gradually move outwards until seated on thecontact surface.

- Tighten bolts to 25 Nm.

75

Note:

It is not possible to adjust the tension of the V-beltfor the coolant pump.

- Check that ribbed belt is properly seated. - Turn ribbed belt tensioner in direction of arrow. - Remove mandrel 3204 if necessary.

- Fit ribbed belt for A/C compressor.

- Apply torque wrench to hexagon on tensioningroller and tension with a torque of 25 Nm.

- At the same time, tighten bolts -A- to 20 Nm. - Start engine and check belt running. - Check again to ensure that the bolts for the

coolant pump pulley are tightened to the correcttorque.

76

Ribbed belt: replace (V6 engines)


♦ Mandrel 3204


- Remove cover for ribbed belt -arrows-.

77

Vehicles > 1991:

- To slacken ribbed belt, turn tensioner in directionof arrow using ring spanner (15 mm A/F).

- Secure tensioner by inserting mandrel 3204. - Remove ribbed belt.

- Fit new ribbed belt onto drive pulley and idlerwheel first, and then push it over the tensioner.

Routing of belt

- A1 - without air conditioner - A2 - with air conditioner

- Take out mandrel 3204 and release tensioner forribbed belt.

- Start engine and check belt running.

78

Vehicles 1992 >:

- To slacken ribbed belt, turn tensioner in directionof arrow using Allen key (10 mm A/F).

- Insert mandrel 3204 into holes -A- and -B- to stoptensioner from turning.

- Remove ribbed belt.

- Fit new ribbed belt onto drive pulley and idlerwheel first, and then push it over the tensioner.

Routing of belt on vehicles 1992 > 1994

- B1 - without air conditioner - B2 - with air conditioner

79

Routing of belt on vehicles 1995 >

- C1 - without air conditioner - C2 - with air conditioner

- Take out mandrel 3204 and release tensioner forribbed belt.

- Start engine and check belt running.

80

Toothed belt for camshaft drive: checkfor damage and measure toothed beltwidth (4-cyl. TDI engines)

- Release 2 clamps on the upper toothed belt coverand pull upper end of cover forwards.

- Check condition of toothed belt: - Cracks, cross-sectional fractures - Layer separation (base, cord strands) - Base break-up - Fraying of cord strands - Surface cracks (plastic outer layer) - Traces of oil and grease

Important


- Measure width of toothed belt -a-. - Wear limit = 22 mm

Important

The toothed belt must be replaced if the beltwidth is less than 22 mm (repair measure).

81

Toothed belt for camshaft drive: checkfor damage and check tension (5 - cylin-der diesel and TDI engines)

- Remove upper toothed belt cover. - Check condition of toothed belt:

- Cracks, cross-sectional fractures - Layer separation (base, cord strands) - Base break-up - Fraying of cord strands - Surface cracks (plastic outer layer) - Traces of oil and grease

Important


Vehicles > 1994:

- Check that toothed belt runs centrally on cam-shaft sprocket.

Note:

If the toothed belt runs on one side of the sprocket,this means that the lower idler wheel is not pressedin straight and should be replaced (repair measure).

- Check tension of toothed belt:


♦ V-belt and toothed belt test unit VW 210

82

- Press in toothed belt firmly by hand betweencamshaft sprocket and injection pump sprocketto equalise tension.

- Measure tension of toothed belt using tester VW210.

- Specification: on scale 12 ... 13

- Adjust toothed belt tension (repair measure) if thereading does not match the specification (toohigh or too low):

=> 5-cyl. Diesel Engine (2.4 ltr Engine), MechanicalComponents; Repair group 13; Dismantling and as-sembling engine; Removing and installing toothedbelt for camshaft


Vehicles 1995 >:

- Check tension of toothed belt:

83

- The two arrows must be aligned (max. distance3 mm)

- If the markings are not opposite each other adjustthe tension of the toothed belt:


84

Toothed belt for injection pump: checkfor damage and check tension (5-cyl. TDIengines), tension toothed belt


♦ Tensioner 3303

Vehicles > 1994:

- Remove rear toothed belt cover.

Vehicles 1995 >:


All models:

- Check condition of toothed belt: - Cracks, cross-sectional fractures - Layer separation (base, cord strands) - Base break-up - Fraying of cord strands - Surface cracks (plastic outer layer) - Traces of oil and grease

Important


85

- Check tension of toothed belt for injection pump.

Vehicles 1995 >:

- Unscrew nut -A- on rear toothed belt guard for in-jection pump drive.

- Push toothed belt guard and sleeve -B- to rear.

All models:

- Hook in spring of tensioner 3303.

Note:

In order to attach the tensioner on vehicles 1995>without removing the stud, first file out a section ofthe tensioner, as shown in the illustration (shadedarea).

86

- With tensioner 3303 -Item 1- hooked in position,loosen nut -2- of tensioning roller.

- Move the tensioning roller by hand to check thatit moves easily; free the roller if necessary.

Note:

When the tensioning roller is released, the spring ofthe tensioner automatically sets the belt to the cor-rect tension.

- Check gap -A- at stop for tensioning roller.

Important

If gap A = 0 mm (tensioning roller lever againststop) the toothed belt must be replaced (repairmeasure).

87

- Tighten nut -2- on tensioning roller. - Remove tensioner 3303 -Item 1-


Tensioning roller nut 45

88

Toothed belt for camshaft drive: checkfor damage (2.6l 2V and 2.8l 2V enginesonly)

- Remove engine cover => Page 34 - Remove upper toothed belt cover. - Check condition of toothed belt:

- Cracks, cross-sectional fractures - Layer separation (base, cord strands) - Base break-up - Fraying of cord strands - Surface cracks (plastic outer layer) - Traces of oil and grease

Important


89

Toothed belt: replace

Toothed belt: replace (4-cyl. petrol engines)

- Removing and installing toothed belt:

=> 4-cylinder Engine (2-valve), Mechanical Compon-ents; Repair group 13; Dismantling and assemblingengine

=> 4-cylinder Injection Engine (4-valve), MechanicalComponents; Repair group 13; Dismantling and as-sembling engine

Toothed belt: Replace (5-cyl. petrol engines)

- Removing and installing toothed belt:

=> 5-cylinder Engine (2-valve), Mechanical Compon-ents; Repair group 13; Dismantling and assemblingengine

=> 5-cylinder Injection Engine (4-valve), MechanicalComponents; Repair group 13; Dismantling and as-sembling engine

4-cylinder 5V 1.8 litre petrol engines

- Removing and installing toothed belt

=> 4-cyl. Engine (5-valve), Mechanical Components;Repair group 13; Dismantling and assembling engine

Toothed belt and tensioning roller: replace (V6 -5V engines)

- Removing and installing toothed belt, replacingtoothed belt tensioning roller:

90

=> 6-cylinder Engine (5-valve), Mechanical Compon-ents; Repair group 13; Dismantling and assemblingcylinder crankcase, crank shaft and flywheel

Ribbed belt: replace (V8 engines)

=> 8-cylinder Engine, Mechanical Components; Re-pair group 15; Cylinder head, valve gear; Removingand installing ribbed belt

Toothed belt: replace (V8 engines)

=> 8-cylinder Engine, Mechanical Components; Re-pair group 15; Cylinder head, valve gear; Removingand installing toothed belt

Toothed belt for camshaft drive and tensioningroller: replace (4-cyl. TDI engines)

- Removing and installing toothed belt, replacingtoothed belt tensioning roller:

=> 4-cyl. Diesel Direct Injection Engine (TDI), Mech-anical Components; Repair group 13; Dismantlingand assembling engine

- Dynamically checking and adjusting commence-ment of injection:

=> Diesel Direct Injection and Glow Plug System(TDI 4-cylinder); Repair group 23; Servicing diesel dir-ect injection system

91

Toothed belt for camshaft and injection pump:replace (5-cylinder diesel engines)

=> 5-cyl. Diesel Engine (2.4 ltr Engine), MechanicalComponents; Repair group 13; Dismantling and as-sembling engine; Removing and installing toothedbelt for camshaft, and toothed belt for injectionpump

- Dynamically checking and adjusting commence-ment of injection.

=> Diesel Injection and Glow Plug System (2.4 l en-gine); Repair group 23; Servicing diesel injection sys-tem

Toothed belt for camshaft and injection pump:replace: (5-cylinder TDI engines)

=> 5-cyl. Diesel Engine (2.5 ltr Engine), MechanicalComponents; Repair group 13; Dismantling and as-sembling engine; Removing and installing toothedbelt for camshaft, and toothed belt for injectionpump

92

- Dynamically checking and adjusting commence-ment of injection:

=> Diesel Direct Injection and Glow Plug System(TDI 5-cylinder); Repair group 23; Dynamically check-ing and adjusting commencement of injection

Filling in toothed belt renewal sticker - allvehicles

- Fill in toothed belt renewal sticker -arrow- on lockcarrier; if necessary, attach a new sticker.

Manual gearbox/final drive: check oillevel and top up if necessary

5-speed manual gearbox 012, front-wheel drive


♦ Socket attachment 3357

or

♦ 17 mm hexagon socket attachment

Notes:

♦ The vehicle must be absolutely horizontal whenchecking gearbox oil level. This work is best per-formed over an inspection pit or using a 4 -column lifting platform.

♦ The oil filler plug is on the left of the gearbox be-low the speedometer sender; it may be con-cealed by the heat shield for the drive shaft.

93

♦ Depending on the version fitted, use either spe-cial tool 3357 or a 17 mm Allen key to loosenthe oil filler plug.

- Unscrew oil filler plug (arrow) to check oil level. - Check oil level using a shop-built tool, e.g. a piece

of angled wire. - Specification: oil level 7 mm below bottom edge

of oil filler hole

Note:

The oil can be filled up to the bottom edge of the oilfiller hole when servicing.

Important

If the oil level is below the range specified, thegearbox must be checked for leaks (repairmeasure). It is then not sufficient to merelytop up the fluid.

- If there are no leaks in the gearbox, top up withSAE 75 W 90 (synthetic fluid), specification "G052 911 A".

- Fit oil filler plug.


Oil filler plug 25

5-speed and 6-speed manual gearbox 01E, frontwheel drive

Notes:

94


♦ The prescribed oil level is to be adhered to ex-actly; the gearbox reacts very sensitively to over-filling.

♦ There are two different procedures for checkingthe gearbox oil level according to the type of fi-nal drive cover fitted.Older version: oil filler hole behind flange shaft.Newer version: oil filler hole in front of flangeshaft.

Older version:

- Remove oil filler plug -A- (behind flange shaft) tocheck gearbox oil level.

- Check oil level using a shop-built tool, e.g. a pieceof angled wire.

- Specification: oil level 6 mm below bottom edgeof oil filler hole

95

Newer version:

- Remove oil filler plug -B- (in front of flange shaft)to check gearbox oil level.

- Specification: oil level up to lower edge of fillerhole

All models:

Important





Oil filler plug 40

5-speed manual gearbox 01A, four-wheel drive


♦ Socket attachment 3357

or

♦ 17 mm hexagon socket attachment

Notes:

96

♦ The oil filler plug is on the left of the gearbox be-low the speedometer sender; it may be con-cealed by the heat shield for the drive shaft.

♦ Depending on the version fitted, use either spe-cial tool 3357 or a 17 mm Allen key to loosenthe oil filler plug.

- Unscrew oil filler plug (arrow) to check oil level. - Specification: oil level up to lower edge of filler

hole

Important





Oil filler plug 25

5-speed and 6-speed manual gearbox 01E, four-wheel drive

Notes:

97


♦ The prescribed oil level is to be adhered to ex-actly; the gearbox reacts very sensitively to over-filling.

♦ There are two different procedures for checkingthe gearbox oil level according to the type of fi-nal drive cover fitted.Older version: oil filler hole behind flange shaft.Newer version: oil filler hole in front of flangeshaft.

Older version:

- Remove oil filler plug -A- (behind flange shaft) tocheck gearbox oil level.



98

Newer version:

- Remove oil filler plug -B- (in front of flange shaft)to check gearbox oil level.



All models:

Important





Oil filler plug 40

99

Final drive (automatic gearbox): checkoil level and top up if necessary

Automatic gearbox 097, 01N

- Unscrew oil filler plug -arrow-. - Specification: oil level up to lower edge of filler

hole

Important

If the oil level is below the range specified, thefinal drive must be checked for leaks (repairmeasure). It is then not sufficient to merelytop up the fluid.

