Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...

Electrical system; General information - Edition 06.2014

Contents

27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Basic information on the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Battery types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Warnings and safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Battery terminal screw connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Test sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Checking colour indicator of magic eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Checking battery using vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Battery tester with printer VAS 5097 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7 Current draw test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.8 Checking no-load voltage of battery, stock vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1 Battery charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3 Battery charger VAS 5903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4 Battery charger VAS 5906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.5 Solar panel VAS 6102 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.6 Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1 Checking alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.2 Bosch alternator up to 2000 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.3 Bosch alternator from 2001 onwards - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4 Removing and installing voltage regulator - Bosch alternator from 2001 onwards . . . . . . 64
4.5 Bosch alternator from 2007 onwards - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.6 Removing and installing voltage regulator - Bosch alternator from 2007 onwards . . . . . . 65
4.7 Checking carbon brushes - all types of Bosch alternators from 2001 onwards . . . . . . . . . . 66
4.8 Valeo alternator up to 2000 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
66
4.9 unlessValeo
permitted alternator
authorised by AUDI AG.from
AUDI AG2001 onwards
does not guarantee -orexploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . .
accept any liability 68
4.10 Removing and installing voltage regulator - Valeo alternator from 2001 onwards . . . . . . . .
with respect to the correctness of information in this document. Copyright by AUDI AG.
69
4.11 Checking carbon brushes - Valeo alternator from 2001 onwards . . . . . . . . . . . . . . . . . . . . 69
4.12 Removing and installing voltage regulator - Valeo alternator from 2007 onwards . . . . . . . . 70
4.13 Checking carbon brushes - Valeo alternator from 2007 onwards . . . . . . . . . . . . . . . . . . . . 70
4.14 Removing and installing poly V-belt pulley without free-wheel . . . . . . . . . . . . . . . . . . . . . . 71
4.15 Removing and installing poly V-belt pulley with free-wheel . . . . . . . . . . . . . . . . . . . . . . . . 72
4.16 Checking poly V-belt pulley with free-wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

1 Washer fluid hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.1 Disconnecting and connecting washer fluid hose connectors . . . . . . . . . . . . . . . . . . . . . . 76
1.2 Servicing a smooth washer fluid pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.3 Servicing a washer fluid hose with corrugated tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

1 Safety precautions when handling gas discharge bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . 81

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

1 Immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.2 Defective transponder or loss of key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Contents i
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Electrical system; General information - Edition 06.2014

1.3 Renewing reader coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

1.4 Procedure for renewing lock set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2 Towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.1 Removing and installing socket for towing bracket - version 1 . . . . . . . . . . . . . . . . . . . . . . 85
2.2 Removing and installing socket for towing bracket - version 2 . . . . . . . . . . . . . . . . . . . . . . 86
2.3 Removing and installing socket for towing bracket - version 3 . . . . . . . . . . . . . . . . . . . . . . 88
2.4 Pin assignment at socket for towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1 Vehicle diagnostic, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.1 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2 Repairing wiring harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.1 General information on repairs to the vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . 93
2.2 Wiring harness repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.3 Description of tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.4 Repairing wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.5 Repairing fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.6 Repairing aerial wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.7 Repairing connector housings and electrical connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.8 Releasing and dismantling connector housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3 Contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3.1 Using contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4 ESD (electrostatic discharge) workplace VAS 6613 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.1 Using ESD workplace VAS 6613 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

ii Contents
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Electrical system; General information - Edition 06.2014

27 – Starter, current supply, CCS

1 Battery
(ARL003847; Edition 06.2014)
⇒ “1.1 Basic information on the battery”, page 1
⇒ “1.2 Battery types”, page 1
⇒ “1.3 Warnings and safety precautions”, page 3
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “1.4 Battery terminal screw
permitted connection”,
unless authorised by AUDI page 6 AG does not guarantee or accept any liability
AG. AUDI
with respect to the correctness of information in this document. Copyright by AUDI AG.
1.1 Basic information on the battery
To ensure a long service life, the battery - A- must be checked,
serviced and maintained according to the specifications in this
Manual.
The battery - A- supplies the power needed to start the engine;
furthermore, it acts as an electrical buffer and supplies power to
all parts of the vehicle's electrical system.

Note

Observe ⇒ Self-study programme No. 234 ; Vehicle batteries .

Caution

To avoid damaging the battery - A- or the vehicle, observe

notes on the types of batteries ⇒ page 1 .

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

1.2 Battery types

General notes

Caution

The batteries - A- described below are maintenance-free bat‐

teries - A- . Do not remove any labels and do not top up with
distilled water. Perform only a visual check. Note the chapter
on checking the battery ⇒ page 7 .

1. Battery 1
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Electrical system; General information - Edition 06.2014

⇒ “1.2.1 Battery A with magic eye”, page 2

⇒ “1.2.2 EFB battery”, page 2
⇒ “1.2.3 AGM battery”, page 3

1.2.1 Battery - A- with magic eye

Maintenance-free battery - A- with liquid electrolyte (wet battery)

Caution

Do not remove any labels and do not top up with distilled water.
Perform only a visual check. Note the chapter on checking the
battery ⇒ page 7 .

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

This battery - A- has a magic eye which provides information on

the battery charge and electrolyte level using a colour indicator.
Checking the colour indicator of the magic eye ⇒ page 10

1.2.2 EFB battery

Maintenance-free battery - A- with liquid electrolyte (wet battery)

Caution

Do not remove any labels and do not top up with distilled water.
Perform only a visual check. Note the chapter on checking the
battery.

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must bebyrenewed.
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

This battery - A- is used for the special requirements that some

vehicles with start/stop system have. This type of battery is
marked with the letters “EFB” on the battery cover.
“EFB” stands for »enhanced flooded battery«.
An EFB battery may only be replaced by another EFB battery.
This battery - A- has a magic eye which provides information on
the battery charge and electrolyte level using a colour indicator.

2 Rep. gr.27 - Starter, current supply, CCS

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Electrical system; General information - Edition 06.2014

Checking the colour indicator of the magic eye ⇒ page 10

Note

“EFB” batteries have been installed in e.g. certain Audi A1 and

A3 vehicles since 08.2011.

1.2.3 AGM battery

Maintenance-free battery - A- with solidified electrolyte (valve-
regulated lead acid)
Lead-acid battery with electrolyte solidified in an absorbent glass
mat (AGM). The battery - A- is sealed and equipped with valves.
“AGM” stands for »absorbent glass mat«.
As the electrolyte is absorbed in the mat, these batteries - A- can‐
not have a magic eye. Absorbent glass mat batteries - A- are
marked with the abbreviation AGM.
An AGM battery must always be replaced by another AGM bat‐
tery.

1.3 Warnings and safety precautions

⇒ “1.3.1 Dangers associated with handling batteries”, page 3
⇒ “1.3.2 Safety markings on battery”, page 5
⇒ “1.3.3 Work on the airbag system”, page 5

1.3.1 Dangers associated with handling bat‐

teries
Knowing and avoiding dangers
Handling batteries - A- is dangerous. However, such dangers can
be avoided by paying attention to the warnings on the battery -
A- , in the ⇒ Owner's Manual and inProtected
ELSA.by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Battery 3
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Electrical system; General information - Edition 06.2014

WARNING

♦ Non-qualified personnel such as trainees and junior staff

must only be allowed to perform work on batteries - A-
under the supervision of skilled workers such as qualified
vehicle mechanics or electricians.
♦ Acid is highly corrosive. If batteries - A- are handled im‐
properly, there is a danger of exposure to electrolyte,
which can be harmful to persons involved. Therefore suit‐
able measures must be taken to ensure that equipment/
solutions etc. are available to neutralise acid burns. Soap
solution is a suitable neutralising agent.
♦ Electrolyte escaping from the battery - A- can cause skin
burns, acid degradation and corrosion on the vehicle. This
may damage safety-relevant components on the vehicle.
♦ The gas given off during charging and emitted by the bat‐
tery at rest after charging is explosive. In the worst case,
improper handling of the battery - A- can lead to explosion
caused by escaping gas.
♦ Renew the battery - A- if the magic eye is colourless or
light yellow. It must not be checked or charged; do not
jump start the vehicle. There is a risk of explosion when
checking or charging the battery or jump starting the ve‐
hicle.
♦ Sparks (caused by grinding, welding or cutting) and naked
flames (e.g. smoking in the vicinity of the battery) are pro‐
hibited. It is likewise important to avoid sparks resulting
from electrostatic discharge. Always touch the vehicle
body before handling the battery - A- .
♦ Only work on batteries - A- in suitable, well ventilated
areas.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
WARNING

Risk of environmental pollution.

♦ Old batteries are hazardous waste. They contain toxic
lead (Pb) and sulphuric acid.
♦ Observe disposal regulations. Old batteries should only
be disposed of in appropriate containers at an official col‐
lection point.

4 Rep. gr.27 - Starter, current supply, CCS

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Electrical system; General information - Edition 06.2014

1.3.2 Safety markings on battery

Safety markings on battery - A-
1- Fires, sparks, naked flames and smoking are prohibited
when handling batteries - A- . Avoid sparks and static dis‐
charge when handling wires and electrical equipment. To
avoid short circuits, never place tools on the battery - A- .
2- Wear eye protection when working on the battery - A- .
3- Keep children away from acid and batteries - by
Protected A-copyright.
. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4- Disposal: Old batteries are hazardous waste. They
with respect must
to the al‐ of information in this document. Copyright by AUDI AG.
correctness
ways be be disposed of at an official collection point; all legal
requirements must be observed.
5- Do not dispose of old batteries with household waste.
6- There is a risk of explosion when handling batteries - A- . A
highly explosive gas mixture is given off when batteries - A-
are under charge.
7- Always observe the notices on the battery - A- , in the ⇒
Electronic parts catalogue “ETKA” and in the ⇒ Owner's
Manual .
8- Danger of acid burns: Electrolyte is highly corrosive; pro‐
tective gloves and eye protection should therefore always
be worn when working on the battery - A- . Do NOT tilt the
battery - A- as electrolyte can leak out of the gas vents.

1.3.3 Work on the airbag system

WARNING

When working on the airbag system (pyrotechnical compo‐

nents, airbag control unit - J234- , wiring) the battery earth strap
must be disconnected when the ignition is switched on.
Exception: On vehicles with a battery in the passenger com‐
partment, the ignition must be switched OFF.
♦ Then put the cover on the battery negative terminal.
♦ Wait 10 seconds after disconnecting the battery.
♦ The ignition must be switched on when re-connecting the
battery.
♦ When re-connecting the battery, there must not be anyone
inside the vehicle.
Ensure that you are not within range of the airbags and belt
tensioners.
If the ignition is not switched on after re-connecting the battery
(indicator lamps in the instrument cluster are not lit), the ignition
may only be switched on (key/button) from the driver's seat
with the seat in the rearmost position.

1. Battery 5
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Electrical system; General information - Edition 06.2014

1.4 Battery terminal screw connection

Caution

Observe the following to avoid damaging the battery clamps

and battery terminals:
♦ Only connect battery clamps by hand without exerting
force.
♦ Battery terminals must not be greased.
♦ Fit battery terminal clamps in such a way that the battery
terminal post is flush with the terminal clamp or protrudes
from it.
♦ Never re-tighten screw connections after tightening bat‐
tery clamps to specified torque.