- If the final drive has no leaks top up with SAE 75W 90 (synthetic oil) specification "G 052 145 A".



Oil filler plug 25

- Fill in sticker for final drive oil check => Page 103.

Automatic gearbox 01K, front wheel drive

100

01F four-wheel drive


hole

Important





Oil filler plug 25


101

Automatic gearbox 018; four-wheel drive


hole

Important





Oil filler plug 25


102

Filling in sticker for final drive oil check - allvehicles

- Fill in sticker for final drive oil check -arrow- onlock carrier; if necessary, attach a new sticker.

103

Engine oil: drain or extract, change oilfilter


♦ Oil filter spanner 3417(4-cyl. petrol engines)

♦ Strap wrench Hazet 2171 - 1 (5 - cyl. petrol en-gines, V6-engines, 4-cyl. TDI engines, 5-cyl. dies-el and TDI engines)

♦ Socket attachment, long, 36 A/F ♦ Oil extractor V.A.G 1307 A or V.A.G 1358 A

Note:



4-cyl. petrol engines:

- Loosen oil filter - arrow - with oil filter spanner3417.

5 - cyl. petrol engines, 4 - cyl. TDI engines, 5 - cyl.diesel and TDI engines:

- Loosen oil filter with strap wrench (e.g. Hazet2171-1).

104

V6 engines:

- Loosen oil filter -arrow- strap wrench (e.g. Hazet2171-1).

V8 engines:

- Loosen oil filter -arrow- with socket attachment30 mm A/F.

All models:

- Remove oil filter. - Unscrew oil drain plug or extract engine oil. - Clean sealing surface on engine for oil filter. - Lightly lubricate rubber seal.

- Screw in new filter and tighten.

Notes:

Note the fitting instructions on the oil filter.

For engines with oil cooler

105

Important

After replacement of oil filter cartridge, checkclearance of hoses from oil cooler to adjacentcomponents; if necessary correct oil cooler po-sition.

- Screw in oil drain plug with new seal. - Top up engine oil, specifications => Page 119. - Observe instructions for turbo engines => Page

121. - Note different oil specifications for Audi S6 with

V8 engine AHK => Page 121.


Oil drain plug 4- and 5-cyl.-engines 30

Oil drain plug V6 - 2V engines: 40

Oil drain plug V6 - 5V engines: 30

Oil drain plugs V8 engines 35

106

Brake system: visual check for leaks anddamage

- Check the following components for leaks anddamage:

- Brake master cylinder - Brake servo - ABS hydraulic unit - Brake calipers - Brake pressure regulator

- Ensure that brake hoses are not twisted. - Ensure that brake hoses do not touch any vehicle

components when steering is on full lock. - Check brake hoses for porosity, blistering and

brittleness. - Check brake hoses and pipes for chafing.

- Check brake pipe connections and mountings forcorrect seating, leaks and corrosion.

Important


107

Brake pads: check thickness

Front disc brake pads:

Important

If the pad thickness is down to 7 mm (includ-ing backing plate), the disc brake pads havereached their wear limit and must be replaced(repair measure). Please inform the customer.

- Determine thickness of outer pads by checkingvisually (with help of electric torch/flashlightthrough cut-out in wheel).

- Determine thickness of inner pads by checkingvisually (with help of electric torch/flashlight andmirror).

Notes:

♦ If the brake pads are not visible because of thetype of wheel rims fitted, remove front wheels.

♦ Before removing the wheels mark the positionof each wheel in relation to the brake disc andmount the wheels in the same position aftercompleting the check.

♦ Observe notes on wheel bolts when mountingthe front wheels => Page 115.

108

Audi 100, Audi A6:

- a -Pad thickness including backing plate - Wear limit: 7 mm

Audi S4 (5 cyl.) > 1993:


109

Audi S4 (5 cyl.) 1994>, Audi S4 (V8), Audi S6:


Rear disc brake pads:

Important

If the pad thickness is down to 7 mm (includ-ing backing plate), the disc brake pads havereached their wear limit and must be replaced(repair measure). Please inform the customer.

- Determine thickness of outer pads by checkingvisually (with help of electric torch/flashlightthrough cut-out in wheel).

- Determine thickness of inner pads by checkingvisually (with help of electric torch/flashlight andmirror).

110


Notes:

♦ If the brake pads are not visible because of thetype of wheel rims fitted, remove rear wheels.

♦ Before removing the wheels mark the positionof each wheel in relation to the brake disc andmount the wheels in the same position aftercompleting the check.

♦ Observe notes on wheel bolts when mountingthe rear wheels => Page 115.

Rear drum brake linings:

- Pull plug out of inspection hole in backplate -ar-row-.

- Determine thickness of brake linings by checkingvisually, using an electric torch (flashlight).

- a -Lining thickness without brake shoe - Wear limit: 2.5 mm

Important

If the pad thickness is down to 2.5 mm (not in-cluding backing plate), the drum brake liningshave reached their wear limit and must be re-placed (repair measure). Please inform the cus-tomer.

111

Underseal: visual check for damage

- When performing visual check, check underbody,wheel housings and side members.

Important


Track rod ends: check play, attachmentand protective boots

Note:

The test must be made with vehicle raised on a lift-ing platform (wheels free to move).

- Check play by moving track rods and wheels. - There should be no play

- Check that lock nuts are secure (40 Nm).

- 1 -Lock nut on wheel side, right-hand thread - 2 -Lock nut on track rod side, left-hand thread

- Check protective boot - arrow - for damage andcorrect seating.

112

Tyres: check and correct condition, wearpattern, tread depth and inflation pres-sures

Notes:

♦ In the interests of driving safety, only tyres ofthe same type and tread pattern should be fittedon a vehicle.

♦ On four wheel drive vehicle tyres of the sametype and tread pattern must be used. Otherwisethe centre differential may be damaged.

- Check tyre tread and side walls for damage andremove any foreign bodies.

- Check tyres for scuffing, one-sided wear, porousside walls, cuts and fractures.

Important

The customer must be informed of any de-fects.

Checking tyre wear pattern

- The wear pattern of the front tyres indicateswhether the toe and camber have to be checked

- Feathering on tread indicates incorrect toe set-ting.

- One-sided tread wear is mainly caused by incor-rect camber.

113

Note:

If the above types of wear are found, check wheelalignment to determine the cause (repair measure).

Checking tyre tread depth

- Minimum permissible tread depth: 1.6 mm

Notes:

♦ This value may vary for individual countries ac-cording to legislation.

♦ The minimum tread depth is reached when thetyres have worn down level with the 1.6 mmhigh tread wear indicators - arrows- positioned atintervals around the tyre.

♦ If the tread depth is approaching the minimumpermissible tread depth, the customer must beinformed.

Inflating to correct pressures

The correct inflation pressures for summer tyres arelisted on the sticker on the inside of the tank flap.

Notes:

♦ Please note that the inflation pressures listed onthe sticker apply to cold tyres. When the tyresare warm, the actual pressures will be higher,but must not be reduced.

♦ When using winter tyres, pressures should beincreased by 0.2 bar.

Spare wheel

114

• Spare wheel with standard-size tyre

- Inflate to the maximum pressure specified for thevehicle.

• Temporary (compact) spare wheel: The correctinflation pressure is indicated on the side wall.

Notes:

♦ The tyre valves must be closed with dust caps.Otherwise, dirt can obstruct the valve pin andcause loss of air.

♦ On vehicles with steel rims and wheel covers,check the tyre valve extensions. Damage anddirt can cause leaks. Replace if necessary.

Wheel bolts: tighten to specified torque

Wheel cover

Puller - 1 - for removing the wheel cover is in thevehicle tool kit.

115

Trim cap

- On vehicles with light-alloy wheels and trim capsinsert a screwdriver in the recess and lever thetrim cap off the wheel rim.

Wheel bolt locks

- Pull trim cap off wheel bolt lock.

- On wheel rims with recessed wheel bolts, insertthe hook -2- at the side of the bolt, turn it slightlyand pull the cap off.

- Turn key -1- anti-clockwise in wheel bolt lock andremove together with wheel bolt lock.

- To re-install, push wheel bolt lock as far as it willgo onto wheel bolt.

- Turn key clockwise in lock and remove key. - When refitting the cap, ensure that it engages all

the way round.

Note:

Ensure that the wheel bolts are tightened in a diag-onal sequence to the following tightening torque:


Wheel bolts 120

116

Correct installation of wheels

- When fitting the road wheels note the followingpoints to ensure that the wheels remain secure atall times.

• Always tighten the wheel bolts to the specifiedtorque, excessive torque can distort the wheelbolt seats in the rim.

• When fitting a wheel do not torque down thefirst wheel bolt immediately (e.g. with an impactwrench), as this would prevent the other boltsfrom centring the wheel properly when they arescrewed in. The rim could then come loose eventhough the bolts have been tightened to the spe-cified torque.

• Before installing the wheels examine the seatsof the wheel bolts and the contact surfacesbetween the rims and the hubs for rust and cor-rosion. Clean off these parts if necessary other-wise this can affect the clamping force of thebolts after installation and the rims can comeloose.

117

Important ♦ If the points listed above are not observed

the wheel mountings can come loose andthe wheel bolt seats can become distorted.

♦ This distortion may be very slight and notvisible to the naked eye.

♦ Even this slight distortion of the wheelbolt seats can prevent the rims from beingheld firmly and the wheels will come looserepeatedly.

Engine oil: fill

The engine is filled with a high quality multigrade oilat the factory which can be used all year round, ex-cept in extremely cold climates.

Viscosity grades

Note:

The oil does not need changing for brief variations ofoutside temperature beyond the temperature rangesshown.

118

Viscosity grades for petrol, diesel and TDI en-gines (but not for Audi S6 with V8 engine AHK):

Select the viscosity grade of the oil according to thechart.

- A - Multigrade high lubricity oils, specification=> Page 120

- B - Multigrade oils, specification => Page 120

Viscosity grades for Audi S6 with V8 engineAHK:

Select the viscosity gradeof the oil according to thechart 1) .

- A - Multigrade high lubricity oils, specification=> Page 121

1) If these oils are not available engine oils withother viscosity grades may be used as an emer-gency measure as long as they conform to VWstandard 500 00 => Page 121.

Oil specifications

The specifications listed here should appear on thecontainer - either singly or together with other spe-ci-fications.

119

Note:

When topping up, different types of oil may bemixed if necessary.

Oil specification for petrol engines (but not forAudi S6 with V8 engine AHK) and diesel engines(but not for TDI engines):

- A - High lubricity multigrade oils, specificationVW 500 00 1)

High - lubricity multigrade oils, specification VW502 00 2)

- B - Multigrade oils, specification VW 501 011)

- - Multigrade oils, Specification API-SF 3)or API-SG 3)

1) The date given after the VW specification mustnot be earlier than 10.97.

2) These oils are particularly suitable for tur-bocharged petrol engines.

3) These oils should only be used if the approvedengine oils are not available.

Oil specifications for TDI engines:

- A - High-lubricity multigrade oils, specificationVW 500 00 1) (only in combination with specifica-tion VW 505 00)

- B - Multigrade oils, specification VW 505 001)

- - Multigrade oils, specification VW 501 01 1)

(only in conjunction with specification VW 505 00)

120

- - Multigrade oils, specification API-CD (shouldonly be used for emergency topping up)


Oil specifications for Audi S6 with V8 engineAHK:

- A - High lubricity multigrade oils, specificationVW 500 00 1)


- Top up engine oil.

Capacities with filter replacement:

=> ELSA Maintenance table

Engines with turbocharger:

- When the engine oil and oil filter have beenchanged, it is important to note the followingafter starting the engine for the first time:

- The engine must only run at idling speed untilthe oil pressure warning lamp in the dash panelinsert goes out.Do not press the accelerat-or!This could cause severe damage to the tur-bocharger.

- The full oil pressure is only reached when thewarning lamp goes out, and the accelerator canthen be pressed.

All models:

- Finally, check the engine oil level => Page 122.

121

Engine: check oil level

Test requirements:

• Engine oil temperature at least 60 °C • Vehicle must be level (horizontal) • Wait a few minutes after switching off the en-

gine to allow the oil to flow back into the sump.

- Pull out the dipstick, wipe with a clean cloth andinsert again to stop.

- Pull out the dipstick again and read off the oillevel.

Markings on oil dipstick:

- a -Oilmust not be topped up. - b -Oil may be topped up. The oil level may rise

as far as area -a- after topping up. - c -Oilmustbe topped up. The oil level is suffi-

cient if somewhere in area -b- (grooved area) aftertopping up.

Note:

The oil level must not be above marking -a- on thedipstick.

122

Automatic gearbox: change ATF (except01N gearbox)

Engine Gearbox Page

4- and 5-cyl. engines > 12.94V6 engines (front-wheel drive) >02.92

097 124

5 cyl. TDI engines > 05.94V6 engines (front-wheel drive)03.92 > 05.94

01K 128

5 cyl. TDI engines 06.94 >V6 engines (front-wheel drive)06.94 >

01K 133

5-cyl. 4V engines > 05.94V6 engines (four-wheel drive) >05.94

01F 128

5-cyl. 4V engines 06.94 >V6 engines (four-wheel drive)06.94 >

01F 133

V8 engines 018 137

Notes:

♦ Use only ATF with the part no. G 052 162 A.(colour: clear/yellow). Do not use any additives!

♦ The engine must not be started or towedwithout ATF in gearbox.

♦ When filling is started, the ATF temperaturemust not be higher than 35 °C.


123

Special tools, testers and auxiliary items required

♦ Drip tray V.A.G 1306 ♦ Oil extractor V.A.G 1358 A with oil suction probe

V.A.G 1358 A/1 (automatic gearbox 097 only) ♦ Fault reader V.A.G 1551 with diagnostic cable

V.A.G 1551/1 ♦ ATF filling system V.A.G 1924 and protective

goggles(not for automatic gearbox 097)

Automatic gearbox 097

Draining ATF

- Draw off ATF with oil extractor V.A.G 1358 A withoil suction probe 1358/A 1.

or

- Raise vehicle. - Place drip tray V.A.G 1306 underneath the gear-

box.

124

- Unscrew union nut on lower ATF filler pipe - 5 -and pull filler pipe out of oil pan.

- Allow the ATF to drain out. - Re - attach ATF filler pipe: tightening torque 80

Nm.

Filling ATF

- First fill approx. 3.0 litres of ATF into the filler pipeusing a funnel.

- Move selector lever to position "P". - Start engine and run at idling speed. - With the engine idling press the brake pedal and

shift the selector lever through all the selectorlever positions leaving the selector lever 2 ... 3seconds in each position.

- Move selector lever to position "P". - Pull out ATF dipstick and wipe clean using a lint-

free cloth. - Insert the ATF dipstick all the way into the ATF

filler pipe and pull it out again.

125

- Check ATF level on dipstick. - ATF should be filled up to the 20 °C-mark when

cold. - Switch ignition off.

Checking ATF level

Test requirements:

• Gearbox not in emergency running mode, ATFtemperature between 50 ... 70 °C.

• Vehicle must be level (horizontal) • Set the selector lever to "P". • The air conditioner and heating system must be

switched off.

- Connect V.A.G 1551 => Page 23. - Start engine and run at idling speed. - Enter "1" to select "Rapid data transfer". - Enter "02" for address word "Gearbox electronics"

and confirm entry with Q key. - Press ⇒ key to continue. - Enter "08" to select the function "Reading meas-

ured value block" and confirm entry with Q key.

Reading measured value block Q

Enter display group number XXX


- Enter "005" to select display group number "005"and confirm entry with Q key.

Read measured value block 5 ⇒

1 2 3 4


- Read off ATF temperature in display zone 1. - When the ATF has reached a temperature of

about. 50 °C, pull out the ATF dipstick and wipe itclean using a lint-free cloth.

126

- Insert the ATF dipstick all the way into the ATFfiller pipe and pull it out again.

- Check ATF level on dipstick.

• If the ATF level is between the min. and max.markings at a temperature of 50 ... 70 °C, theATF level is OK.

Notes:

♦ The ATF level must not be checked at temperat-ures above 70 °C. If necessary wait for the ATFto cool down again.

♦ The markings on the ATF dipstick are for an ATFtemperature of 60°C.

Important

An insufficient ATF filling as well as filling toexcess affects the function of the gearbox.

• If ATF level is too low:

- Fill up with ATF using a clean funnel.

Note:

Use only ATF "G 052 162 A." (colour: clear/yellow).Do not use any additives!

- With vehicle stationary and engine running, moveselector lever through all selector lever positions.

- Check ATF level again at test temperature.

• If ATF level is too high:

127

- Draw off excess ATF with oil extractor V.A.G1358 A and oil suction probe 1358/A 1.



01F four-wheel drive > 1994

Draining ATF


box. - Unscrew ATF drain plug -arrow 1-. - Allow the ATF to drain out.

Filling ATF

- Fit ATF drain plug with new seal and screw in.

- Pull sealing cap -arrow- off ATF filler pipe. - First put approx. 2.7 litres of ATF into the filler

pipe using a funnel. - Move selector lever to position "P". - Start engine and run at idling speed. - With the engine idling press the brake pedal and


- Move selector lever to position "P".

128

- Measure ATF level using ATF dipstick. - For the following vehicles, check the ATF level

using the dipstick marked "02": - All vehicles with V6 engines - Audi S4 up to vehicle identification number 4A

RN 033 426( > approx. 11.93)

Note:

Vehicles requiring "02" dipstick have "02" marked onATF filler pipe -arrow-.

- For the following vehicles, check the ATF levelusing the dipstick marked "03":

- All with 5 cyl. TDI engine - Audi S4 from vehicle identification number 4A

RN 033 427 (approx. 11.93 >)

Note:

Vehicles requiring "03" dipstick have "03" marked onATF filler pipe -arrow-.

- Use a lint - free cloth to wipe the ATF dipstickclean.



129

- ATF should be filled up to the 20 °C mark whencold.



ATF drain plug 40

Checking ATF level

Test requirements:

• Gearbox not in emergency running mode, ATFtemperature between 50 ... 70 °C.

• Vehicle must be level (horizontal) • Set the selector lever to "P". • The air conditioner and heating system must be

switched off.


and confirm entry with Q key.

4A0927156AL AG4 01F 2.8l 5V RoW D26 ⇒

Coding 00001 WSC 06744

If following display appears (example):

- Check control unit identification.

Control unit identification containing code "01D".

- Press ⇒ key to continue. - Enter "08" to select the function "Reading meas-





130

- Enter "000" for "display group number 000" andconfirm entry with Q key.


1 2 3 4 5 6 7 8 9


- Read off ATF temperature in display zone 1.

Notes:

♦ Subtract 50 from displayed value to calculateATF temperature in °C.

♦ The display is only accurate if the temperatureshown is above 40 °C.

Control unit identification containing code "01F"or "01K":

- Press ⇒ key to continue. - Enter "08" to select the function "Reading meas-





- Enter "004" for "display group number 004" andconfirm entry with Q key.


1 2 3 4



All models:

- When the ATF has reached a temperature ofabout. 70 °C, pull out the ATF dipstick and wipe itclean using a lint-free cloth.



131

• If the ATF level is between the min. and max.markings at a temperature of 70... 90 °C, the ATFlevel is OK.

Notes:

♦ The ATF level must not be checked at temperat-ures above 90 °C. If necessary wait for the ATFto cool down again.

♦ The MIN and MAX-markings on the ATF dipstickare for an ATF temperature of 80 ° ± 10 °C, (i.e.the ATF level should be between the "MIN" and"MAX" markings within this temperature range.

Important


• If ATF level is too low:

- Fill up with ATF using a clean funnel.

Note:


- With vehicle stationary and engine running, moveselector lever through all selector lever positions.


• If ATF level is too high:

- Draw off excess ATF with oil extractor V.A.G1358 A and oil suction probe 1358/A 1.

132



01F four-wheel drive 1995 >

Draining ATF

- Hang the full ATF container V.A.G 1924 as high aspossible on the vehicle (e.g. radiator grille).


box.

- Unscrew ATF drain plug -arrow 2-. - Allow the ATF to drain out.

Filling ATF

- Unscrew ATF filler plug -arrow 1-. - Fit ATF drain plug with new seal and screw in.

133

- Use V.A.G 1924 to add ATF up to lower edge offiller hole.

- Start engine and run at idling speed.

Important

Wear protective goggles.

- With the engine running add more ATF until fluidlevel reaches lower edge of filler hole again.

- Cut open seal -arrow- for ATF filler plug using side-cutting pliers and fit new seal.

- Screw in ATF filler plug hand-tight. - With the engine idling press the brake pedal and




ATF drain plug 40

Checking ATF level

Test requirements:

• Gearbox not in emergency running mode; ATFtemperature not more than approx. 30 °C

• Vehicle must be level (horizontal) • Set the selector lever to "P".

134

• The air conditioner and heating system must beswitched off.


and confirm entry with Q key. - Press ⇒ key to continue. - Enter "08" to select the function "Reading meas-





- Enter "004" to select display group number "004"and confirm entry with Q key.


1 2 3 4



Note:

The ATF temperature must not be more than 30 °C.

135

- Unscrew ATF filler plug -arrow 1-.

Important


- The ATF level is correct if a small quantity of flu-id leaks out at the hole when the ATF temperat-ure is between 35 and 40 °C 1) .The leak occursbecause the ATF level rises as the temperatureincreases.

1)50 °C for tropical countries

• If ATF flows out of the hole the ATF level is OK.

- Tighten ATF filler plug -arrow 1-. The ATF check isnowcompleted.


ATF filler plug 60

136

Topping up ATF

• If no ATF comes out of the hole when the checkis performed, fill up with ATF:


Note:


Important


- Tighten ATF-filler plug -arrow 1-. The ATF check isnow completed.


ATF filler plug 60

Automatic gearbox 018; four-wheel drive

137

Draining ATF

- Hang the full ATF container V.A.G 1924 as high aspossible on the vehicle (e.g. radiator grille).


box.

- Unscrew ATF drain plug -arrow 2-. - Allow the ATF to drain out.

Filling ATF

- Unscrew ATF filler plug -arrow 1-. - Fit ATF drain plug with new seal and screw in.

138



Important


- With the engine running add more ATF until fluidlevel reaches lower edge of filler hole again.

- Cut open seal -arrow- for ATF filler plug using side-cutting pliers and fit new seal.

- Screw in ATF filler plug hand-tight. - With the engine idling press the brake pedal and




ATF drain plug 40

Checking ATF level

Test requirements:

• Gearbox not in emergency running mode; ATFtemperature not more than approx. 30 °C

• Vehicle must be level (horizontal) • Set the selector lever to "P".

139

• The air conditioner and heating system must beswitched off.


Note:

The ATF temperature must not be more than 30 °C(the oil pan should be warm but not too hot totouch).

- Unscrew ATF filler plug -arrow 1-.

Important


- The ATF level is correct if a small quantity of flu-id leaks out at the hole when the ATF temperat-ure is between 35 and 40 °C 1) .The leak occursbecause the ATF level rises as the temperatureincreases.

1)50°C for tropical countries

• If ATF flows out of the hole the ATF level is OK.

140



ATF filler plug 60

Topping up ATF

• If no ATF flows out of the hole (apart from theATF in the overflow pipe) top up with ATF as fol-lows:


Note:


Important


141



ATF filler plug 60

Idling speed: check and adjust if neces-sary (2.4 ltr diesel AAS only)


♦ Diesel tester V.A.G 1743

- Connect diesel tester V.A.G 1743:

=> Operating Instructions

142

- Before connecting the piezo-electric sender -1- ,remove any dirt and corrosion from the connec-tion point of the injector pipe for cylinder 1.

- Ensure that adequate contact is made with theearth terminal -2-.

Notes:

♦ Illustration shows 4-cylinder engine. ♦ If the piezo - electric sender is clamped to the

pipe, it must not be rotated. ♦ If the speed signal issued from the piezo-electric

sender cannot be utilised, the engine speed canbe measured using the TDC sender of the dieseltester. Insert TDC sender to stop in bore on bellhousing.


- Check the engine idling speed on diesel testerV.A.G 1743

- Specification: 800...900 rpm1)

1) Current values:

=> "Exhaust Emission Test" binder

If the idling speed shown is in not within the toler-ance range:

143

- Loosen lock nut on idling speed adjuster screw -arrow-.

- Adjust idling speed and secure idling speed ad-juster screw again with lock nut.