Specified torque for battery clamps ⇒ Electrical system; Rep. gr.

27 ; Battery; Exploded view - battery

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

6 Rep. gr.27 - Starter, current supply, CCS

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Electrical system; General information - Edition 06.2014

2 Checking battery
⇒ “2.1 Test sequence”, page 7
⇒ “2.2 Visual check”, page 9
⇒ “2.3 Checking colour indicator of magic eye”, page 10
⇒ “2.4 Checking battery using vehicle diagnostic tester”,
page 11
⇒ “2.5 Battery tester with printer VAS 6161 ”, page 13
⇒ “2.6 Battery tester with printer VAS 5097 A ”, page 18
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “2.7 Current draw test”, page 23 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ “2.8 Checking no-load voltage of battery, stock vehicles”, page
24

2.1 Test sequence

⇒ “2.1.1 Checking battery - vehicles with battery monitor control
unit J367 or energy management control unit J644 and data bus
diagnostic interface J533 ”, page 7
⇒ “2.1.2 Checking battery - vehicles without battery monitor con‐
trol unit J367 or energy management control unit J644 ”,
page 8

2.1.1 Checking battery - vehicles with battery

monitor control unit - J367- or energy
management control unit - J644- and
data bus diagnostic interface - J533-
♦ On some models, the electrical system is monitored by the
energy management control unit - J644- or the battery monitor
control unit - J367- in connection with the data bus diagnostic
interface - J533- (allocation ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations). The battery test for these
vehicles is performed via “Guided Fault Finding”.
♦ If is not possible to check the battery in the “Guided Fault
Finding” because of a partially or totally discharged battery,
the charge status of the battery can be assessed quickly via
“Checking battery by measuring current draw”.
♦ Do not open maintenance-free batteries; this would invalidate
the warranty.

Caution

On the following models up to model year 2010, checking the

battery in “Guided Fault Finding” is not possible even if, de‐
pending on the version, the battery monitor control unit - J367-
is installed:
♦ A3 2004 ▶ (8P)
♦ TT 2007 ▶ (8J)
♦ R8 2007 ▶ (42)
Checking battery
⇒ “2.1.2 Checking battery - vehicles without battery monitor
control unit J367 or energy management control unit J644 ”,
page 8

2. Checking battery 7
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Electrical system; General information - Edition 06.2014

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

Perform checks in the following sequence:

1. Visual check ⇒ page 9 .
2. Check colour indicator of magic eye (where applicable)
⇒ page 10 .

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

3. Check battery using vehicle diagnostic tester ⇒ page 11 .

2.1.2 Checking battery - vehicles without bat‐

tery monitor control unit - J367- or ener‐
gy management control unit - J644-

Caution

On the following models up to model year 2010, checking the

battery in “Guided Fault Finding” is not possible even if, de‐
pending on the version, the battery monitor control unit - J367-
is installed:
♦ A3 2004 ▶ (8P)
♦ TT 2007 ▶ (8J)
♦ R8 2007 ▶ (42)

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

Perform checks in the following sequence:

1. Visual inspection ⇒ page 9
2. Check colour indicator of magic eye (where applicable)
⇒ page 10 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

8 Rep. gr.27 - Starter, current supply, CCS

 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Note

In the near future, battery tester with printer - VAS 5097 A- will no
longer be used for testing the battery; only battery tester with
printer - VAS 6161- will be used.

3. Checking battery with:

♦ Battery tester with printer - VAS 6161- ⇒ page 13
♦ Battery tester with printer - VAS 5097 A- ⇒ page 18
4. Depending on result of battery load test, perform current
draw test ⇒ page 23 .

2.2 Visual check

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
WARNING with respect to the correctness of information in this document. Copyright by AUDI AG.

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

Before carrying out any extensive measurements, perform a vis‐

ual check of the outside of the battery - A- and its connections,
and ensure that it is securely seated.

Caution

♦ Battery - A- may be damaged if it is not properly secured.

♦ Vibrations shorten the life of the battery. There is a danger
of explosion; the plates in the battery may be damaged
and the retainer plate may damage the battery housing.
♦ Check that battery - A- is securely seated (tighten securing
bolt to specified torque if necessary).

Perform visual check for the following:

♦ Damage to battery housing. Electrolyte can leak out if the
housing is damaged and cause severe damage to the vehicle.
Treat any components contaminated by battery acid immedi‐
ately with acid neutraliser or soap solution.
♦ Damage to battery terminals. The necessary contact on the
battery clamps cannot be guaranteed if the battery terminals
are damaged. When connecting the battery clamps, always
observe the specified torque indicated in the Workshop Man‐
ual for relevant vehicle ⇒ Electrical system; Rep. gr. 27 ;
Battery; Exploded view - battery . If the battery clamps are not
correctly seated and tightened, there is a risk of a cable fire.
This would cause severe malfunctions in the electrical system,

2. Checking battery 9
 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

and safe operation of the vehicle would no longer be guaran‐

teed.

2.3 Checking colour indicator of magic eye

⇒ “2.3.1 Checking 3-colour indicator, up to 03/2008”, page 10
⇒ “2.3.2 Checking 2-colour indicator, from 04/2008 onwards”,
page 11

2.3.1 Checking 3-colour indicator, up to

03/2008

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

General information on magic eye:

The magic eye indicates the electrolyte level and charge level of
the battery - A- .
Prior to visual inspection, use a screwdriver handle to tap gently
and carefully on the magic eye. Any air bubbles that could cause
distortion will be dispersed, and the colour indicator of the magic
eye will be more accurate.

Note

♦ In particular when charging the battery - A- (or when it is

charged when the vehicle is driven), air bubbles may form un‐
der the magic eye and falsify the colour indicator.
♦ As the magic eye is only located in one battery cell, the indi‐
cator only shows the level for this battery cell. The battery
condition can be determined exactly only by a battery load test
⇒ page 19 .
♦ The magic eye can be located at different positions on the
battery - A- .

There are three different indicator colours:

♦ Green: Battery - A- is charged sufficiently.
♦ Black: Battery - A- is partly discharged, charged less than 65
% or completely discharged.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Colourless/light yellow: Battery - A- must be renewed. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

10 Rep. gr.27 - Starter, current supply, CCS

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Electrical system; General information - Edition 06.2014

2.3.2 Checking 2-colour indicator, from

04/2008 onwards

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

General information on magic eye:

These batteries - A- do not have a green colour indicator for the
charge level display. The only colours are black or colourless/light
yellow.
The colour indicator shows the electrolyte level of the battery -
A- .
The charge level of the battery - A- cannot be determined using
the magic eye; a battery load test is required ⇒ page 19 .
Prior to visual inspection, use a screwdriver handle to tap gently
and carefully on the magic eye. Any air bubbles that could cause
distortion will be dispersed, and the colour indicator of the magic
eye will be more accurate.

Note

♦ In particular when charging the battery - A- (or when it is

charged when the vehicle is driven), air bubbles may form un‐
der the magic eye and falsify the colour indicator.
♦ As the magic eye is only located in one battery cell, the indi‐
cator only shows the level for this battery cell. The battery
condition can be determined exactly only by a battery load test
⇒ page 19 .
♦ The magic eye can be located at different positions on the
battery - A- .

Two different colour displays are possible:

♦ Black: Electrolyte level is OK.
♦ Colourless/light yellow: Electrolyte level is too low. The battery
- A- must be renewed.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
WARNING
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

2.4 Checking battery using vehicle diagnos‐

tic tester
The battery - A- can be tested using the ⇒ Vehicle diagnostic
tester with the battery installed and without connecting the battery
charger.
Special tools and workshop equipment required

2. Checking battery 11
 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

♦ ⇒ Vehicle diagnostic tester

Test requirements
♦ No battery charger connected.
♦ Battery - A- connected.
♦ Battery temperature at least +10 ℃.
Procedure
⇒ Vehicle diagnostic tester is connected.
– Select
ProtectedDiagnosis mode
by copyright. Copying and orstart
for private diagnosis.
commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Select
with respect
Testto the tab. of information in this document. Copyright by AUDI AG.
correctness
plan

– Select Own test then the following options one after the oth‐
er:
♦ Body
♦ Electrical system
♦ 27 - Starter, current supply
♦ Electrical components
♦ A - Battery, Testing
The ⇒ Vehicle diagnostic tester will guide you through the battery
check from here on.

12 Rep. gr.27 - Starter, current supply, CCS

 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

2.5 Battery tester with printer - VAS 6161-

General description:

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

It is not necessary to remove or disconnect battery - A- when us‐

ing battery tester with printer - VAS 6161- .
Battery tester with printer - VAS 6161- does not put battery - A-
under load, but works by measuring dynamic conductivity.
All battery types are stored in battery tester with printer - VAS
6161- .
Data can be stored on an SD card.
Battery tester with printer - VAS 6161- can be updated via an in‐
terface or an SD card, so that battery data from VW are always
up to date.
An integrated infrared sensor (for measuring battery temperature)
improves measurement quality.
An optional scanner is available for reading data directly from bar
code of battery - A- .

Note

Observe ⇒ Operating instructions for battery tester with printer -

VAS 6161- .

♦ Description of battery tester with printer - VAS 6161-

⇒ page 14
♦ Checking battery ⇒ page 14
♦ Performing maintenance test ⇒ page 15
♦ Performing service test ⇒ page 16
♦ Performing warranty test ⇒ page 16
♦ Explanation of test printout ⇒ page 17
♦ Evaluating test results ⇒ page 17

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Checking battery 13
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Electrical system; General information - Edition 06.2014

2.5.1 Description of battery tester with printer

- VAS 6161-
Battery tester with printer - VAS 6161-
1- Internal printer
2- Operating lever for paper compartment
3- Paper slot
4- Display with main menu
5- Control panel with ON/OFF button
6- Connection for battery test cable
7- SD card slot
8- Infrared temperature sensor
9- Data transmitter for PC

2.5.2 Performing battery test using battery

tester with printer - VAS 6161-
Special tools and workshop equipment required
♦ Battery tester with printer - VAS 6161-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

Procedure

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

14 Rep. gr.27 - Starter, current supply, CCS

 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

Note

The temperature of the battery - A- must be at least 10 ℃.

– Switch off ignition and all electrical equipment and remove ig‐
nition key.
– Check colour indicator on batteries - A- with magic eye
⇒ page 7 .
– Switch on battery tester with printer - VAS 6161- ⇒ page 14 .
– Connect red clamp (+) to positive terminal of battery - A- .
– Connect black clamp (-) to negative terminal of battery - A- .

Note

Make sure
Protected the testCopying
by copyright. clamps make
for private proper purposes,
or commercial contact.in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Select one of the following functions:
♦ Maintenance test (only for new cars prior to registration that
are not in use or are in storage) ⇒ page 15
♦ Service test ⇒ page 16
♦ Warranty test ⇒ page 16

Note

♦ The test is completed after about 10 seconds.

♦ The result of the test will be printed out.
♦ It is not necessary to let the battery tester with printer - VAS
6161- cool down before the next measurement.