Brake fluid level (depending on brakepad wear): checking

Only use new genuine VW/Audi brake fluid accord-ing to US standard FMVSS 116 DOT 4.

Important ♦ Brake fluid is poisonous. On account of its

corrosive effect it must also never be al-lowed to come into contact with paint.

♦ Brake fluid is hygroscopic, i.e. it absorbsmoisture from the surrounding atmo-sphere. It is thus always to be kept in con-tainers with an air-tight seal.

- Note the following:

When the vehicle is driven, the brake fluid level willdecrease slightly with use and as a result of theautomatic adjustment of the brake pads.

144

- When checking the brake fluid level, always takeinto account the amount of wear on the brakepads:

- If the brake pads are new or a long way fromreaching the wear limit, the fluid level should bebetween the MIN and MAX marks.

- If the brake fluid level is at or slightly above theMIN mark and the brake pads have almostreached the wear limit, topping up is not re-quired.

Important

If the fluid level has fallen below the MINmark, the brake system must be checked (re-pair measure) before adding brake fluid.

145

Brake fluid: change brake fluid (every 24months)

Only use new genuine VW/Audi brake fluid accord-ing to US standard FMVSS 116 DOT 4.

Important ♦ Do not under any circumstances allow

brake fluid to come into contact with li-quids which contain mineral oils (e.g. oil,petrol, cleaning agents). Mineral oils dam-age the plugs and seals in the brake sys-tem.

♦ Brake fluid is poisonous and must on noaccount be siphoned by mouth through ahose. Because of its caustic properties itmust also not come into contact withpaintwork.

Important ♦ Brake fluid is hygroscopic, i.e. it absorbs

moisture from the surrounding atmo-sphere. It is thus always to be kept in con-tainers with an air-tight seal.

♦ Always observe the relevant environment-al regulations for disposal.

Special tools and auxiliary equipment required

♦ Brake filling and bleeding unit V.A.G 1238 B orV.A.G 1869

♦ Container

Changing brake fluid with brake filling and bleed-ing unit V.A.G 1238 B or V.A.G 1869 146

- Open the brake fluid reservoir.

Note:

The brake fluid reservoir must be kept adequatelyfilled to ensure that no air can enter the brake sys-tem from the reservoir.

- Open the bleed screw on rear right brake caliper/wheel brake cylinder.

- Place a suitable container under the bleed screwto catch the used brake fluid.

- With the engine running, use the brake pedal topump out brake fluid until the fluid level reachesthe connection-arrow- on the reservoir.

- Close bleed screw.

On vehicles with manual gearbox the clutch slavecylinder should also be "flushed" with new brake flu-id. When doing so, note the following:

- Connect V.A.G 1238 B or V.A.G 1869 but do notswitch on.

- Open bleed screw on clutch slave cylinder. - Connect breather hose of brake fluid collector to

bleed screw on clutch slave cylinder. - Switch on the bleeder appliance and allow about

100 cm3 of brake fluid to drain out. - Close bleed screw.

Sequence for changing brake fluid in brake calipers(or wheel brake cylinders):

- 1 -Rear right brake calliper/brake cylinder - 2 -Rear left brake calliper/brake cylinder

147

- 3 -Front right brake caliper - 4 -Front left brake caliper

- Connect breather hose of brake fluid collector tobleed screw on relevant brake caliper or brakecylinder.

Vehicles with front-wheel drive:

- While bleeding rear brakes, grip lever for brakepressure regulator - arrow - and push firmly to-wards rear axle.

148

Vehicles with four-wheel drive:

- While bleeding rear brakes, insert a drill bit ø (atleast 6 mm diameter) between bottom end ofspring and attachment point on brake pressureregulator.

All models:

Note:

When changing brake fluid, note different quantitiesrequired for different vehicles:

♦ Vehicles > 1994: approx. 500 cm3per brake cal-iper (wheel brake cylinder).

♦ Vehicles 1995 >: approx. 250 cm3per brake cal-iper.

- Unscrew bleed screw and allow about 250 cm3orabout 500 cm3 of brake fluid to drain out.

Pumping in new brake fluid flushes the used brakefluid out of the system.

- Close bleed screw. - Disconnect hose from brake fluid reservoir. - Check pedal pressure and brake pedal free play.

- Free play: max. 1/3 of pedal travel - During the final test drive for a vehicle with ABS,

ensure that an ABS-controlled brake application iscarried out at least once (with noticeable pulsingof brake pedal).

149

Headlights: check settings and adjust ifnecessary

The following checking and adjustment proceduresare applicable to all countries. However, national le-gislation and guidelines for individual countries mustbe adhered to.

Checking and adjustment conditions

♦ Tyre pressures OK. ♦ Lenses must not be damaged or dirty. ♦ Reflectors and bulbs OK. ♦ Vehicle correctly loaded.

- Loading: With one person or 75 kg on the driver'sseat and the vehicle otherwise unloaded (curbweight).

- The curb weight is the weight of the vehicleready for operation with full fuel tank (at least 90%) including the weight of all equipment normallycarried (e.g. spare wheel, tools, jack, fire extin-guisher, etc.).

- Roll the vehicle several metres or bounce at frontand rear several times so that springs settle cor-rectly.

♦ The vehicle and the headlight adjuster must beon a level surface

=> Operating instructions for headlight adjuster

♦ Vehicle and headlight adjuster must be aligned.

150

- Ensure that the headlight adjuster is positioned30 cm in front of the headlight.

♦ Inclination must be set.

- The inclination values are marked on the head-light as percentages. The headlight must be ad-justed according to these values. The percentagevalue is for a range of 10 m. For example, at anangle of inclination of 1.0 % (for vehicles withheadlight range control), this means 10 cm.

♦ The knurled wheel for the headlight range con-trol must be in position -0-.

Checking headlight setting (using new testscreen without 15° setting line)

- Switch the ignition on. - Switch on dipped headlight beams.

- The horizontal light -dark border should coincidewith the setting line -1- on the test surface.

- The break-away point -2- between the horizontalsection of the light -dark border on the left andthe rising section on the right should coincidewith the vertical line running through the centralpoint - 3 - . The bright spot in the centre of thebeam should be to the right of the vertical line.

151

Notes:

♦ In order to find the break-away point -2 - moreeasily, cover and uncover left half of headlight(facing direction of travel) a few times. Thencheck dipped beam again.

♦ If the dipped beam headlights have been cor-rectly adjusted, the centre spot of the mainbeam should lie on the central mark -3-.

♦ If using the old test screen with 15° setting line,the adjustment procedure is the same as for thenew test screen. To avoid incorrect settings, ig-nore the 15° setting line.

- If the headlight setting is incorrect adjust the set-ting as follows:

Adjusting headlights

• Observe requirements for checking and adjusting=> Page 150.

- Adjust setting using a suitable screwdriver (donot damage adjuster wheel) or Allen key.

- A - Height adjustment screw - B - Lateral adjustment screw

Note:

Illustration shows right headlight. The positioning ofthe adjustment screws on the left headlight is sym-metrically opposite.

152

Fog lights:

♦ Fog lights in headlights:

The fog lights are set automatically when the head-lights are set.

♦ Fog lights in bumper:

- Check whether the upper light - dark bordertouches the setting line and runs horizontallyacross the full width of the test screen.

- Turn the adjuster screw -arrow-to alter the beam.There is no provision for lateral adjustment.

Notes:

♦ The illustration shows the left fog light. ♦ The position of the adjuster screw on the right

fog light is symmetrically opposite. For access toscrew remove air intake grille in lower part ofbumper on right => Page 164.

Additional lights:

Additional lights from other systems which havebeen retrofitted must be checked and adjusted ac-cording to the applicable guidelines.

153

Test drive: perform

The extent to which the following can be checked isdependent upon the vehicle equipment and localconditions (city/country).

- The following points must be checked during thetest drive:

- Engine: output, misfiring, idling, acceleration - Clutch: pulling away, pedal pressure, smell - Gear selection: ease of actuation, gear lever po-

sition - Automatic gearbox: Select lever position, Shift -

Lock / ignition key interlock, gearshifts, displayon dash panel insert

- Brake pedal and handbrake: function, free playand effectiveness, pulling to one side, juddering,squealing, ABS function

- Steering: function, steering play, steering wheelin centre position when driving straight ahead

- Sun roof: Function - Cruise control system: Function - Radio: reception, GALA, interference

- On-board computer auto- check system: Func-tions

- Air conditioner: Function - Vehicle: moving off line when driving straight

ahead (level road) - Imbalance: wheels, drive shafts - Wheel bearings: noise - Engine: hot starting performance

154

Vehicle data sticker

The type plate -arrow- is on the right side panel.

Note:

Vehicles for certain export countries have no typeplate.

The vehicle identification number -arrow- is stampedon the rear cross panel of the engine compartment.

155

Meaning of vehicle identification number:

WAU ZZZ 4A Z T N 081 130

Manufacturer'scode

Filler characters Model Filler characters Model year1996

Production loca-tion

Serialnumber

156

The vehicle data sticker can be found in the custom-er's service schedule and in the spare wheel well oron the luggage compartment floor.

The sticker contains the following vehicle data:

- 1 -Production control number (not specified inService Schedule)

- 2 -Vehicle identification number - 3 -Model identification number/production con-

trol number - 4 -Model code - 5 -Engine output/emissions standard/gearbox - 6 -Engine- and gearbox code (not specified on

some export versions) - 7 -Paint number/interior equipment identifica-

tion number - 8 -Identification numbers for optional equip-

ment

157

Engine code and engine number

Notes:

♦ The "engine code" can be found on the vehicledata stickers in the service schedule and in thespare wheel well or on the luggage compart-ment floor.

♦ Additionally, there is a sticker on the toothedbelt cover with engine code and engine number.

4 - cyl. - 2V petrol engines, 5 - cyl. 2V petrol en-gines:

The engine number ("Engine code" and "Serial num-ber") is on the left of the cylinder block, below theexhauster on the 5-cylinder. - 2V engine.

158

4-cyl. 4V petrol engines:

The engine number ("Engine code" and "Serial num-ber") can be found on the left of the cylinder block -arrow-.

4-cyl. 5V petrol engines:

The engine number ("Engine code" and "Serial num-ber") can be found on the left of the cylinder block.

159

4-cyl. TDI engines:

The engine number ("Engine code" and "serial num-ber") can be found on the cylinder block - arrow -between the injection pump and exhauster.

5-cyl. 4V petrol engines (turbo):

The engine number ("Engine code" and "Serial num-ber") can be found on the rear right of the cylinderhead.

160


The engine number ("Engine code" and "Serial num-ber") can be found on the left of the cylinder block -arrow-.

V6 petrol engines:

The engine number ("engine code" and "serial num-ber") is stamped on the right inner side of the cylin-der block between cylinder head and hydraulicpump.

161

V8 petrol engines:

The engine number (engine code and serial number)is stamped on the left side of the cylinder block im-mediately above the hydraulic pump.

Lifting the vehicle

Important ♦ To avoid damaging the vehicle floor and to

prevent the vehicle from tipping, thevehicle should only be lifted at the pointsshown in the illustration.

♦ Never start engine and engage gear withthe vehicle lifted, even with only onewheel on the floor. There is a risk of acci-dent if this is not observed.

♦ If work is to be performed under thevehicle, it must be securely supported bysuitable stands.

162

Trolley jack

Always use a suitable rubber or wooden block toavoid damage.

A trolley jack can only be applied at the lifting pointsshown in the illustrations.

On no account should the vehicle be lifted at the en-gine sump, gearbox or front or rear axle, as this maycause serious damage.

Lifting platform

Before driving on to a lifting platform, ensure there issufficient clearance between the low - lying vehiclecomponents and lifting platform.

Lifting points for lifting platform and trolley jack

On the trolley jack lifting points on the underside ofthe door sills.

163

Front:

Rear:

Tow-starting/towing

- Attach tow rope or tow bar only to the followingtowing eyes:

Front towing eye

The front towing eye is behind the air intake grille onthe lower right of the bumper.

Audi 100, Audi S4:

- Unclip the air intake grille to the lower right of thebumper -arrows-.

164

Audi A6, Audi S6:

- Pull back retainer catch -arrows- and remove airintake grille.

Note:

When reinstalling the air intake grille, ensure that thelugs are inserted into the recesses provided.

Rear towing eye

The rear towing eye -arrow- is located below the rearright of the bumper.

Notes:

♦ The tow rope should be elastic to reduce therisk of damage to both vehicles. It is advisable touse synthetic fibre ropes or ropes of similarelastic material. However, it is safer to use thetow bar.

♦ Avoid excessive tensile forces and jerking. Dur-ing towing operations on roads which are notsurfaced, there is always a danger that the at-tachment parts will be over - stressed and dam-aged.

♦ The vehicle should only be tow-started if it is notpossible to start the engine using jump leads.

165

If the vehicle has to be towed or tow - started,please note the following points:

♦ Legal regulations concerning towing must be ob-served.

♦ Both drivers must be familiar with towing pro-cedures. Inexperienced drivers should not at-tempt to tow-start or tow.

♦ When using a tow rope, the driver of the towingvehicle must engage the clutch very gentlywhen moving off and changing gear.

♦ The driver of the towed vehicle must ensurethat the tow rope is always taut.

♦ Both vehicles must switch on their hazard warn-ing lights, unless otherwise specified by localregulations.

♦ The ignition must be switched on so that thesteering wheel is free and the turn signals, hornand windscreen wiper and washer system canbe used.

♦ Because the brake servo only works when theengine is running, considerably more pressure isrequired on the brake pedal when the engine isnot running.

♦ The power assisted steering does not workwhen the engine is not running, therefore moreforce is required to turn the steering wheel.

♦ If there is no lubricant in the manual or automat-ic gearbox, the vehicle must be towed with thedrive wheels raised.

When tow - starting vehicles with manual gear-box, please note the following points:

166

- Before moving off, engage 2nd or 3rd gear, pressclutch pedal and hold.

- Switch ignition on. - When both vehicles are moving, release clutch

pedal. - As soon as the engine starts, depress clutch and

move gear stick to neutral to avoid running intothe towing vehicle.

Notes:

♦ Vehicles with a catalytic converter (petrol en-gines only) must not be tow-started over a dis-tance of more than 50 m with the catalytic con-verter at operating temperature. Otherwise, un-burned fuel may enter the catalytic converterand cause damage.

♦ For technical reasons, it is not possible to tow-start a vehicle with an automatic gearbox.

When towinga vehicle with front - wheel driveand automatic gearbox the following pointsmust also be noted:

♦ Selector lever must be in position "N". ♦ Do not tow vehicle at a speed of more than 50

km/h. ♦ The maximum towing distance is 50 km.

If towing over greater distances, the vehicle must belifted at the front.

167

- Reason: When the engine is not running, thegearbox oil pump does not work, therefore thegearbox is not sufficiently lubricated for highspeeds and long distances.

Using a breakdown vehicle, the vehicle can only betowed with the front wheels raised.

- Reason: If raised at the rear, the drive shafts turnbackwards. As a result, the planetary gears in theautomatic gearbox will then turn at such highspeeds that the gearbox will be severely dam-aged in a short time.

When towinga vehicle with four wheel drive andmanual gearbox the following points must alsobe noted:

♦ Do not tow vehicle at a speed of more than 50km/h.

♦ The maximum towing distance is 50 km.

Using a breakdown vehicle the vehicle may betowed suspended at front or rear.

Note:

If it is not possible to tow the vehicle normally, itmust be transported by a special transporter or trail-er. This also applies to distances greater than 50 kilo-metres.

When towinga vehicle with four-wheel drive andautomatic gearbox the following points mustalso be noted:

♦ Selector lever must be in position "N".

168

♦ Do not tow vehicle at a speed of more than 50km/h.

♦ The maximum towing distance is 50 km.

If using a breakdown vehicle or tow truck the vehiclemust not be suspended (either at front or rear) whentowing.

Note:

If it is not possible to tow the vehicle normally, itmust be transported by a special transporter or trail-er.

Arbeitsabläufe Benzinmotoren

Motorspezifischer Arbeitsablauf nach Motorken-nbuchstaben:

AAD: Seite 190

AAE: Seite 193

AAH: Seite 195

AAN: Seite 198

AAR: Seite 201

ABC: Seite 204

ABH: Seite 207

ABK: Seite 210

ACE: Seite 213

ACK: Seite 215

ADA: Seite 220

169

ADR: Seite 222

AEC: Seite 207

AHK: Seite 227

Arbeitsabläufe Dieselmotoren

Arbeitsablauf nach Motorkennbuchstaben:

1Z: Seite 231

AAS: Seite 231

AAT: Seite 231

ABP: Seite 231

AEL:Seite 231

AHU: Seite 231

170

Abgasuntersuchung Deutschland

Intervalle für die Abgasuntersuchung

Fahrzeuge mit geregeltem Katalysator bzw.Fahrzeuge mit Dieselmotor:

♦ 36 Monate nach der Erstzulassung und dann alle24 Monate nach der letzten AU.

♦ Taxi und Mietwagen: Alle 12 Monate.

Der Fälligkeitstermin für die nächste Abgasunter-suchung ist der AU-Plakette zu entnehmen.

Beispiel

Ein Fahrzeug mit der abgebildeten AU - Plakette aufdem amtlichen Kennzeichen vorn muß im Dezember1997 zur Abgasuntersuchung.

Nach bestandener Abgasuntersuchung erhält dasFahrzeug eine AU-Plakette mit einer Gültigkeitsdauerbis Dezember 1999.

Hinweis:

Bei Taxi und Mietwagen wird eine Plakette mitGültigkeitsdauer 12 Monate vergeben.

171

Arbeitsabläufe Benzinmotoren

Hinweise:

♦ Intervalle für Abgasuntersuchung =>Seite 171. ♦ Alle für die Abgasuntersuchung benötigten Prüf-

bedingungen und Daten:

=> Ordner "Abgasuntersuchung"

♦ Beheben Sie beim Abfragen des Fehlerspeich-ers erkannte Fehler (Motorelektronik) undlöschen Sie den Fehlerspeicher vor der Ab-gasuntersuchung.

♦ Bei der Lambda-Regelkreisprüfung durch Fehler-speicher - Abfrage über das V.A.G 1551 ist dieVorbereitung einer Störgröße nicht erforderlich.

♦ Speziell bei neuen Katalysatoren kann esvorkommen, daß die Störgröße von der Regel-ung so schnell ausgeregelt wird, daß der Re-gelvorgang von den Meßgeräten nicht aus-reichend erfaßt wird.

♦ Bei der Lambda-Regelkreisprüfung durch Fehler-speicher - Abfrage über das V.A.G 1551 ist dieVorbereitung einer Störgröße nicht erforderlich.

Sichtprüfung

- Führen Sie eine Sichtprüfung der schadstoffbee-influssenden Bauteile durch auf:

- Vorhandensein - Vollständigkeit - Dichtigkeit - Beschädigung

172

Störgröße vorbereiten

Das Vorbereiten einer Störgröße ist nur erforderlichbei Prüfung ohne Fehlerspeicher - Abfrage (V.A.G1551) zur Lambda-Regelkreisprüfung => Seite 190.

Hinweise:

♦ Die nachstehend beschriebenen Benzinmotoren,ausgenommen Kennbuchstaben AAD und AAR,sind mit Fehlerspeichern ausgestattet, die es er-möglichen, die Lambda-Regelkreisprüfung durchFehlerspeicher - Abfrage über das V.A.G 1551bzw. 1552 vorzunehmen.

♦ Unterdruckleitungen nicht bei laufendem Motorabziehen, sonst erfolgt Fehlerspeicher-Eintrag.

♦ Unterdruckleitung für Störgröße beim Ab-schneiden nicht quetschen; der Leitungsquer-schnitt muß frei sein.

Motorkennbuchstaben: AAR

- Bereiten Sie die Störgröße wie folgt vor:

173

- Ziehen Sie den Blindstopfen bzw. den Leitung-sanschluß am hinteren Unterdruckanschluß desSammelsaugrohrs ab.

- Montieren Sie folgende Teile, wie in der Abb.dargestellt:

- 1 -Tülle 034 133 335 A - 2 -Unterdruckleitung 85 mm lang N 020 139 1 - 3 -Verschlußkappe 034 133 335

Motorkennbuchstaben: ABC

- Prüfen Sie bei Lambda - Regelkreisprüfung ohneFehlerspeicher - Abfrage (V.A.G 1551), ob die fol-genden, zur AU-Prüfung notwendigen Teile einge-baut sind:

- 1 -Verschlußkappe 034 133 335 - 2 -Unterdruckleitung 30 mm lang, N 020 139 1;

mit Kabelbinder -Pfeil- befestigen. - 3 -Gewebeschläuche 40 mm lang, N 020 353 5 - 4 -T-Anschluß 113 201 943 B

- Ggf. Teile einbauen.

174

Vorbereitung zu Prüfung

- Verschlußkappe -1- von T-Anschluß -4- abziehenund auf Unterdruckleitung -2- stecken.

- Unterdruckleitung -2- mit T-Anschluß -4- verbind-en.

Hinweis:

Nach der AU alle Unterdruckleitungen wieder an-schließen => Abb. A28-0014, Seite 174, da sonstFahrverhaltensmängel zu erwarten sind.

Motorkennbuchstaben: ABK

- Prüfen Sie bei Lambda - Regelkreisprüfung ohneFehlerspeicher - Abfrage (V.A.G 1551), ob die fol-genden, zur AU-Prüfung notwendigen Teile einge-baut sind:

- 1 -Verschlußkappe 034 133 335 - 2 -Unterdruckleitung 30 mm lang N 020 139 1 - 3 -Gewebeschlauch 40 mm lang N 020 353 5

- Ggf. Teile einbauen.

Motorkennbuchstaben: ADR

- Bauen Sie bei Lambda - Regelkreisprüfung ohneFehlerspeicher - Abfrage (V.A.G 1551) die fol-genden, zur AU-Prüfung notwendigen Teile ein:

175

- 1 -Verschlußkappe 034 133 335 (3x) - 2 -Unterdruckleitung 15 mm lang, N 020 139 1 - 3 -Gewebeschlauch 40 mm lang, N 020 353 5 - 4 -Winkelstück 034 129 737 - 5 -Schlauch 50 mm lang, 050 133 784 G

- Ziehen Sie den Schlauch -Pfeil- zum AKF-Behältervon der starren Leitung zum Saugrohr ab.

- Bestücken Sie das Winkelstück -4-, wie unten inder Abb. gezeigt.

- Stecken Sie das Winkelstück mit Schlauch auf diestarre Leitung auf, wie oben in der Abb. gezeigt.

Hinweise:

♦ Prüfen Sie den Innenquerschnitt des Winkel-stücks mit Draht auf freien Durchgang.

♦ Feilen Sie den Anschluß des Winkelstücks zumleichteren Einstecken in den Schlauch ggf. et-was dünner.

176

Prüfgeräte

Der Prüfablauf ist ausgelegt für Prüfungen mit derPrüfgerätekombination für Abgasuntersuchung, be-stehend aus:

♦ Fehlerauslesegerät V.A.G 1551 mit Diagnoselei-tung V.A.G 1551/1

♦ Zündungstester V.A.G 1767 ♦ 4-Komponenten-Abgastester V.A.G 1788 ♦ Datenlesegerät V.A.G 1799

montiert und verbunden auf Meßgerätewagen V.A.G1700

Achtung!

Um Verletzungen von Personen und/oder eineZerstörung der Einspritz - und Zündanlage zuvermeiden, ist folgendes zu beachten: ♦ Zündleitungen bei laufendem Motor bzw.

bei Anlaßdrehzahl nicht berühren bzw.abziehen.

♦ Leitungen der Einspritz - und Zündanlage,auch Meßgeräteleitungen nur bei aus-geschalteter Zündung ab- und anklemmen.

177

Fehlerauslesegerät V.A.G 1551 anschließen

Hinweis:

Das Fehlerauslesegerät wird zur Datenübertragungvom Abgastester zum Datenlesegerät gebraucht undmuß deshalb immer angeschlossen sein.

- Ziehen Sie die Handbremse an. - Schalten Sie bei Fahrzeugen mit Automatischem

Getriebe den Wählhebel in Stellung "P" oder "N". - Nehmen Sie die Abdeckung vom Zusatzrelais-

träger I im Wasserkasten links ab. - Schließen Sie bei ausgeschalteter Zündung den

schwarzen Stecker am schwarzen Diagnosean-schluß an.