– Switch off battery tester with printer - VAS 6161- ⇒ page 14 .

– Remove test clamps.

2.5.3 Performing maintenance test

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Procedure
– Select “maintenance test” from the menu.
– Connect scanner.

2. Checking battery 15
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Electrical system; General information - Edition 06.2014

Note

If no scanner is available, write the vehicle identification number

on the test printout.

– Scan in vehicle identification number.

– Select “On battery terminal” or “On jump-start point”.
– Select vehicle model.
– Scan in barcode or select “Type and Manufacturer” in menu
manually.
– Determine temperature above battery - A- by holding temper‐
ature sensor approx. 5 cm over one of the battery terminals
until temperature is constant.
– Start test.
– Print test report.

2.5.4 Performing service test

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Procedure
– Select “service test” from the menu.
– Select “On battery terminal” or “On jump-start point”.
– Select vehicle model.
– Protected
Determine temperature
by copyright. above
Copying for private battery purposes,
or commercial - A- by inholding temper‐
part or in whole, is not
ature
permittedsensor approx.
unless authorised 5 cm
by AUDI AG.over one
AUDI AG ofnot
does the battery
guarantee terminals
or accept any liability
until temperature is constant.
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Select type of battery (normal, AGM, 2*6 V or gel).

– Select standard (CCA, JIS, DIN, SAE, IEC or EN).
– Start test.
– Print test report.

2.5.5 Performing warranty test

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

16 Rep. gr.27 - Starter, current supply, CCS

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Electrical system; General information - Edition 06.2014

Procedure
– Select “warranty test” from the menu.
– Select “In vehicle” or “Out of vehicle”.
– Select “On battery terminal” or “On jump-start point”.
– Select vehicle model.
– Determine temperature above battery - A- by holding temper‐
ature sensor approx. 5 cm over one of the battery terminals
until temperature is constant.
– Select type of battery (normal, AGM, 2*6 V or gel).
– Select battery capacity.
– Start test.
– Print test report.

2.5.6 Explanation of test printout

1- Test mode Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

2- Test result
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3- Voltage measured
4- Measured cold start value of battery - A-
5- Cold start value of battery - A- set on battery tester with
printer - VAS 6161-
6- Temperature measured above battery - A-
7- Fitting location of battery - A-
8- Position of battery clamp set on battery tester with printer -
VAS 6161-
9- Selected battery type

Note

The test log is required for warranty processing.

2.5.7 Evaluating test results

Evaluating battery test results for warranty test and service test
Battery test results Measure
Battery - A- OK No measure necessary for bat‐
tery - A- .
Battery - A- OK - Recharge – Charge battery - A-
⇒ page 26 and trace
cause of fault responsible
for discharging.
Perform current draw test – Perform current draw test
⇒ page 23 .

– Charge battery - A-
⇒ page 26 and repeat test.
Replace battery - A- – Disconnect battery - A- and
repeat test.

Poor contact of the cables can

be responsible for the result
“Replace battery”.

2. Checking battery 17
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Electrical system; General information - Edition 06.2014

Battery test results Measure

Bad cell - replace – Renew battery - A- ⇒ Elec‐
trical system; Rep. gr. 27 .
Check connection – Test clamps must be con‐
nected directly to battery -
A- and not to jump start post.
Evaluating battery test results for maintenance test
Battery test results Measure
Battery - A- OK No measure.
Charge battery - A- immediate‐ – Charge battery - A-
ly ⇒ page 26 .
Mark as defective – Mark battery - A- as “defec‐
tive”.
Check tester connection – Disconnect battery - A- and
repeat test.

Poor contact of the test clamps

can beProtected
responsible for the re‐
by copyright. Copying for private or commercial purposes, in part or in whole, is not

sult “Check
with respect toconnec‐
tester
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
the correctness of information in this document. Copyright by AUDI AG.
tions”.
Check connection – Test clamps must be con‐
nected directly to battery -
A- and not to jump start post.
Noises Wait until measured value ap‐
pears on display.

2.6 Battery tester with printer - VAS 5097 A-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

It is not necessary to remove or disconnect battery - A- when us‐

ing battery tester with printer - VAS 5097 A- .
The battery tester with printer - VAS 5097 A- can be used to test/
check the following batteries - A- :
♦ 80 to 499 A: Low temperature test current according to DIN
(German Industrial Standard) 1)
♦ 95 to 574 A: Low temperature test current according to IEC
(International Engineering Consortium)
♦ 136 to 855 A: Low temperature test current according to EN/
SAE (European Norm/Standard of Automotive Engineers)
1) Batteries - A- with a low temperature test current greater than 499 A according
to DIN can be tested using setting for 499 A.

For testing, the battery - A- is placed under a load equivalent to

the starting current of a passenger car; the battery - A- is then
evaluated and the measurement is printed out.

Note

Observe ⇒ Instruction manual for battery tester with printer - VAS

5097 A- , ⇒ Brief instructions for battery tester with printer - VAS
5097 A- sticker on battery tester with printer - VAS 5097 A- and
temperature test current table ⇒ page 21 .

18 Rep. gr.27 - Starter, current supply, CCS

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Electrical system; General information - Edition 06.2014

♦ Description of battery tester with printer - VAS 5097 A-

⇒ page 19
♦ Battery load test ⇒ page 19
♦ Table: low temperature test current ⇒ page 21
♦ Results of battery load test ⇒ page 22
♦ Explanation of test printout ⇒ page 22
♦ Evaluating test results ⇒ page 22

2.6.1 Description of battery tester with printer

- VAS 5097 A-
Battery tester with printer - VAS 5097 A-
1- Green LED: device in use
2- Red LED: device connected with reverse polarity
3- Red LED: battery cannot be tested; battery - A- must be re‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

newed with respect to the correctness of information in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

4- Start button

5- Low temperature test current selection switch

6- ON/OFF switch

7- Sliding switch (terminal on battery - A- /on jump start point)

8- Paper feed button

9- Printer

2.6.2 Battery load test

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

Special tools and workshop equipment required

♦ Battery tester with printer - VAS 5097 A-

Observe ⇒ TPL 2012182 .

2. Checking battery 19
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Electrical system; General information - Edition 06.2014

Procedure

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Note

The temperature of the battery - A- must be at least 10 ℃.

Caution
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ permitted
Switchunless
off authorised
ignitionbyand
AUDIall
AG.electrical equipment.
AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Take out ignition key.

– Check colour indicator on batteries - A- with magic eye

⇒ page 7 .
– Switch on battery tester with printer - VAS 5097 A-
⇒ page 19 .
– Determine low temperature test current in amps (A) according
to DIN from data on battery - A- and use table ⇒ page 21 to
read off setting range for battery tester with printer - VAS 5097
A- .

Note

If battery - A- values are shown in IEC or EN/SAE units instead

of DIN units, convert figures using table ⇒ page 21 or using table
on battery tester with printer - VAS 5097 A- .

– Set low temperature test current with low temperature test

current selection switch ⇒ page 19 .
– Set measuring range (80 to 379 A or 380 to 499 A) using ON/
OFF switch ⇒ page 19 .

Note

Batteries - A- with a low temperature test current greater than

499 A according to DIN can be tested using setting for 499 A.

– Connect red clamp (+) to positive terminal of battery - A- .

– Connect black clamp (-) to negative terminal of battery - A- .

20 Rep. gr.27 - Starter, current supply, CCS

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Electrical system; General information - Edition 06.2014

Note

♦ Make sure the test clamps make proper contact.

♦ For information on the battery tester with printer - VAS 5097
A- , refer to ⇒ TPL 2012182 .

– Use the sliding switch to select the connection point for the test
clamps ⇒ page 19 .
1- Direct connection to battery - A-
2- Connection to jump start point
– Check whether low temperature test current indicated on bat‐
tery - A- matches value set on battery tester with printer - VAS
5097 A- .
– Press Start button ⇒ page 19 .
The green LED will light up ⇒ page 19 . The test program runs
through automatically. The test result will be printed out
⇒ page 22 . If battery tester with printer - VAS 5097 A- does not
start up (no LED lights, no printout), battery - A- must be charged
⇒ page 26 .
– Switch off battery tester with printer - VAS 5097 A-
⇒ page 19 .
– Remove test clamps.

Note

♦ The test is completed after about 20 seconds.

♦ The result of the test will be printed out.
♦ Only perform the test once. Repeating the test would falsify
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

the result.with respect to the correctness of information in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

♦ Battery tester with printer - VAS 5097 A- needs approximately

30 minutes (to cool down) before it is ready for the next meas‐
urement.

2.6.3 Table: low temperature test current

Low temperature test current in A (Ampere)
EN/SAE IEC DIN
136 – 177 95 – 124 80 – 104
178 – 219 125 – 154 105 – 129
220 – 261 155 – 184 130 – 154
262 – 303 185 – 214 155 – 179
304 – 345 215 – 244 180 – 204
346 – 387 245 – 274 204 – 229
388 – 429 275 – 304 230 – 254
430 – 471 305 – 334 255 – 279
472 – 513 335 – 364 280 – 304
514 – 555 365 – 394 305 –329
556 – 597 395 – 424 330 – 354
598 – 639 425 – 454 355 – 379
640 – 657 455 – 464 380 – 389
658 – 675 465 – 474 390 – 399

2. Checking battery 21
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Electrical system; General information - Edition 06.2014

Low temperature test current in A (Ampere)

EN/SAE IEC DIN
676 – 693 475 – 484 400 – 409
694 – 711 485 – 494 410 – 419
712 – 729 495 – 504 420 – 429
730 – 747 505 – 514 430 – 439
748 – 765 515 – 524 440 – 449
766 – 783 525 – 534 450 – 459
784 – 801 535 – 544 460 – 469
802 – 819 545 – 554 470 – 479
820 – 837 555 – 564 480 – 489
838 – 855 565 – 574 490 – 4992)
2) Batteries - A- with a low temperature test current greater than 499 A according to DIN can be tested using setting for 499 A.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2.6.4 Results of battery load test permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
The battery - A- voltage will decrease during the test due to the
high load.
♦ If battery - A- is OK, voltage only drops to minimum voltage.
♦ If battery - A- is defective or only weakly charged, battery volt‐
age will drop very quickly to below specified minimum voltage
level.
♦ After test, voltage will remain at a low level for a long time,
rising only slowly.
♦ Only perform the test once. Repeating the test would falsify
the result.
♦ To ensure a correct measurement, battery tester with printer -
VAS 5097 A- must be allowed to cool down for approximately
30 minutes before checking another battery - A- .

2.6.5 Explanation of test printout

1- Measuring range set on battery tester with printer - VAS
5097 A-
2- Diagram (-arrow- indicates battery - A- status)
3- Test result
4- Battery - A- voltage during load test
5- Vehicle data and date (to be entered by mechanic)

Note

♦ The test log is required for warranty processing.

♦ Only perform the test once. Repeating the test would falsify
the result.

2.6.6 Evaluating test results

Printout Measures
Battery Very Good Battery - A- OK.
Battery Good Battery - A- OK.

22 Rep. gr.27 - Starter, current supply, CCS

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Electrical system; General information - Edition 06.2014

Printout Measures
Battery Sufficient Evaluation by current draw
test ⇒ page 23 .
Battery Not Good Evaluation by current draw
test ⇒ page 23 .
Battery Faulty Evaluation by current draw
test ⇒ page 23 .
Cannot be tested – Charge battery - A-
⇒ page 26 and repeat
test.

2.7 Current draw test

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Check that the correct charging mode is set on the battery charger
to ensure that the results of the current draw test are accurate.
♦ Battery charger - VAS 5095 A- ⇒ page 27
♦ Battery charger - VAS 5900- ⇒ page 31
♦ Battery charger - VAS 5903- ⇒ page 43
By checking the current draw of the battery - A- during charging,
it is possible to quickly determine the condition of a discharged
battery - A- (whether it must be renewed or fully charged).

Note

When using the battery tester with printer - VAS 6161- , always
perform a current draw test when the test result “Perform current
draw test” appears on the display.

When using battery tester with printer - VAS 5097 A- , always

perform current draw test for following test results:
1- Battery Sufficient
2- Battery Not Good
3- Battery Faulty
4- Cannot be tested – Charge battery - A- and repeat test
5- Battery tester with printer - VAS 5097 A- does not switch on
(no LED, no printout)
Depending on test result ⇒ page 22 using battery tester with print‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
er - VAS 5097 A-permitted
, further tests
unless or procedures
authorised by AUDI AG. AUDImay be required
AG does not guarantee or accept any liability
before condition ofwith
battery
respect can
to the be determined
correctness forincertain.
of information this document. Copyright by AUDI AG.

Checking the current draw capacity of a battery - A- during charg‐

ing allows you to assess quickly whether a partially or totally
discharged battery - A- ⇒ page 59 can be made serviceable
again by re-charging.

2. Checking battery 23
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Electrical system; General information - Edition 06.2014

Test requirements
♦ Battery temperature must be at least 10 ℃ during charging.
♦ Battery charger must be capable of supplying a charging cur‐
rent of at least 30 A; examples: battery charger - VAS 5095
A- / battery charger - VAS 5900- / battery charger - VAS 5903- .
♦ When charging using battery charger - VAS 5095 A- , current
draw of battery - A- must be measured using a trigger clamp
( trigger clamp, 100 A - VAS 5051B/7- ).
♦ Battery charger - VAS 5900- and battery charger - VAS 5903-
indicate current draw on unit.
Procedure
– Connect battery - A- to battery charger and start charging pro‐
cedure.
– Measure battery - A- charging current after a charging period
of 5 minutes.
Test result
Charging current must be greater than 10% of nominal capacity
after charging for 5 minutes.
Example:
For a 60 Ah battery, charging current must be greater than 6 A
after charging for 5 minutes.
– Fully charge battery - A- if charge current is greater than 10%
of nominal capacity.
– After allowing battery - A- to stand for 2 hours, perform battery
load test ⇒ page 19 .
If charging current is below 10% of nominal capacity after charg‐
ing for 5 minutes (for a 60 Ah battery with less than 6 A), renew
battery - A- ⇒ Electrical system; Rep. gr. 27 .
– For warranty claims and goodwill service/repairs: fillProtected
out bat‐by copyright. Copying for private or commercial purposes, in part or in whole, is not

tery test sheet and keep it together with battery - A- . with respect to the correctness of information in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

2.8 Checking no-load voltage of battery,

stock vehicles

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

Note

♦ The no-load voltage must only be checked as part of the

specified care and maintenance work for vehicles in storage
or not in use to determine the condition of the battery - A- .
♦ Measuring no-load voltage, it is possible to determine whether
it is necessary to re-charge the battery - A- of a vehicle in stor‐
age or not in use ⇒ Maintenance tables “Service for stock
vehicles” .

Special tools and workshop equipment required

24 Rep. gr.27 - Starter, current supply, CCS

 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

♦ Hand-held multimeter - V.A.G 1526 B-

Test conditions
Battery - A- must not have been charged or discharged within last
2 days.
Procedure
– Measure no-load current of battery - A- using hand-held mul‐
timeter - V.A.G 1526 B- .
Test result
No-load voltage Charge state Condition of battery - A-
11.60 V 0% Discharged, no capacity. Totally discharged ⇒ page 59 .

Measured value Required measures

No-load voltage greater than or No-load voltage OK.
equal to 12.5 V
No-load voltage less than 12.5 – Charge battery - A-
V ⇒ page 26 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Checking battery 25
 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

3 Charging battery
⇒ “3.1 Battery charger VAS 5095 A ”, page 26
⇒ “3.2 Battery charger VAS 5900 ”, page 31
⇒ “3.3 Battery charger VAS 5903 ”, page 43
⇒ “3.4 Battery charger VAS 5906 ”, page 55
⇒ “3.5 Solar panel VAS 6102 A ”, page 58
⇒ “3.6 Totally discharged batteries”, page 59

3.1 Battery charger - VAS 5095 A-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .
To avoid damaging the battery - A- or the vehicle, observe
notes on the types of batteries ⇒ page 1 .

WARNING

If the magic eye is colourless or light yellow, the battery - A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
must not be checked or charged. Do NOT permitted jump start the
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
vehicle. with respect to the correctness of information in this document. Copyright by AUDI AG.

There is a risk of explosion when checking or charging the bat‐

tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Note

♦ The current draw cannot be determined using battery charger

- VAS 5095 A- ; it must be measured externally using a trigger
clamp ( trigger clamp, 100 A - VAS 5051B/7- ).
♦ Refer to ⇒ Operating manual for battery charger - VAS 5095
A- .

♦ Description of battery charger - VAS 5095 A- ⇒ page 26 .

♦ Charging battery - A- ⇒ page 27
♦ Charging totally discharged battery - A- ⇒ page 28
♦ Backup power supply ⇒ page 29 .
♦ Buffer mode/maintenance charging ⇒ page 31 .

3.1.1 Description of battery charger - VAS

5095 A-
Battery charger - VAS 5095 A- is suitable for charging all 12V
batteries - A- supplied by Volkswagen.

26 Rep. gr.27 - Starter, current supply, CCS

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Electrical system; General information - Edition 06.2014

The battery is charged without current and voltage peaks; the ve‐
hicle electronics are not affected by the charging process. The
battery - A- can remain in the vehicle during charging and does
not need to be disconnected from the vehicle electrical system.
Battery charger - VAS 5095 A-
1- ON/OFF switch (0 = OFF)

2- Charging current indicator (I greater than 12 A)

3- Charging current indicator: battery - A- partially charged
(greater than 90 %)
4- Maintenance charging; lights up green when battery - A- is
fully charged
5- Malfunction indicator
6- Backup power supply indicator (Stützbetrieb Standby)
7- Stützbetrieb Standby/Normal selector switch

8- Charging cable: red charger clamp (+), black charger clamp

(-)
9- Battery type selector switch (on bottom of charger)

3.1.2 Charging battery with battery charger -

VAS 5095 A-

WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Risk of injury. Observe warnings and safety precautions

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 3 .

Special tools and workshop equipment required

♦ Battery charger - VAS 5095 A-

Caution

Always select 2.4 V/C (volts/cell) as the battery type when

charging; this applies to all batteries - A- .

Note

The temperature of the battery - A- must be at least 10 ℃.

3. Charging battery 27
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Electrical system; General information - Edition 06.2014

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Procedure
– Switch off ignition and all electrical equipment and remove ig‐
nition key.
– Check battery type set on Battery type selector switch
⇒ page 26 . Battery type switch must be set to 2.4 V/C
(volts/cell).
– Connect red charger clamp (+) to positive terminal of battery
- A- .

Note

For vehicles with start/stop function and battery monitor control

unit - J367- , the black charger clamp (-) must be connected to
the vehicle body earth. Connecting it to the negative terminal of
the battery - A- will cause the start/stop system to malfunction.

– Connect black charger clamp (-) to negative terminal of battery

- A- /negative connection point.
– Switch on battery charger - VAS 5095 A- ⇒ page 26 .
Charging current indicators -2- and -3- ⇒ page 27 will light up
yellow. If only the yellow LED -3- lights up, battery - A- is partially
charged (approx. 90%).
If green LED -4- ⇒ page 27 lights up as well, battery charger -
VAS 5095 A- has switched to maintenance charging mode. Bat‐
tery - A- is fully charged.
– Switch off battery charger - VAS 5095 A- ⇒ page 26 .
– Remove charger clamps from battery clamps.

3.1.3 Charging totally discharged battery with

battery charger - VAS 5095 A-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

Battery charger - VAS 5095 A- detects totally discharged batteries

- A- automatically and starts charging process gently at a low
charging current. Charging current is adapted automatically to
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
battery charge. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

28 Rep. gr.27 - Starter, current supply, CCS

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Electrical system; General information - Edition 06.2014

Note

♦ See notes in chapter ⇒ page 59 .

♦ Battery voltage must be at least 0.6 V.
♦ Totally discharged batteries - A- in vehicles that have not yet
been registered must be renewed prior to delivery as the pos‐
sibility of damage cannot be excluded.

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Procedure
– Charge battery - A- ⇒ page 27 .

3.1.4 Backup power supply with battery

charger - VAS 5095 A-
General notes
Backup power supply mode provides the electrical system with
power when the battery - A- is removed or disconnected.
For additional information, refer to ⇒ Operating manual for battery
charger - VAS 5095 A- .
Backup power supply mode is suitable in the following situations:
♦ Backup power supply for electrical system with battery - A- not
installed
♦ Maintaining power when renewing battery
♦ Testing ancillaries without battery - A-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

WARNING

If the magic eye is colourless or light yellow, the battery - A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

must not withberespect

checked or charged. Do inNOT jumpCopyright
start by the
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
to the correctness of information this document. AUDI AG.
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Special tools and workshop equipment required

3. Charging battery 29
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Electrical system; General information - Edition 06.2014

♦ Battery charger - VAS 5095 A-

Procedure

Caution

♦ The terminal polarity protection is not active in the oper‐

ating mode “Charging totally discharged batteries/Stütz‐
betrieb Standby”. Ensure that you connect battery charger
clamps to the correct battery terminal clamps!
♦ A short-circuit can cause sparks.
♦ Danger of explosion.
♦ Ensure that charger clamps are fitted securely.

– Remove battery - A- ⇒ Electrical system; Rep. gr. 27 ; Battery;

Removing and installing battery .

Caution

When the battery - A- is removed, it is very important to ensure

that the charger clamp on the positive battery terminal does not
come into contact with the vehicle body earth. Also ensure that
there is no contact between the battery terminal clamps.

– Connect red charger clamp (+) to positive battery terminal of

vehicle.

Note

For vehicles with start/stop function and battery monitor control

unit - J367- , the black charger clamp (-) must be connected to
the vehicle body earth. Connecting it to the negative terminal of
the battery - A- will cause the start/stop system to malfunction.

– Connect black charger clamp (-) to negative battery terminal

of vehicle.
– Check setting of Stützbetrieb Standby/Normal selector
switch ⇒ page 26permitted
; it must
unlessbe set toby“Stützbetrieb
AUDI AG. AUDI AGStandby”.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
authorised does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Check that charger clamps are connected correctly (correct
polarity).
– Switch on battery charger - VAS 5095 A- ⇒ page 26 .
Battery charger - VAS 5095 A- will start backup power supply.