V.A.G - EIGENDIAGNOSE HELP1 - Schnelle Datenübertragung 1)

2 - Blinkcodeausgabe 1)

Anzeige am Display:1) erscheint wechselweise

Hinweis:

Erfolgt keine Anzeige am Display:

=> Bedienungsanleitung des Fehlerauslesegerätes

- Schließen Sie den weißen Stecker am weißenbzw. braunen Diagnoseanschluß an (Stecker blauwird nicht verwendet).

178

Prüfablauf

am Datenlesegerät V.A.G 1799

Prüfvoraussetzungen:

• Klimaanlage ausgeschaltet. • Elektrolüfter für Kühler darf nicht laufen. • Viskolüfter für Kühler darf nicht kraftschlüssig

mitlaufen. • Alle elektrischen Verbraucher ausgeschaltet.

- Motor anlassen und im Leerlauf laufen lassen. - Drücken Sie am Datenlesegerät die F1-Taste für

"AU Benzin". - Führen Sie die Abgasuntersuchung nach den An-

weisungen am Display des Datenlesegerätesdurch.

Fahrzeugidentkarte bitte einstecken !!

Manuelle Eingabe mit " -Taste

Bei Anzeige am Display:

- Drücken Sie die ⇒-Taste. - Geben Sie die Fahrzeug - Identdaten (amtl. Ken-

nzeichen, Fzg.-Identnummer usw.) aus dem Kraft-fahrzeugschein über die Tastatur des Datenleseg-erätes ein.

Eingabe überprüfen mit " -Taste

Weiter mit Q-Taste


- Bestätigen Sie die Eingabe der Fahrzeugdaten mitder Q-Taste.

Strich-Code einlesen

Manuelle Eingabe mit ⇒ -Taste


- Ziehen Sie den Lesestift des Datenlesegerätesüber den entsprechenden Strichcode des Daten-blattes im Ordner "Abgasuntersuchung".

179

oder

- Führen Sie mit der ⇒-Taste die manuelle Eingabenach den Anweisungen am Display des Datenle-segerätes durch.

Eingabe überprüfen mit ⇒ -Taste

Weiter mit Q-Taste


- Bestätigen Sie die eingegebenen bzw. einge-lesenen Fahrzeugdaten mit der Q-Taste.

Sichtprüfung i.O. = j Nicht i.O. = n Bei Anzeige am Display:

- Geben Sie das Ergebnis der Sichtprüfung ein.

HC-Rückstandstest

Sonde an Frischluft? X ppm vol HC


Der Abgastester führt einen HC-Rückstandstest aus.Ist der Wert über 20 ppm, wird der Ablauf nicht weit-ergeführt. Die Entnahmesonde darf sich nicht im Ab-gasendrohr befinden.

AU-Prüfablauf beginnen

Sonde im Abgasendrohr? X % CO


- Setzen Sie die Entnahmesonde des Abgastestersin das Abgasendrohr ein.

F1 Temperaturmessung mit Meßfühler

F2 Temperaturmessung manuell eingeben


- Ziehen Sie den Ölmeßstab heraus. - Schieben Sie den Temperatur - Meßfühler in das

Ölmeßstabführungsrohr ein. - Drücken Sie die F1 - Taste für "Temperaturmes-

sung mit Meßfühler".

Motoröltemperatur

Ist XX5 C Soll 80° C


- Warten Sie, bis die Motoröltemperatur größer80°C ist.

180

Prüfung i.O. Weiter mit der Q-Taste

Prüfung wiederholen mit der F1-Taste


- Nehmen Sie den Meßfühler heraus. - Schieben Sie den Ölmeßstab ein. - Setzen Sie den Prüfablauf durch Drücken der Q-

Taste fort. - Schließen Sie den Zündungstester an, wie im Fol-

genden für die einzelnen Motorkennbuchstabenbeschrieben.

Zündungstester V.A.G 1767 anschließen

Motorkennbuchstaben:

AAD, AAE, AAR, ABK, ACE, ADA

- Triggerzange an die Hauptzündleitung zwischenZündspule und Zündverteiler anschließen.

Hinweis:

Bei geringer Öffnung der Triggerzange (z.B. durch zustarken Zug am Spiralkabel) kann es zu Fehlanzeigenkommen.

- Drücken Sie die ⇒-Taste.

Zylinder: Auswahl ⇒, Bestätigen Q

3 4 5 6 8 12 autom.

Bei Anzeige am Display des Zündungstesters:

- Wählen Sie die Zylinderanzahl "4" bzw. "5" mit der⇒-Taste an und bestätigen Sie mit der Q-Taste.

Ruhende Hochspannungsverteilung?

weiter mit ⇒ Taste, beenden mit Q Taste


- Beenden Sie mit der Q-Taste.

XXXX/min X Zyl.

XX,X° vor OT XX °C


181

- Führen Sie den Prüfablauf am DatenlesegerätV.A.G 1799 fort.

Motorkennbuchstaben: AAH, ABC

- Triggerzange am Leitungsstrang zum 3 - poligenStecker - Pfeil - zur Zündungs - Endstufe anklem-men.

Hinweis:




3 4 5 6 8 12 autom.


- Wählen Sie die Zylinderanzahl "6" mit der ⇒-Tastean und bestätigen Sie mit der Q-Taste.


weiter mit " -Taste, beenden mit Q-Taste



XXXX/min 6-Zyl.




182

Motorkennbuchstaben: AAN

- Triggerzange an der Zuleitung zu den Zündspulenanklemmen.

Hinweis:




3 4 5 6 8 12 autom.




weiter mit ⇒ Taste, beenden mit Q Taste



XXXX/min 5-Zyl.




183

Motorkennbuchstaben: ABH, AEC

- Triggerzange an der Hauptzündleitung Klemme 4an einer der Zündspulen anschließen -Pfeil-.

Hinweis:




3 4 5 6 8 12 autom.


- Wählen Sie die Zylinderanzahl "4" mit der ⇒-Tastean (obwohl 8-Zylinder) und bestätigen Sie mit derQ-Taste.


weiter mit ⇒ -Taste, beenden mit Q-Taste



XXXX/min 4 Zyl.




184

Motorkennbuchstaben: ACK

- Motor-Abdeckung ausbauen -Pfeile-.

- Klemmen Sie die Triggerzange am Leitungsstrang- Pfeil - zur Steckverbindung 3fach der Leistung-sendstufe an.

Hinweis:




3 4 5 6 8 12 autom.






185


XXXX/min 6-Zyl.





- Motorabdeckung ausbauen. - Triggerzange am Leitungsstrang -2- zum Stecker

der Zündungs-Endstufe anklemmen.

Hinweise:

♦ Das Massekabel -1 - darf sich nicht in der Trig-gerzange befinden, sonst ungenaue Drehzahlan-zeige.

♦ Bei geringer Öffnung der Triggerzange (z.B.durch zu starken Zug am Spiralkabel) kann es zuFehlanzeigen kommen.



3 4 5 6 8 12 autom.







XXXX/min 4 Zyl.




186

Motorkennbuchstaben: AHK

- Triggerzange am Leitungsstrang - Pfeil - zumStecker 4 - fach der Zündungs - Endstufe anklem-men.

Hinweis:




3 4 5 6 8 12 autom.


- Wählen Sie die Zylinderanzahl "4" mit der ⇒-Tastean (obwohl 8-Zylinder) und bestätigen Sie mit derQ-Taste.


weiter mit ⇒ -Taste, beenden mit Q-Taste



XXXX/min 4 Zyl.




Prüfablauf am Datenlesegerät V.A.G 1799(Fortsetzung)

Alle Motorkennbuchstaben

Warmlaufzeit für KAT XX s

Drehz.IST XXX/min SOLL XXXX/min


187

- Erhöhen Sie die Drehzahl zur Aufwärmung desKatalysators für vorgegebene Warmlaufzeit aufüber Sollwert.

Prüfung im erhöhten Leerlauf 30 s

Drehz.IST XXXX/min SOLL 2500...2800/min


- Halten Sie die Drehzahl für 30 Sekunden im Soll-wertbereich.

Hinweis:

Falls der Drehzahl - Sollwertbereich auf Grund desschnell ein- und ausschaltenden Lüfters für Kühlmit-tel nicht gehalten werden kann (z.B. bei Motorken-nbuchstaben AAN), Motor zur Prüfung wieder etwasabkühlen lassen.

- Überprüfen Sie die Istwerte (CO-Gehalt, Lambda-Wert). Schalten Sie dazu mit der ⇒ - Taste dieIstwerteanzeige weiter.

- Wiederholen Sie ggf. die Prüfung. - Setzen Sie den Prüfablauf durch Drücken der Q-

Taste fort.

Leerlaufprüfung 10 s

Drehz. IST XXX/min SOLL XXX...XXX/min


Das Datenlesegerät übernimmt innerhalb 10 Sekun-den die Istwerte.

- Überprüfen Sie den Istwert (CO-Gehalt), schaltenSie dazu mit der ⇒ - Taste die Istwerteanzeigeweiter.

- Wiederholen Sie ggf. die Prüfung. - Setzen Sie den Prüfablauf durch Drücken der Q-

Taste fort.

188

Prüfung mit Fehlerspeicher - Abfrage(V.A.G 1551) zur Lambda-Regelkreisprü-fung

Motorkennbuchstaben:

AAE, AAH, AAN, ABC, ABH, ABK, ACK, ADA,ADR, AEC, AHK

F1 Regelkreisprüfung - Grundverfahren

F2 Regelkreisprüfung - alternatives Verf.


- Drücken Sie die F2 - Taste für "alternatives Ver-fahren". Damit wird der Fehlerspeicher desSteuergerätes abgefragt (automatischer Prüfab-lauf).

F1 Fehlerspeicher abfragen (V.A.G 1551)

F2 Manuelle Beurteilung des Regelkreises


- Drücken Sie die F1-Taste für Fehlerspeicher-Ab-frage.




- Drücken Sie die Q-Taste.

Hinweis:

Prüfung n. i.O. Weiter mit der Q-Taste



F1-Taste drücken und Prüfung wiederholen bzw. Re-paraturmaßnahme durchführen.

Eingabe von Erläuterungen mit " -Taste

Weiter mit Q-Taste


- Geben Sie ggf. Erläuterungen nach Drücken der⇒-Taste ein.


Prüfer auswählen / manuelle Eingabe F3

F1 XXXXX F2 XXXXX


189

- Wählen Sie mit der F1 ... 3 -Taste den Prüfer anbzw. geben Sie den Namen ein.

- Drücken Sie die Q - Taste, warten Sie den Pro-tokollausdruck ab.

- Drücken Sie die ⇒-Taste. - Beenden Sie die Prüfung durch Drücken der Q -

Taste und der F2-Taste.

Prüfung ohne Fehlerspeicher - Abfrage(V.A.G 1551) zur Lambda-Regelkreisprü-fung

Alle Motorkennbuchstaben

F1 Regelkreisprüfung - Grundverfahren

F2 Regelkreisprüfung - alternatives Verf.


- Drücken Sie die F1-Taste für "Grundverfahren".

F1 Grundverfahren - Störgrösse/Halbwellen

F2 Regelkreisprüfung - Ersatzverfahren


- Drücken Sie die F1-Taste.

Regelkreisprüfung XX s

Drehz. IST XXXX/min SOLL XXX...XXXX/min


Das Datenlesegerät führt Soll/Istwert - Vergleich derDrehzahl für die Regelkreisprüfung aus.

Motorkennbuchstabe: AAD

Regelkreisprüfung beginnen

Weiter mit ⇒ -Taste


- Drücken Sie die ⇒ -Taste, die Regelkreisprüfungwird eingeleitet.

Regelkreisprüfung Störgröße EIN 60 s

X.XXX X.XXX


- Schalten Sie sofort die Störgröße wie folgt auf:

190

- Ziehen Sie die AKF-Leitung am Drosselklappenteil-Pfeil- ab.

Nachdem die Störgröße erkannt wurde => Display -Anzeige, muß sie innerhalb 60 Sekunden wiederausgeregelt werden.

Regelkreisprüfung Störgröße AUS 60 s

X.XXX X.XXX X.XXX X.XXX


- Schalten Sie sofort die Störgröße wie folgt aus: - Stecken Sie die AKF-Leitung am Drosselklappen-

teil -Pfeil- auf.