30 Rep. gr.27 - Starter, current supply, CCS

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Electrical system; General information - Edition 06.2014

Ending backup power supply mode

– Switch off battery charger - VAS 5095 A- ⇒ page 26 .
– Remove charger clamps from battery clamps.
– Disconnect battery charger - VAS 5095 A- from electrical sys‐
tem.

3.1.5 Maintenance charging with battery

charger - VAS 5095 A-

WARNING

Risk of injury. Observe warnings and safety precautions

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 3 . with respect to the correctness of information in this document. Copyright by AUDI AG.

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

In maintenance charging mode, battery charger - VAS 5095 A-

ensures that the battery - A- is charged correctly and that it
maintains its charge.
Procedure
– Proceed in the same way as when charging the battery - A-
⇒ page 27 .
If battery - A- is under electrical load during charging in mainte‐
nance charging mode, battery charger - VAS 5095 A- automati‐
cally compensates for the current drawn from the battery.
Maintenance charging can be continued for an unlimited period.
The battery - A- is ready for use at any time.

3.2 Battery charger - VAS 5900-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

3. Charging battery 31
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Electrical system; General information - Edition 06.2014

The charging current can be read directly on battery charger -

VAS 5900- .

Note

Refer to ⇒ Operating manual for battery charger - VAS 5900- .

♦ Description of battery charger - VAS 5900- ⇒ page 32 .

♦ Charging battery - A- ⇒ page 32
♦ Service charging ⇒ page 34
♦ Charging totally discharged battery - A- ⇒ page 37
♦ Backup power supply ⇒ page 39 .
♦ Maintenance charging ⇒ page 42

3.2.1 Description of battery charger - VAS

5900-
Battery charger - VAS 5900- is suitable for charging all 12V bat‐
teries - A- supplied by Volkswagen.
Battery charger - VAS 5900-

Overview - controls
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1- Display permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2- ↑ button: up

3- ↓ button: down

4- START/STOP button

5- INFO button

3.2.2 Charging battery with battery charger -

VAS 5900-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

32 Rep. gr.27 - Starter, current supply, CCS

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Electrical system; General information - Edition 06.2014

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Special tools and workshop equipment required

♦ Battery charger - VAS 5900-

Note

The temperature of the battery - A- must be at least 10 ℃.

Procedure
– Switch off ignition and all electrical equipment and remove ig‐
nition key. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Connect battery charger - VAS 5900- to electrical system. The
with respect to the correctness of information in this document. Copyright by AUDI AG.

last mode selected will be shown on display ⇒ page 32 .

– Set battery type with INFO button.
Symbol -1- for “Standard charging of wet batteries” or symbol
-2- for “Standard charging of gel/absorbent glass mat batteries”
will be shown on display.
– Use ↑ button or ↓ button to set battery capacity (Ah) of battery
- A- being charged.
– Connect red charger clamp (+) to positive terminal of battery
- A- .

Note

For vehicles with start/stop function and battery monitor control

unit - J367- , the black charger clamp (-) must be connected to
the vehicle body earth. Connecting it to the negative terminal of
the battery - A- will cause the start/stop system to malfunction.

– Connect black charger clamp (-) to negative terminal of battery

- A- /negative connection point.
Battery charger - VAS 5900- detects the nominal voltage of the
connected battery - A- (6 V/12 V/24 V) and starts the charging
process automatically.

3. Charging battery 33
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Electrical system; General information - Edition 06.2014

When the charge reaches about 80 - 85% the battery charger -

VAS 5900- starts “final charging”. The fourth bar will appear on
the display -1-. The battery - A- is now ready for operation.

When the charge is 100 % all the bars appear on the display
-1-.

Note

♦ It is possible to operate electrical equipment in the vehicle

while standard charging of the battery is in progress; this will
increase the time needed to charge the battery.
♦ Depending on the type of battery, battery charger - VAS 5900-
switches to maintenance charging mode after about 1 to 7
hours. To fully charge the battery - A- , it should remain con‐
nected to battery charger - VAS 5900- for this length of time.

Possible faults and fault rectification

1- Battery voltage displayed does not correspond to nominal
voltage:
– Press and hold ↑ or ↓ button until charging process starts.
2- Battery voltage displayed does not correspond to nominal
voltage; charging is already in progress:
– Press START/STOP button twice.
– Press and hold ↑ or ↓ button until charging process starts
again.
3- Battery charger - VAS 5900- does not detect a battery
Protected - A- Copying for private or commercial purposes, in part or in whole, is not
by copyright.
when battery voltage is less than 2 V: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Display remains unchanged.
Battery type and ampere hours (Ah) that were set are displayed.
Stopping battery - A- charging process
– Press START/STOP button.
– Remove charger clamps from battery clamps.
– Disconnect battery charger - VAS 5900- from electrical sys‐
tem.

3.2.3 Service charging with battery charger -

VAS 5900-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

34 Rep. gr.27 - Starter, current supply, CCS

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Caution

The operating mode “service charging” is not permitted on

Group vehicles as the voltage peaks could damage the vehicle
electronics.
If “service charging” mode is used, the battery - A- must be
disconnected from the electrical system.

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Caution Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
When charging, always set the battery charger to the correct
type of battery - A- ⇒ Operating instructions for battery charger
- VAS 5900- .
“Service charging” is suitable for:
♦ Wet batteries where magic eye is black or green, indicat‐
ing that battery may be charged.

The “service charging (SERV)” mode is only used for sulphated

batteries - A- . The battery - A- is charged at voltages higher than
14.4 V. This can result in a partial reduction of the sulphated layer.
After charging, always check the colour of the magic eye before
using the battery - A- ⇒ page 10 .
Special tools and workshop equipment required
♦ Battery charger - VAS 5900-

Note

The temperature of the battery - A- must be at least 10 ℃.

Procedure
– Switch off ignition and all electrical equipment and remove ig‐
nition key.

3. Charging battery 35
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Electrical system; General information - Edition 06.2014

– Connect battery charger - VAS 5900- to electrical system. The

last mode selected will be shown on display ⇒ page 32 .
– Set battery type with INFO button.
Symbol -1- for “Service charging of wet batteries” or symbol -2-
for “Service charging of gel/absorbent glass mat batteries” will be
shown on display.
– Use ↑ button or ↓ button to set battery capacity (Ah) of battery
- A- being charged.
– Connect red charger clamp (+) to positive terminal of battery
- A- .

Note

For vehicles with start/stop function and battery monitor control

unit - J367- , the black charger clamp (-) must be connected to
the vehicle body earth. Connecting it to the negative terminal of
the battery - A- will cause the start/stop system to malfunction.

– Connect black charger clamp (-) to negative terminal of battery

- A- /negative connection point.
Battery charger - VAS 5900- detects the nominal voltage of the
connected battery - A- (6 V/12 V/24 V) and starts the charging
process automatically.

When the charge reaches about 80 - 85% of the battery voltage,

the battery charger - VAS 5900- starts “final charging”. The fourth
bar will appear on the display -1-. The battery - A- is now ready
for operation.

Note

Whether “service charging” is successful or not depends on the

degree of sulphation in the battery - A- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Possible faults and fault rectification
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
1- Battery voltage displayed does not correspond to nominal
voltage:
– Press and hold ↑ or ↓ button until charging process starts.
2- Battery voltage displayed does not correspond to nominal
voltage; charging is already in progress:
– Press START/STOP button twice.
– Press and hold ↑ or ↓ button until charging process starts.
3- Battery charger does not detect a battery - A- when battery
voltage is less than 2 V:
Display remains unchanged.
Operating mode and ampere hours (Ah) that were set are dis‐
played.
Stopping battery - A- charging process
– Press START/STOP button.
– Remove charger clamps from battery clamps.
– Disconnect battery charger - VAS 5900- from electrical sys‐
tem.

36 Rep. gr.27 - Starter, current supply, CCS

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3.2.4 Charging totally discharged battery with

battery charger - VAS 5900-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Caution

♦ The terminal polarity protection is not active in the oper‐

ating mode “Charging totally discharged batteries/Stütz‐
betrieb Standby”. Ensure that you connect battery charger
clamps to the correct battery terminal clamps!
♦ When charging, always set the battery charger to the cor‐
rect type of battery - A- ⇒ Operating instructions for battery
charger - VAS 5900- .
♦ If a totally discharged battery - A- is not recognised by
battery charger - VAS 5900- , refer to ⇒ page 59 .
♦ Do not press the START/STOP button if the charger clamps
are connected incorrectly. This could damage the battery
charger - VAS 5900- .

Batteries - A- with a voltage of less than 2 V will not be recognised

automatically by battery charger - VAS 5903- .
Special tools and workshop equipment required
♦ Battery charger - VAS 5900-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Charging battery 37
 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

Note

♦ See notes in chapter ⇒ page 59 .

♦ The temperature of the battery - A- must be at least 10 ℃.
♦ Totally discharged batteries in vehicles that have not yet been
registered must be renewed prior to delivery as the possibility
of damage cannot be excluded.

Procedure
– Switch off ignition and all electrical equipment and remove ig‐
nition key.
– Connect battery charger - VAS 5900- to electrical system. The
last mode selected will be shown on display ⇒ page 32 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

38 Rep. gr.27 - Starter, current supply, CCS

 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

– Set battery type with INFO button.

Symbol -1- for “Service charging of wet batteries” or symbol -2-
for “Service charging of gel/absorbent glass mat batteries” will be
shown on display.
– Use ↑ button or ↓ button to set battery capacity (Ah) of battery
- A- being charged.
– Connect red charger clamp (+) to positive terminal of battery
- A- .

Note

For vehicles with start/stop function and battery monitor control

unit - J367- , the black charger clamp (-) must be connected to
the vehicle body earth. Connecting it to the negative terminal of
the battery - A- will cause the start/stop system to malfunction.

– Connect black charger clamp (-) to negative terminal of battery

- A- /negative connection point.
– Press START/STOP button for approx. 5 seconds. Menu option
“Charging totally discharged batteries/Stützbetrieb Standby”
is activated.
– Press ↑ or ↓ button to set corresponding battery voltage (6 V/
12 V/24 V).

Note

The battery charger - VAS 5900- returns to the main menu (op‐
erating mode selection) if no button is pressed within 5 seconds.

– Confirm selected battery voltage with START/STOP button.

Battery charger will then check correct polarity of charger clamps.
– Check that charger clamps are connected
Protected bycorrectly (correct
copyright. Copying for private or commercial purposes, in part or in whole, is not
polarity). permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Confirm that charger clamps are connected with correct po‐
larity by pressing START/STOP button.
Battery charger - VAS 5900- will start charging for totally dis‐
charged battery - A- .
Stopping battery - A- charging process
– Press START/STOP button.
– Remove charger clamps from battery clamps.
– Disconnect battery charger - VAS 5900- from electrical sys‐
tem.

3.2.5 Backup power supply with battery

charger - VAS 5900-
General notes
Backup power supply mode provides the electrical system with
power when the battery - A- is removed or disconnected.
For additional information, refer to ⇒ Operating manual for battery
charger - VAS 5900- .
Backup power supply mode is suitable in the following situations:

3. Charging battery 39
 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

♦ Backup power supply for electrical system with battery - A- not

installed
♦ Maintaining power when renewing battery
♦ Testing ancillaries without battery - A-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
If the magic eye is colourless or light permitted
yellow, the battery - A-
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

must not be checked or charged. Do NOT jump start the

with respect to the correctness of information in this document. Copyright by AUDI AG.

vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Special tools and workshop equipment required

♦ Battery charger - VAS 5900-

Procedure

Caution

♦ The terminal polarity protection is not active in the oper‐

ating mode “Charging totally discharged batteries/Stütz‐
betrieb Standby”. Ensure that you connect battery charger
clamps to the correct battery terminal clamps!
♦ A short-circuit can cause sparks.
♦ Danger of explosion.
♦ Do not press the START/STOP button if the charger clamps
are connected incorrectly. This could damage the battery
charger - VAS 5900- .

– Remove battery - A- ⇒ Electrical system; Rep. gr. 27 ; Battery;

Removing and installing battery .
– Connect battery charger - VAS 5900- to electrical system. The
last mode selected will be shown on display ⇒ page 32 .

40 Rep. gr.27 - Starter, current supply, CCS

 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

Caution

When the battery - A- is removed, it is very important to ensure

that the charger clamp on the positive battery terminal does not
come into contact with the vehicle body earth. Also ensure that
there is no contact between the battery terminal clamps.

– Connect red charger clamp (+) to positive terminal of battery

- A- .

Note

For vehicles with start/stop function and battery monitor control

unit - J367- , the black charger clamp (-) must be connected to
the vehicle body earth. Connecting it to the negative terminal of
the battery - A- will cause the start/stop system to malfunction.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Connect black charger with
clamp (-)toto
respect thenegative terminal
correctness of informationof battery
in this document. Copyright by AUDI AG.
- A- /negative connection point.
– Press START/STOP button for approx. 5 seconds. Menu option
“Charging totally discharged batteries/Stützbetrieb Standby”
is activated.
– Press ↑ or ↓ button to set corresponding battery voltage (6 V/
12 V/24 V).

Note

The battery charger - VAS 5900- returns to the main menu (op‐
erating mode selection) if no button is pressed within 5 seconds.

– Confirm selected battery voltage with START/STOP button.

Battery charger will then check correct polarity of charger clamps.
– Check that charger clamps are connected correctly (correct
polarity).
– Confirm that charger clamps are connected with correct po‐
larity by pressing START/STOP button.
Battery charger - VAS 5900- will start backup power supply mode
for battery - A- .
Ending backup power supply mode
– Press START/STOP button.
– Remove charger clamps from battery clamps.
– Disconnect battery charger - VAS 5900- from electrical sys‐
tem.

3. Charging battery 41
 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

3.2.6 Maintenance charging with battery

charger - VAS 5900-

Note

♦ If battery - A- is under electrical load during charging in main‐

tenance charging mode, battery charger - VAS 5900- auto‐
matically compensates for the current drawn from the battery.
♦ Maintenance charging can be continued for an unlimited pe‐
riod.
♦ The battery - A- is ready for use at any time.
♦ Observe battery manufacturer's maintenance instructions.

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

When the battery - A- is fully charged, battery charger - VAS 5900-

switches to maintenance charging.
Special tools and workshop equipment required
♦ Battery charger - VAS 5900-

Procedure
– Proceed in the same way as when charging the battery - A-
⇒ page 32 .

42 Rep. gr.27 - Starter, current supply, CCS

 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

When the charge is 100 % all the bars appear on the display
-1-.

3.3 Battery charger - VAS 5903-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Note

Refer to ⇒ Operating manual for battery charger - VAS 5903- .

♦ Description of battery charger - VAS 5903- ⇒ page 44 .

♦ Charging battery - A- ⇒ page 44
♦ Refresh charging ⇒ page 46
♦ Charging totally discharged battery - A- ⇒ page 49
♦ Backup power supply ⇒ page 51 .
♦ Maintenance charging ⇒ page 54

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Charging battery 43
 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

3.3.1 Description of battery charger - VAS

5903-
Battery charger - VAS 5903- is suitable for charging all 12V bat‐
teries - A- supplied by Volkswagen.
Battery charger - VAS 5903-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Overview - controls
1- Display
2- ↑ button: up

3- ↓ button: down

4- START/STOP button

5- INFO button

3.3.2 Charging battery with battery charger -

VAS 5903-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Special tools and workshop equipment required

44 Rep. gr.27 - Starter, current supply, CCS

 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

♦ Battery charger - VAS 5903-

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
The temperature of the battery - A- must be at least 10 ℃.

Procedure
– Switch off ignition and all electrical equipment and remove ig‐
nition key.
– Connect battery charger - VAS 5903- to electrical system. The
display shows the last mode selected ⇒ page 44 .
– Set battery type with INFO button.
Symbol -1- for “Standard charging of wet batteries” or symbol
-2- for “Standard charging of gel/absorbent glass mat batteries”
will be shown on display.
– Use ↑ button or ↓ button to set battery capacity (Ah) of battery
- A- being charged.
– Connect red charger clamp (+) to positive terminal of battery
- A- .

Note

For vehicles with start/stop function and battery monitor control

unit - J367- , the black charger clamp (-) must be connected to
the vehicle body earth. Connecting it to the negative terminal of
the battery - A- will cause the start/stop system to malfunction.

– Connect black charger clamp (-) to negative terminal of battery

- A- /negative connection point.
Battery charger - VAS 5903- detects the nominal voltage of the
connected battery - A- (6 V/12 V/24 V) and starts the charging
process automatically.

3. Charging battery 45
 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

When the charge reaches about 80 - 85% the battery charger -

VAS 5903- starts “final charging”. The fourth bar will appear on
the display -1-. The battery - A- is now ready for operation.

When the charge is 100 % all the bars appear on the display
-1-.

Note

♦ It is possible to operate electrical equipment in the vehicle

while standard charging of the battery is in progress; this will
increase the time needed to charge the battery.
♦ Depending on the type of battery, battery charger - VAS 5903-
switches to maintenance charging mode after about 1 to 7
hours. To fully charge the battery - A- , it should remain con‐
nected to battery charger - VAS 5903- for this length of time.

Possible faults and fault rectification

1- Battery voltage displayed does not correspond to nominal
voltage:
– Press and hold ↑ or ↓ button until charging process starts.
2- Battery voltage displayed does not correspond to nominal
voltage; charging is already in progress:
– Press START/STOP button twice.
– Press and hold ↑ or ↓ button until charging process starts
again.
3- Battery charger does not detect a battery - A- when battery
voltage is less than 2 V:
Display remains unchanged.
Battery type and ampere hours (Ah) that were set are displayed.
Stopping battery - A- charging process
– Press START/STOP button.
– Remove charger clamps from battery clamps.
– Disconnect battery charger - VAS 5903- from electrical sys‐
tem.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
3.3.3 Charging battery in refresh charge
with respect to the correctness of information in this document. Copyright by AUDI AG.

mode with battery charger - VAS 5903-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

46 Rep. gr.27 - Starter, current supply, CCS

 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Caution

The operating mode “refresh charging” is not permitted on VW

Group vehicles as the voltage peaks could damage the vehicle
electronics.
If “refresh charging” mode is used, the battery - A- must be
disconnected from the electrical system.

Caution

When charging, always set the battery charger to the correct

type of battery - A- ⇒ Operating instructions for battery charger
- VAS 5903- .
“Refresh charging” is suitable for wet batteries which can be
topped up with distilled water.
Do not use “refresh charging” mode for maintenance-free wet
batteries.

“Refresh charging (Refr)” mode is only used for batteries - A- that

are presumed defective (e.g. due to sulphation). The battery - A-
is charged up to the maximum electrolyte density to reactivate the
plates by breaking down the sulphate layer.
Special tools and workshop equipment required
♦ Battery charger - VAS 5900- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

The temperature of the battery - A- must be at least 10 ℃.

Procedure
– Switch off ignition and all electrical equipment and remove ig‐
nition key.

3. Charging battery 47
 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

– Connect battery charger - VAS 5903- to electrical system. The

display shows the last mode selected ⇒ page 44 .
– Set battery type with INFO button.
Symbol -1- for “Refresh charging of wet batteries” or symbol -2-
for “Refresh charging of gel/absorbent glass mat batteries” will be
shown on display.
– Use ↑ button or ↓ button to set battery capacity (Ah) of battery
- A- being charged.
– Connect red charger clamp (+) to positive terminal of battery
- A- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note

For vehicles with start/stop function and battery monitor control

unit - J367- , the black charger clamp (-) must be connected to
the vehicle body earth. Connecting it to the negative terminal of
the battery - A- will cause the start/stop system to malfunction.

– Connect black charger clamp (-) to negative terminal of battery

- A- /negative connection point.
Battery charger - VAS 5900- detects the nominal voltage of the
connected battery - A- (6 V/12 V/24 V) and starts the charging
process automatically.

When the charge reaches about 80 - 85% of the battery voltage,

the battery charger - VAS 5900- starts “final charging”. The fourth
bar will appear on the display -1-. The battery - A- is now ready
for operation.

Note

Whether “refresh charging” is successful or not depends on the

degree of sulphation in the battery - A- .

Possible faults and fault rectification

1- Battery voltage displayed does not correspond to nominal
voltage:
– Press and hold ↑ or ↓ button until charging process starts.
2- Battery voltage displayed does not correspond to nominal
voltage; charging is already in progress:
– Press START/STOP button twice.
– Press and hold ↑ or ↓ button until charging process starts.
3- Battery charger does not detect a battery - A- when battery
voltage is less than 2 V:
Display remains unchanged.
Operating mode and ampere hours (Ah) that were set are dis‐
played.
Stopping battery - A- charging process
– Press START/STOP button.
– Remove charger clamps from battery clamps.
– Disconnect battery charger - VAS 5903- from electrical sys‐
tem.

48 Rep. gr.27 - Starter, current supply, CCS

 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

3.3.4 Charging totally discharged battery with

battery charger - VAS 5903-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Caution

♦ The terminal polarity protection is not active in the oper‐

ating mode “Charging totally discharged batteries/Stütz‐
betrieb Standby”. Ensure that you connect battery charger
clamps to the correct battery terminal clamps!
♦ When charging, always set the battery charger to the cor‐
rect type of battery - A- ⇒ Operating instructions for battery
charger - VAS 5903- .
♦ If a totally discharged battery - A- is not recognised by
battery charger - VAS 5903- , refer to ⇒ page 59 .
♦ Do not press the START/STOP button if the charger clamps
are connected incorrectly. This could damage the battery
charger - VAS 5903- .

Batteries - A- with a voltage of less than 2 V will not be recognised

automatically by battery charger - VAS 5903- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Special tools and workshop equipment required
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Battery charger - VAS 5903-

3. Charging battery 49
 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

Note

♦ See notes in chapter ⇒ page 59 .