Nachdem das Ausschalten der Störgröße erkanntwurde => Display - Anzeige, muß sie innerhalb 60Sekunden wieder ausgeregelt werden.

l-AGW Str. EIN Ausger. Str. AUS Ausger.

X.XXX X.XXX X.XXX X.XXX X.XXX







Hinweise:

Anstelle der Display - Anzeige "Prüfung i.O." kannauch einer der beiden folgenden Display - Texte an-gezeigt werden:

191

Störgröße nur in einer Richtung erkannt

F1 1 Halbwelle erlaubt F2 Nicht erlaubt


♦ Die Störgröße wurde nur in einer Richtungerkannt.

♦ Die Regelkreisprüfung gilt auch als bestanden,wenn die Störgröße nur in einer Richtung erkan-nt wurde.

♦ Prüfablauf durch Drücken der F1 - Taste fortset-zen.




♦ F1 - Taste drücken und Prüfung ggf. mehrfachwiederholen, bis die Störgröße zumindest in ein-er Richtung erkannt wurde. Andernfalls Reparat-urmaßnahme durchführen.

Fortsetzung der Prüfung:


Weiter mit Q-Taste





F1 XXXXX F2 XXXXX






192

Hinweis:

Durch Drücken der F3 - Taste kann ein Kontrollaus-druck mit den Meßdaten erstellt werden.

Motorkennbuchstabe: AAE






X.XXX X.XXX



- Ziehen Sie die Unterdruckleitung -Pfeil- am Bimet-allregler ab.





- Schalten Sie sofort die Störgröße wie folgt aus: - Stecken Sie die Unterdruckleitung -Pfeil - am Bi-

metallregler auf.

193










Hinweise:














Weiter mit Q-Taste


194




F1 XXXXX F2 XXXXX






Hinweis:


Motorkennbuchstaben: AAH

- Motorabdeckung abbauen.

- Ziehen Sie den Unterdruckschlauch für Kraftstoff-Druckregler an der Saugrohrseite ab und ver-schließen Sie den Stutzen -Pfeil - von Hand, bissich die Lambda-Regelung eingeregelt hat (mind.20 Sekunden).

Hinweis:

Statt von Hand läßt sich der Stutzen des Unter-druckschlauches auch mit einer Gummi - Ver-schlußkappe 034 133 335 verschließen (z.B. beiheißem Motor).

195






X.XXX X.XXX


- Schalten Sie sofort die Störgröße wie folgt auf: - Öffnen Sie den Unterdruckanschluß Saugrohr-

seite.





- Schalten Sie sofort die Störgröße wie folgt aus:

- Verschließen Sie den UnterdruckanschlußSaugrohrseite -Pfeil- von Hand.









196


Hinweise:














Weiter mit Q-Taste





F1 XXXXX F2 XXXXX



197




Hinweise:

♦ Durch Drücken der F3 - Taste kann ein Kontrol-lausdruck mit den Meßdaten erstellt werden.

♦ Schließen Sie nach der AU den Unterdrucksch-lauch wieder am Stutzen -Pfeil- an.

Motorkennbuchstabe: AAN






X.XXX X.XXX



198

- Ziehen Sie die Unterdruckleitung -Pfeil- am Kraft-stoffdruckregler ab.





- Schalten Sie sofort die Störgröße wie folgt aus: - Stecken Sie die Unterdruckleitung -Pfeil- am Kraft-

stoffdruckregler auf.










Hinweise:


199











♦ Im Ausnahmefall kann es vorkommen, daß dieStörgröße nicht erkannt wird.

• Maßnahme bei nicht erkannter Störgröße:

- Ziehen Sie die Unterdruckleitung -Pfeil- vom Kraft-stoffdruckregler ab.

- Verschließen Sie das Leitungsende mit einemDorn.

- Warten Sie, bis sich die Lambda - Regelungeingeregelt hat (mind. 20 Sekunden).

- Ziehen Sie zum Aufschalten der Störgröße denDorn von der Unterdruckleitung ab.

- Stecken Sie zum Ausschalten der Störgröße denDorn wieder auf die Unterdruckleitung auf.



Weiter mit Q-Taste


200




F1 XXXXX F2 XXXXX






Hinweis:


Motorkennbuchstabe: AAR






X.XXX X.XXX



201

- Ziehen Sie die Verschlußkappe -3- ab.





- Schalten Sie sofort die Störgröße wie folgt aus: - Stecken Sie die Verschlußkappe auf.










Hinweise:





202







♦ F1 - Taste drücken und Prüfung ggf. mehrfachwiederholen, bis die Störgröße zumindest in ein-er Richtung erkannt wurde.

♦ Im Ausnahmefall kann es vorkommen, daß dieStörgröße nicht erkannt oder nicht ausgeregeltwird.


- Verkürzen Sie die Unterdruckleitung - 2 - schritt-weise um 10 mm, bis die Störgröße erkannt wird.

• Maßnahme bei nicht ausgeregelter Störgröße:

- Verlängern Sie die Unterdruckleitung -2 - schritt-weise um 10 mm, bis Störgröße ausgeregelt wer-den kann.



Weiter mit Q-Taste


203




F1 XXXXX F2 XXXXX






Hinweise:


♦ Stecken Sie nach der AU den Blindstopfen bzw.den Leitungsanschluß des Sammelsaugrohrswieder auf. Montieren Sie eine Schlauchschelle,die dem Serienstand entspricht.

=> Teile-Katalog

♦ Unterdruckleitungen nicht bei laufendem Motorabziehen, sonst Fehlerspeicher-Eintrag.

Motorkennbuchstaben: ABC






X.XXX X.XXX


204







- Schalten Sie sofort die Störgröße wie folgt aus: - Stecken Sie die Verschlußkappe -1- auf.










Hinweise:


205











♦ Im Ausnahmefall kann es vorkommen, daß dieStörgröße nicht erkannt oder nicht ausgeregeltwird.


- Verkürzen Sie den Schlauch -2- schrittweise um100 mm, bis die Störgröße erkannt wird.


- Verlängern Sie den Schlauch -2- schrittweise um100 mm, bis Störgröße ausgeregelt werden kann.



Weiter mit Q-Taste


206




F1 XXXXX F2 XXXXX





- Beenden Sie die Prüfung durch Drücken der Q -Taste und der F2-Taste.

Hinweise:


♦ Schließen Sie nach der AU alle Unterdruckleitun-gen wieder an, wie in der Abb. gezeigt, da sonstFahrverhaltensmängel zu erwarten sind.


Motorkennbuchstaben: ABH, AEC




207

- Unterdruckleitung - A - vom Kraftstoffdruckreglerabziehen und mit Dorn verschließen, Handvak-uumpumpe V.A.G 1390 mit Hilfsschlauch -B- amDruckregler anschließen, bis sich die Lambda-Re-gelung eingeregelt hat (min. 20 Sekunden).



X.XXX X.XXX


- Schalten Sie sofort die Störgröße wie folgt auf: - Gleichzeitig Unterdruckleitung - A - öffnen und

Handvakuumpumpe mehrmals schnell betätigen.






208

- Gleichzeitig Handvakuumpumpe am Kraftstoff-druckregler abziehen und Unterdruckleitung - A -verschließen.


- Stecken Sie die Unterdruckleitung -A- am Kraft -stoffdruckregler wieder auf.









Hinweise:








209







Weiter mit Q-Taste





F1 XXXXX F2 XXXXX






Hinweis:


Motorkennbuchstaben: ABK






X.XXX X.XXX


210







- Schalten Sie sofort die Störgröße wie folgt aus: - Stecken Sie die Verschlußkappe -1- auf.










Hinweise:


211













Weiter mit Q-Taste





F1 XXXXX F2 XXXXX






212

Hinweis:


Motorkennbuchstaben: ACE




- Unterdruckleitung - Pfeil - am Saugrohr abziehenund mit Dorn verschließen, bis sich die Lambda-Regelung eingeregelt hat (min. 20 Sekunden).



X.XXX X.XXX


- Schalten Sie sofort die Störgröße wie folgt auf: - Öffnen Sie die Unterdruckleitung -Pfeil-.






213

- Verschließen Sie die Unterdruckleitung -Pfeil-.










Hinweise:








214







Weiter mit Q-Taste





F1 XXXXX F2 XXXXX






Hinweis:


Motorkennbuchstabe: ACK




215

- Unterdruckschlauch vom Stutzen am Kraftstoff -Druckregler -Pfeil 2- abziehen und mit Dorn -Pfeil3 - verschließen, bis sich die Lambda - Regelungeingeregelt hat (min. 20 Sekunden).



X.XXX X.XXX


- Schalten Sie sofort die Störgröße wie folgt auf: - Ziehen Sie den Dorn - Pfeil 3 - aus dem Unter-

druckschlauch und ziehen Sie zusätzlich den Sch-lauch -Pfeil 1- am Rückschlagventil ab.






216

- Stecken Sie den Dorn -Pfeil 3-wieder in den Un-terdruckschlauch und stecken Sie den Schlauch -Pfeil 1- auf das Rückschlagventil.










Hinweise:








217







- Klemmen Sie den Unterdruckschlauch -Pfeil- vomMotor zum AKF - Ventil mit SchlauchklemmeV.A.G 3094 ab.

- Ziehen Sie den abgeklemmten Unterdrucksch-lauch am AKF-Ventil ab. Stecker des AKF-Ventilsnicht abziehen, sonst Fehlerspeicher-Eintrag!

- Stecken Sie das Winkelstück 034 129 737 -Pos. 4-auf den abgezogenen Unterdruckschlauch -Pfeil-

auf. - Feilen Sie ggf. den Anschluß des Winkelstückes

zum leichteren Einstecken in den Schlauch etwasdünner.

- Prüfen Sie den Innenquerschnitt des Winkel-stückes mit Draht auf freien Durchgang.

218

- Bestücken Sie das Winkelstück -4-, wie gezeigt:1 - Verschlußkappe 034 133 335 (3x)2 - Unterdruckleitung 30 mm lang, N 020 139 13 - Gewebeschlauch 40 mm lang, N 020 353 5

- Bauen Sie die Schlauchklemme V.A.G 3094wieder aus.

- Ziehen Sie zum Aufschalten der Störgröße diebeiden mit Pfeilen gekennzeichneten Ver-schlußkappengleichzeitigab.

- Stecken Sie zum Ausschalten der Störgrößebeide Verschlußkappengleichzeitigauf.


Eingabe von Erläuterungen mit ⇒ -Taste

Weiter mit Q-Taste





F1 XXXXX F2 XXXXX






Hinweise:


219

♦ Ziehen Sie keine Unterdruckschläuche beilaufendem Motor ab, sonst erfolgt Fehlerspeich-er-Eintrag.

♦ Schließen Sie nach der AU alle Unter-druckschläuche wieder an.

♦ Entfernen Sie nach der AU das ggf. eingebauteWinkelstück wieder und befestigen Sie den Sch-lauch am AKF - Behälter mit einer Schlauch-schelle, die dem Serienstand entspricht.

=> Teile-Katalog

Motorkennbuchstaben: ADA






X.XXX X.XXX



- Ziehen Sie die Unterdruckleitung - Pfeil - amSaugrohr ab.


220




- Schalten Sie sofort die Störgröße wie folgt aus: - Stecken Sie die Unterdruckleitung - Pfeil - am

Saugrohr auf.










Hinweise:











221




Weiter mit Q-Taste





F1 XXXXX F2 XXXXX






Hinweis:








X.XXX X.XXX



222

- Ziehen Sie die Verschlußkappe - 1 - von der Lei-tung -2- ab (die beiden anderen Verschlußkappenbleiben immer aufgesteckt).






223

- Stecken Sie die Verschlußkappe -1 - auf die Lei-tung -2- auf.










Hinweise:





224








♦ Im Ausnahmefall kann es vorkommen, daß dieStörgröße nicht erkannt bzw. nicht ausgeregeltwird.


225

- Verkürzen Sie die Leitung -2- schrittweise um 5mm, bis Störgröße erkannt wird.

- Entfernen Sie ggf. die Leitung -2- zum Aufschal-ten der Störgröße ganz.


- Verlängern Sie die Leitung -2- schrittweise um 5mm, bis Störgröße ausgeregelt werden kann.



Weiter mit Q-Taste





F1 XXXXX F2 XXXXX





226

- Beenden Sie die Prüfung durch Drücken der Q -Taste und der F2-Taste.