♦ The temperature of the battery - A- must be at least 10 ℃.
♦ Totally discharged batteries in vehicles that have not yet been
registered must be renewed prior to delivery as the possibility
of damage cannot be excluded.

Procedure Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Switch off ignition and all electrical equipment and removewithig‐
respect to the correctness of information in this document. Copyright by AUDI AG.
nition key.
– Connect battery charger - VAS 5903- to electrical system. The
display shows the last mode selected ⇒ page 44 .

50 Rep. gr.27 - Starter, current supply, CCS

 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

– Set battery type with INFO button.

Symbol -1- for “Service charging of wet batteries” or symbol -2-
for “Service charging of gel/absorbent glass mat batteries” will be
shown on display.
– Use ↑ button or ↓ button to set battery capacity (Ah) of battery
- A- being charged.
– Connect red charger clamp (+) to positive terminal of battery
- A- .

Note

For vehicles with start/stop function and battery monitor control

unit - J367- , the black charger clamp (-) must be connected to
the vehicle body earth. Connecting it to the negative terminal of
the battery - A- will cause the start/stop system to malfunction.

– Connect black charger clamp (-) to negative terminal of battery

- A- /negative connection point.
– Press START/STOP button for approx. 5 seconds. Menu option
“Charging totally discharged batteries/Stützbetrieb Standby”
is activated.
– Press ↑ or ↓ button to set corresponding battery voltage (6 V/
12 V/24 V).

Note

The battery charger - VAS 5903- returns to the main menu (op‐
erating mode selection) if no button is pressed within 5 seconds.

– Confirm selected battery voltage with START/STOP button.

Battery charger will then check correct polarity of charger clamps.
– Check that charger clamps are connected correctly (correct
polarity).
– Confirm that charger clamps are connected with correct po‐
larity by pressing START/STOP button.
Battery charger - VAS 5903- will start charging for totally dis‐
charged battery - A- .
Stopping battery - A- charging process
– Press START/STOP button.
– Remove charger clamps from battery clamps.
– Disconnect battery charger - VAS 5903- from electrical sys‐
tem.

3.3.5 Backup power supply with battery

charger - VAS 5903-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
General notes permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Backup power supply mode provides the electrical system with
power when the battery - A- is removed or disconnected.
For additional information, refer to ⇒ Operating manual for battery
charger - VAS 5903- .
Backup power supply mode is suitable in the following situations:

3. Charging battery 51
 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

♦ Backup power supply for electrical system with battery - A- not

installed
♦ Maintaining power when renewing battery
♦ Testing ancillaries without battery - A-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Special tools and workshop equipment required

♦ Battery charger - VAS 5903-

Procedure

Caution

♦ The terminal polarity protection is not active in the oper‐

ating mode “Charging totally discharged batteries/Stütz‐
betrieb Standby”. Ensure that you connect battery charger
clamps to the correct battery terminal clamps!
♦ A short-circuit can cause sparks.
♦ Danger of explosion.
♦ Ensure that charger clamps are fitted securely.
♦ Do not press the START/STOP button if the charger clamps
are connected incorrectly. This could damage the battery
charger - VAS 5903- .

– Remove battery - A- ⇒ Electrical system; Rep. gr. 27 ; Battery;

Removing and installing battery .
– Connect battery charger - VAS 5903- to electrical system. The
display shows the last mode selected ⇒ page 44 .

52 Rep. gr.27 - Starter, current supply, CCS

 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

Caution

When the battery - A- is removed, it is very important to ensure

that the charger clamp on the positive battery terminal does not
come into contact with the vehicle body earth. Also ensure that
there is no contact between the battery terminal clamps.

– Connect red charger clamp (+) to positive terminal of battery

- A- .

Note

For vehicles with start/stop function and battery monitor control

unit - J367- , the black charger clamp (-) must be connected to
the vehicle body earth. Connecting it to the negative terminal of
the battery - A- will cause the start/stop system to malfunction.

– Connect black charger clamp (-) to negative terminal of battery

- A- /negative connection point.
– Press START/STOP button for approx. 5 seconds. Menu option
“Charging
Protected by copyright. totally discharged
Copying for batteries/Stützbetrieb
private or commercial Standby”
purposes, in part or in whole, is not

with is activated.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by AUDI AG.

– Press ↑ or ↓ button to set corresponding battery voltage (6 V/

12 V/24 V).

Note

The battery charger - VAS 5903- returns to the main menu (op‐
erating mode selection) if no button is pressed within 5 seconds.

– Confirm selected battery voltage with START/STOP button.

Battery charger will then check correct polarity of charger clamps.
– Check that charger clamps are connected correctly (correct
polarity).
– Confirm that charger clamps are connected with correct po‐
larity by pressing START/STOP button.
Battery charger - VAS 5903- will start backup power supply mode
for battery - A- .
Ending backup power supply mode
– Press START/STOP button.
– Remove charger clamps from battery clamps.
– Disconnect battery charger - VAS 5903- from electrical sys‐
tem.

3. Charging battery 53
 Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 06.2014

3.3.6 Maintenance charging with battery

charger - VAS 5903-

Note

♦ If battery - A- is under electrical load during charging in main‐

tenance charging mode, battery charger - VAS 5903- auto‐
matically compensates for the current drawn from the battery.
♦ Maintenance charging can be continued for an unlimited pe‐
riod.
♦ The battery - A- is ready for use at any time.
♦ Observe battery manufacturer's maintenance instructions.

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is abyrisk
Protected of explosion
copyright. whenor checking
Copying for private or charging
commercial purposes, in part or the bat‐is not
in whole,
terypermitted
or jump starting
unless authorisedthe vehicle.
by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
If this is the case, the battery - A- must be renewed.

Special tools and workshop equipment required

♦ Battery charger - VAS 5903-

When the battery - A- is fully charged, battery charger - VAS 5903-

switches to maintenance charging.
Procedure
– Proceed in the same way as when charging the battery - A-
⇒ page 44 .

54 Rep. gr.27 - Starter, current supply, CCS

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When the charge is 100 % all the bars appear on the display
-1-.

3.4 Battery charger - VAS 5906-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Note

Refer to ⇒ Operating manual for battery charger - VAS 5906- .

♦ Description of battery charger - VAS 5906- ⇒ page 56 .

♦ Charging battery - A- ⇒ page 56

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Charging battery 55
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Electrical system; General information - Edition 06.2014

3.4.1 Description of battery charger - VAS

5906-
Battery charger - VAS 5906-
Battery charger - VAS 5906- has been specially developed for
providing power to the electrical system when a vehicle is on dis‐
play.
It has an automatic charging characteristic for starter batteries
with 3 to by
Protected 300 Ah. Copying for private or commercial purposes, in part or in whole, is not
copyright.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
The with
charging
respect to voltage does
the correctness not exceed
of information 14.4 V.Copyright
in this document. Maintenance
by AUDI AG.
charging provides all the electrical equipment in the vehicle with
up to 30 A.
For sustained operation, battery charger - VAS 5906- changes to
maintenance charging once the battery - A- is fully charged.
Battery charger - VAS 5906- starts fully automatically and does
not require the adjustment of any settings; simply connect the
charging clamps and power cable.
For additional information, refer to ⇒ Operating manual for battery
charger - VAS 5906- .

Overview - controls
1- Charge level display 25 %
2- Charge level display 50 %
3- Charge level display 75 %
4- Charge level display 100 %
5- "Ready" indicator
6- START/STOP button and Setup button for interrupting and
resuming charging process. Press for 10 seconds to access
setup menu and select characteristic curve type.
7- Malfunction indicator

3.4.2 Charging battery with battery charger -

VAS 5906-

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

Special tools and workshop equipment required

56 Rep. gr.27 - Starter, current supply, CCS

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♦ Battery charger - VAS 5906-

Procedure
– Place charger - VAS 5906- in engine compartment or under
vehicle.
– Connect battery charger - VAS 5906- to electrical system.
Battery charger - VAS 5906- is in no-load operation; “ready” in‐
dicator will light up.

WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Risk of injury. Observe warnings and
permitted unless safety
authorised precautions
by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 3 . with respect to the correctness of information in this document. Copyright by AUDI AG.

Caution

♦ Switch off ignition and all electrical equipment.

♦ Take out ignition key.

– Connect red charger clamp (+) to positive terminal of battery

- A- .

Note

For vehicles with start/stop function and battery monitor control

unit - J367- , the black charger clamp (-) must be connected to
the vehicle body earth. Connecting it to the negative terminal of
the battery - A- will cause the start/stop system to malfunction.

– Connect black charger clamp (-) to negative terminal of battery

- A- /negative connection point.
Charging starts after approximately 2 seconds.
The number of LEDs lit indicates charge level of battery - A- .
When all the LEDs light up, the battery - A- is fully charged.
When the battery - A- is fully charged, battery charger - VAS 5906-
automatically switches to maintenance charging.

Caution

Danger of sparks if charging clamps are removed too soon.

Terminate charging by pressing START/STOP button.

3. Charging battery 57
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Stopping battery - A- charging process

– Press START/STOP button.
– Remove charger clamps from battery clamps.
– Disconnect battery charger - VAS 5906- from electrical sys‐
tem.

3.5 Solar panel - VAS 6102 A-

⇒ “3.5.1 Description of solar panel VAS 6102 A ”, page 58
⇒ “3.5.2 Maintenance charging using solar panel VAS 6102 A ”,
page 58

3.5.1 Description of solar panel - VAS 6102 A-

Solar panel - VAS 6102 A-
The solar panel - VAS 6102 A- supports the vehicle's electrical
system and prevents self-discharge of the battery - A- .
The solar panel - VAS 6102 A- achieves maximum voltage of 14.3
V and a maximum charging current of 255 mA.
The solar panel - VAS 6102 A- may be used to charge all re‐
chargeable lead batteries or lead-gel batteries.
The solar panel - VAS 6102 A- is plugged into the diagnostic con‐
nection in the vehicle.
A green LED is integrated in the frame of the solar panel - VAS
6102 A- to indicate that the panel is in operation. The brighter the
LED, the higher the charging current.
The integrated electronics prevent the battery - A- from over‐
charging.

The solar panel - VAS 6102 A- is attached to the interior mirror

-1- with the underside on the dash panel -2-.

Note

Do not allow the complete solar panel - VAS 6102 A- to make

contact with the dash panel; only place down the lower edge to
provide support. Placing down the whole panel can result in col‐
our change of the dash panel.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3.5.2 Maintenance charging using solar panel

- VAS 6102 A-
Special tools and workshop equipment required

58 Rep. gr.27 - Starter, current supply, CCS

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♦ Solar panel - VAS 6102 A-

Procedure
– Secure solar panel - VAS 6102 A- to interior mirror -1-.
– Place underside on dash panelby -2-.
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

Do not allow the complete solar panel - VAS 6102 A- to make

contact with the dash panel; only place down the lower edge to
provide support. Placing down the whole panel can result in col‐
our change of the dash panel.

– Pull securing cable together until solar panel - VAS 6102 A- is

close to windscreen.
– Connect solar panel - VAS 6102 A- to diagnostic connection
of vehicle. Connect in same way as ⇒ Vehicle diagnostic test‐
er.
– Check that solar panel - VAS 6102 A- is functioning properly.
The green LED must light up.