Hinweise:


♦ Entfernen Sie nach der AU das Winkelstückwieder und befestigen Sie den Schlauch zumAKF - Behälter an der starren Leitung zumSaugrohr mit einer Schlauchschelle, die demSerienstand entspricht.

=> Teile-Katalog


Motorkennbuchstaben: AHK






X.XXX X.XXX



227

- Ziehen Sie den Unterdruckschlauch -Pfeil- an derStirnseite des Saugrohrs in Motormitte ab.

Hinweis:

Der Saugrohr-Anschluß befindet sich je nach Motor-Baudatum weiter unten am Saugrohr.





- Schalten Sie sofort die Störgröße wie folgt aus: - Stecken Sie den Unterdruckschlauch - Pfeil -

wieder auf den Schlauchstutzen.










Hinweise:


228













- Klemmen Sie den Unterdruckschlauch - 2 - vomMotor zum AKF - Ventil mit SchlauchklemmeV.A.G 3094 ab.

- Ziehen Sie den abgeklemmten Unterdrucksch-lauch am AKF-Ventil ab. Stecker des AKF-Ventilsnicht abziehen, sonst Fehlerspeicher-Eintrag!

- Stecken Sie das Winkelstück 034 129 737 -Pos. 1-auf den abgezogenen Unterdruckschlauch - 2 -

auf. - Feilen Sie ggf. den Anschluß des Winkelstückes

zum leichteren Einstecken in den Schlauch etwasdünner.

- Prüfen Sie den Innenquerschnitt des Winkel-stückes mit Draht auf freien Durchgang.

229

- Bestücken Sie das Winkelstück -1 - , wie gezeigtmit 3 Verschlußkappen 034 133 335.

- Bauen Sie die Schlauchklemme V.A.G 3094wieder aus.

- Ziehen Sie zum Aufschalten der Störgröße zweider Verschlußkappen -Pfeile-gleichzeitigab.

- Stecken Sie zum Ausschalten der Störgrößebeide Verschlußkappen gleichzeitigauf.



Weiter mit Q-Taste





F1 XXXXX F2 XXXXX






Hinweise:


♦ Ziehen Sie keine Unterdruckschläuche beilaufendem Motor ab, sonst erfolgt Fehlerspeich-er-Eintrag.

♦ Schließen Sie nach der AU alle Unter-druckschläuche wieder an.

230

♦ Entfernen Sie nach der AU das ggf. eingebauteWinkelstück wieder und befestigen Sie den Sch-lauch am AKF - Behälter mit einer Schlauch-schelle, die dem Serienstand entspricht.

=> Teile-Katalog

Arbeitsablauf Dieselmotoren

Motorkennbuchstaben: 1Z, AAS, AAT, ABP, AEL,AHU

Hinweise:

♦ Intervalle für Abgasuntersuchung =>Seite 171. ♦ Alle für die Abgasuntersuchung benötigten Prüf-

bedingungen und Daten:

=> Ordner "Abgasuntersuchung"

♦ Beheben Sie beim Abfragen des Fehlerspeich-ers erkannte Fehler (Motorelektronik) undlöschen Sie den Fehlerspeicher vor der Ab-gasuntersuchung.

♦ Motor nicht im Stand warmlaufen lassen, son-dern anläßlich einer Probefahrt warmfahren.

♦ Sind die Trübungswerte nicht im Sollbereich, zü-gige Probefahrt durchführen und Messungwiederholen.

Sichtprüfung

- Führen Sie eine Sichtprüfung der schadstoffbee-influssenden Bauteile durch auf:

- Vorhandensein - Vollständigkeit - Dichtigkeit

231

- Beschädigung

Prüfgeräte

Der Prüfablauf ist ausgelegt für Prüfungen mit derPrüfgerätekombination für Abgasuntersuchung, be-stehend aus:

♦ Datenlesegerät V.A.G 1799 ♦ Dieseltester V.A.G 1743 ♦ Fehlerauslesegerät V.A.G 1551 mit Diagnoselei-

tung V.A.G 1551/1

montiert und verbunden auf Meßgerätewagen V.A.G1700

Prüfgeräte anschließen

- Ziehen Sie die Handbremse an. - Schalten Sie bei Fahrzeugen mit Automatischem

Getriebe den Wählhebel in Stellung "P" oder "N".

Dieseltester V.A.G 1743 anschließen

- Bauen Sie bei den TDI - Motoren die Motor - Ab-deckung aus -Pfeile-.

- 4-Zyl TDI-Motor

232

- 5-Zyl TDI-Motor

- Schließen Sie den Dieseltester V.A.G 1743 an:

=> Bedienungsanleitung

- Reinigen Sie vor dem Anklemmen des Piezo-Ge-bers - 1 - die Einspritzleitung Zylinder 1 an derKlemmstelle von Schmutz und Korrosion.

- Achten Sie auf guten Kontakt der Masseklemme -2-.

Hinweise:

♦ Ist der Piezo-Geber an der Leitung angeklemmt,darf er nicht mehr auf der Leitung gedreht wer-den.

♦ Falls der Piezo - Geber kein verwertbares Dre-hzahlsignal liefert, kann die Motordrehzahl mitdem OT - Geber des Dieseltesters abgegriffenwerden. OT-Geber in Bohrung an der Getriebeg-locke bis zum Anschlag einstecken.

233

Fehlerauslesegerät V.A.G 1551 anschließen

Hinweis:

Das Fehlerauslesegerät wird zur Datenübertragungvom Dieseltester zum Datenlesegerät gebraucht undmuß deshalb immer angeschlossen sein. Dabei istes gleichgültig, ob die Spannungsversorgung - wiebeschrieben - vom Fahrzeug kommt oder ob sie überdie Spannungsversorgungsleitung (5-poliger Stecker)vom Meßgerätewagen aus erfolgt.

- Nehmen Sie die Abdeckung vom Zusatzrelais-träger I im Wasserkasten links ab.

- Schließen Sie bei ausgeschalteter Zündung denschwarzen Stecker am schwarzen Diagnosean-schluß an.

V.A.G - EIGENDIAGNOSE HELP1 - Schnelle Datenübertragung 1)

2 - Blinkcodeausgabe 1)

Anzeige am Display:1) erscheint wechselweise

Hinweis:

Erfolgt keine Anzeige am Display:

=> Bedienungsanleitung des Fehlerauslesegerätes

- Schließen Sie den weißen Stecker am weißenDiagnoseanschluß an (Stecker blau wird nicht ver-wendet).

234

Prüfablauf

Prüfvoraussetzungen:

• Klimaanlage ausgeschaltet. • Elektrolüfter für Kühler darf nicht laufen. • Viskolüfter für Kühler darf nicht kraftschlüssig

mitlaufen. • Alle elektrischen Verbraucher ausgeschaltet.

- Drücken Sie am Datenlesegerät die F2-Taste für"AU Diesel".

- Führen Sie die Abgasuntersuchung nach den An-weisungen am Display des Datenlesegerätesdurch.

Fahrzeugidentkarte bitte einstecken !!

Manuelle Eingabe mit " -Taste


- Drücken Sie die ⇒-Taste. - Geben Sie die Fahrzeug - Identdaten (amtl. Ken-

nzeichen, Fzg.-Identnummer usw.) aus dem Kraft-fahrzeugschein über die Tastatur des Datenleseg-erätes ein.


Weiter mit Q-Taste


- Bestätigen Sie die Eingabe der Fahrzeugdaten mitder Q-Taste.

Strich-Code einlesen

Manuelle Eingabe mit ⇒ -Taste


- Ziehen Sie den Lesestift des Datenlesegerätesüber den entsprechenden Strichcode des Daten-blattes im Ordner "Abgasuntersuchung".

oder

235

- Führen Sie mit der ⇒-Taste die manuelle Eingabenach den Anweisungen am Display des Datenle-segerätes durch.

Eingabe überprüfen mit ⇒ -Taste

Weiter mit Q-Taste


- Bestätigen Sie die eingegebenen bzw. einge-lesenen Fahrzeugdaten mit der Q-Taste.

F1 AU Diesel (V.A.G 1500)

F2 AU Diesel (V.A.G 1743)


- Drücken Sie die F2-Taste für "AU mit V.A.G 1743".


Weiter mit Q-Taste


- Bestätigen Sie die Eingabe mit der Q-Taste.

Sichtprüfung i.O. = j Nicht i.O. = n Bei Anzeige am Display:

- Geben Sie das Ergebnis der Sichtprüfung ein.

Sonde aus dem Abgasendrohr nehmen

Weiter mit " -Taste


- Ziehen Sie die Entnahmesonde des Dieseltestersaus dem Abgasendrohr heraus.


Datenübertragung zum Dieseltester

Frischluft-Abgleich


- Warten Sie den Abgleich ab.

Sonde in das Abgasendrohr einstecken

Weiter mit " -Taste


- Stecken Sie die Entnahmesonde des Dieseltest-ers in das Abgasendrohr.

- Motor anlassen und im Leerlauf laufen lassen. - Drücken Sie die ⇒-Taste.

F1 Temperaturmessung mit Meßfühler

F2 Temperaturmessung manuell eingeben


236

- Ziehen Sie den Ölmeßstab heraus. - Schieben Sie den Temperatur - Meßfühler in das

Ölmeßstabführungsrohr ein. - Drücken Sie die F1 - Taste für "Temperaturmes-

sung mit Meßfühler".

Motoröltemperatur

Ist XX5 C Soll 80° C


- Warten Sie, bis die Motoröltemperatur größer80°C ist.




- Nehmen Sie den Meßfühler heraus.

- Schieben Sie den Ölmeßstab ein. - Setzen Sie den Prüfablauf durch Drücken der Q-

Taste fort.

Leerlaufprüfung 30 s



Das Datenlesegerät übernimmt innerhalb 30 Sekun-den die Istwerte, während der Motor mit Leerlauf-drehzahl läuft.

Leerlaufdrehzahl ⇒




Hinweise:

Liegt die Leerlaufdrehzahl nicht im Toleranzbereich:

♦ TDI-Motoren 1Z, AAT, ABP, AEL, AHU (Drehzahlnicht einstellbar):

- Führen Sie eine Reparaturmaßnahme durch.

237

♦ Dieselmotor AAS:

- Lösen Sie die Kontermutter der Leerlaufdrehzahl-Einstellschraube -Pfeil-.

- Stellen Sie die Leerlaufdrehzahl ein und sichernSie die Leerlaufdrehzahl -Einstellschraube wiedermit der Kontermutter.

- Setzen Sie den Prüfablauf durch Drücken der Q-Taste fort.

Abregeldrehzahl 5 s



- Treten Sie das Gaspedal für die vorgegebeneSollzeit ganz durch und halten Sie es in dieserStellung.

Abregeldrehzahl ⇒



- Lassen Sie das Gaspedal los. - Drücken Sie die ⇒-Taste.

Hinweise:

Liegt die Abregeldrehzahl nicht im Toleranzbereich:

♦ TDI-Motoren 1Z, AAT, ABP, AEL, AHU (Drehzahlnicht einstellbar):

- Führen Sie eine Reparaturmaßnahme durch.

238

♦ Dieselmotor AAS:

- Lösen Sie die Kontermutter der Einstellschraube -Pfeil-.

- Vollgas geben und Drehzahl mit der Einstells-chraube einstellen.

- Sichern Sie die Einstellschraube wieder mit derKontermutter.

- Setzen Sie den Prüfablauf durch Drücken der Q-Taste fort.

Leerlaufdrehzahl 1. Messung 15 s





Fahrpedal schnell durchtreten


- Treten Sie das Gaspedal ganz durch und haltenSie es in dieser Stellung.


Freie Beschleunigung läuft


- Halten Sie das Gaspedal weiterhin durchgetreten.




- Lassen Sie das Gaspedal los.





239
































240

Trübungswert-Spitzenwert ⇒

IST X,XX/m SOLL X...X,XX/m


- Lassen Sie das Gaspedal los. - Drücken Sie die ⇒-Taste.

Trübungswert-Mittelwert ⇒




Trübungswert-Bandbreite ⇒








Hinweis:




F1-Taste drücken und Prüfung wiederholen bzw. Re-paraturmaßnahme durchführen.


Weiter mit Q-Taste





F1 XXXXX F2 XXXXX






241

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Maintenance audi 100

Automotive

Transcript of Maintenance audi 100