3.6 Totally discharged batteries

WARNING

Risk of injury. Observe warnings and safety precautions

⇒ page 3 .

A battery - A- is considered totally discharged if the no-load volt‐

age is less than 11.6 V.

WARNING

If the magic eye is colourless or light yellow, the battery - A-

must not be checked or charged. Do NOT jump start the
vehicle.
There is a risk of explosion when checking or charging the bat‐
tery or jump starting the vehicle.
If this is the case, the battery - A- must be renewed.

3. Charging battery 59
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Caution

♦ Totally discharged batteries - A- freeze at higher temper‐

atures.
♦ Never re-use frozen batteries - A- .

Note

♦ Batteries - A- that have not been used for an extended period

of time (e.g. in vehicles that have been stored) self-discharge.
♦ In a totally discharged battery - A- the electrolyte is comprised
almost entirely of water, as the sulphuric acid content is heavily
reduced.
♦ Totally discharged batteries - A- become sulphated, meaning
that the entire battery plate surfaces harden.
♦ If discharged batteries - A- are charged directly after being
discharged, the sulphation dissipates.
♦ If this is not done, the plates become even harder and the bat‐
tery's - A- ability to absorb charge is impaired. This results in
reduced power output.
♦ Totally discharged batteries - A- in vehicles that have not yet
been registered must be renewed prior to delivery as the pos‐
sibility of damage cannot be excluded.

Procedure
– Check no-load voltage of battery - A- ⇒ page 26 .
– Charge battery - A- :
♦ Battery charger - VAS 5095 A- ⇒ page 28
♦ Battery charger - VAS 5900- ⇒ page 37
♦ Battery charger - VAS 5903- ⇒ page 49
♦ Battery charger - VAS 5906- ⇒ page 56

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

60 Rep. gr.27 - Starter, current supply, CCS

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4 Alternator

4.1 Checking alternator

Performing check of alternator
⇒ Vehicle diagnostic tester is connected.
– Select Diagnosis mode and start diagnosis.
– Select Test plan tab.
– Select Own test then the following options one after the oth‐
er:
♦ Body
♦ Electrical system
♦ 27 - Starter, current supply
♦ Electrical components
♦ C - Alternator, checking
The ⇒ Vehicle diagnostic tester will guide you through the alter‐
nator check from here on.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4.2 Bosch alternator
permitted unless authorisedup to AG.
by AUDI 2000AUDI AG - does
exploded
not guarantee view
or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Alternator 61
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Electrical system; General information - Edition 06.2014

1 - Bolts
❑ 1 Nm
2 - Cover
❑ With three retaining tabs
3 - Bolts
❑ 2 Nm
4 - Voltage regulator
❑ Removing:
– Unscrew bolts -item 1-
and detach protective
cap -item 2-

– Unscrew bolts -item 3-

and detach voltage reg‐
ulator
❑ Carbon brush wear limit:
5 mm
5 - Alternator

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

62 Rep. gr.27 - Starter, current supply, CCS

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4.3 Bosch alternator from 2001 onwards - exploded view

Note

The alternators were introduced gradually.

1 - Alternator
2 - Voltage regulator
❑ Removing and installing
⇒ page 64
❑ Checking carbon brush‐
es ⇒ page 66
3 - Bolt
❑ 2.5 Nm
4 - Cover
5 - Nut
❑ 12 Nm
6 - Nut
❑ 30 Nm
7 - Bolt
❑ 3 Nm
8 - Bolt
❑ 1.5 Nm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Alternator 63
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4.4 Removing and installing voltage regula‐

tor - Bosch alternator from 2001 on‐
wards
Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 .
– Unscrew bolt -1- and nuts -3- and -4-.
– Detach cover -2- from rear of alternator.

– Unscrew bolts -arrows-.

– Remove voltage regulator.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Installing with respect to the correctness of information in this document. Copyright by AUDI AG.

– When positioning voltage regulator, ensure carbon brushes

are positioned correctly on contact surfaces.
Further installation is carried out in the reverse order; note the
following:
– Install alternator ⇒ Electrical system; Rep. gr. 27 .
• Tightening torque ⇒ page 63

4.5 Bosch alternator from 2007 onwards - exploded view

Note

The new alternators were introduced gradually.

64 Rep. gr.27 - Starter, current supply, CCS

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1 - Nut
❑ 65 Nm
2 - Poly V-belt pulley
3 - Alternator
4 - Voltage regulator
❑ Removing and installing
⇒ page 65
❑ Checking carbon brush‐
es ⇒ page 66
5 - Bolt
❑ 1.5 Nm
6 - Cover
7 - Bolt
❑ 3 Nm
8 - Bolt
❑ 2.5 Nm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4.6 Removing and installing voltage regula‐

tor - Bosch alternator from 2007 on‐
wards
Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 .
– Unscrew bolts -arrows-.
– Detach cover -1- from rear of alternator.

4. Alternator 65
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– Unscrew bolts -arrows-.

– Detach voltage regulator -1-.
Installing
– When positioning voltage regulator, ensure carbon brushes
are positioned correctly on contact surfaces.
Further installation is carried out in the reverse order; note the
following:
– Install alternator ⇒ Electrical system; Rep. gr. 27 .
• Tightening torque ⇒ page 63

4.7 Checking carbon brushes - all types of

Bosch alternators from 2001 onwards
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Procedure
– Remove voltage regulator: Up to 2007 ⇒ page 64 ; from 2007
onwards ⇒ page 65 .
– Check length -a- of carbon brushes.
• Wear limit: -a- = 5 mm.
– Install voltage regulator: Up to 2007 ⇒ page 64 ; from 2007
onwards ⇒ page 65 .

4.8 Valeo alternator up to 2000 - exploded view

66 Rep. gr.27 - Starter, current supply, CCS

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1 - Alternator
2 - Voltage regulator
❑ Removing:
– Remove nuts -item 5-
and detach cover
-item 4-

– Unscrew bolt -item 6-

and nuts -item 7- and
detach voltage regulator
❑ Carbon brush wear limit:
5 mm
3 - Protective cap
4 - Cover
5 - Nut
❑ 2 Nm
6 - Bolt
❑ 2 Nm
7 - Nut
❑ 2x
❑ 3.5 Nm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Alternator 67
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4.9 Valeo alternator from 2001 onwards - exploded view

Note

The alternators were introduced gradually.

1 - Alternator
2 - Voltage regulator
❑ Removing and instal‐
ling: Up to 2007
⇒ page 69 ; from 2007
onwards ⇒ page 70
❑ Checking carbon brush‐
es: Up to 2007
⇒ page 69 ; from 2007
onwards ⇒ page 70
3 - Bolt
❑ 2 Nm
4 - Cover
5 - Protective cap
6 - Bolt
❑ 2 Nm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

68 Rep. gr.27 - Starter, current supply, CCS

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4.10 Removing and installing voltage regula‐

tor - Valeo alternator from 2001 onwards
Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 .
– Press cover on rear of alternator off studs -arrows-.

– Unscrew bolts -1- and centre hex stud -2-.

– byRemove
Protected voltage
copyright. Copying regulator.
for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Installing
– Press protective cap -2- off voltage regulator -1- in direction of
-arrow-.
– When positioning voltage regulator, ensure carbon brushes
are positioned correctly on contact surfaces.
– Refit protective cap when voltage regulator has been installed.
Further installation is carried out in the reverse order; note the
following:
– Install alternator ⇒ Electrical system; Rep. gr. 27 .
• Tightening torque ⇒ page 68

4.11 Checking carbon brushes - Valeo alter‐

nator from 2001 onwards
Procedure
– Remove voltage regulator ⇒ page 69 .
– Check length -a- of carbon brushes.
• Wear limit: -a- = 5 mm.
– Install voltage regulator ⇒ page 69 .

4. Alternator 69
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4.12 Removing and installing voltage regula‐

tor - Valeo alternator from 2007 onwards
Special tools and workshop equipment required
♦ Feeler gauge, 0.3 mm
Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 .
– Press cover on rear of alternator off studs -arrows-.

– Unscrew bolts -1- and centre hex stud -2-.

– Remove voltage regulator.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Installing
– Insert 0.3 mm feeler gauge -item 4- between protective cap
-2- and carbon brushes -3-.
– Pull protective cap off only as far as point where projection on
protective cap keeps carbon brushes pressed down.
– After installing voltage regulator, press protective cap on as
far as stop.
Further installation is carried out in the reverse order; note the
following:
– Install alternator ⇒ Electrical system; Rep. gr. 27 .
• Tightening torque ⇒ page 68

4.13 Checking carbon brushes - Valeo alter‐

nator from 2007 onwards
Special tools and workshop equipment required
♦ Feeler gauge, 0.3 mm

70 Rep. gr.27 - Starter, current supply, CCS

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Procedure
– Remove voltage regulator ⇒ page 70 .
– Insert 0.3 mm feeler gauge -item 3- between protective cap
-2- and carbon brushes.
– Pull protective cover off voltage regulator -1- -arrow-.

– Check length -a- of carbon brushes.

• Wear limit: -a- = 5 mm.

– With protective cap -2- in position, press down carbon brushes

-3- with feeler gauge -4-.
– Slide protective cap on in direction of -arrow- until projection
onbyprotective
Protected capforkeeps
copyright. Copying private orcarbon
commercial brushes pressed
purposes, in down.
part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
–withInstall
respect tovoltage regulator
the correctness ⇒ page
of information 70 .
in this document. Copyright by AUDI AG.

4.14 Removing and installing poly V-belt pul‐

ley without free-wheel
Special tools and workshop equipment required

4. Alternator 71
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Electrical system; General information - Edition 06.2014

♦ Socket - 3310-

♦ 8 mm hexagon socket or TORX T50 socket

Removing
– If necessary,permitted
remove alternator
authorised by⇒ Electrical system; Rep. gr.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless AUDI AG. AUDI AG does not guarantee or accept any liability
27 . with respect to the correctness of information in this document. Copyright by AUDI AG.

– On some engines, removal is possible with alternator installed;

to do so, slacken and remove poly V-belt.
– If fitted, press off protective cap on alternator pulley.
– Counterhold on securing nut using socket - 3310- and turn al‐
ternator shaft clockwise to loosen.
– Detach poly V-belt pulley.
Installing
Installation is carried out in the reverse order; note the following:
– Turn alternator shaft anti-clockwise to tighten.
– Clip protective cap onto alternator pulley.
Tightening torque
Component Nm
Poly V-belt pulley to alternator 65

4.15 Removing and installing poly V-belt pul‐

ley with free-wheel
General description
There are different versions of the poly V-belt pulley with free-
wheel.
Before removing the poly V-belt pulley with free-wheel, determine
which special tools are required for the pulley in question.

Caution

The length of the poly V-belt varies depending on the type of

pulley fitted.
Check which type of poly V-belt pulley with free-wheel is fitted
and ensure that the correct poly V-belt is installed. For the cor‐
rect allocation of the poly V-belt, refer to ETKA.

Different versions of poly V-belt pulley with free-wheel:

-A- Small poly V-belt pulley with free-wheel; special tool to use:
adapter - T10474- or adapter - 3400-

72 Rep. gr.27 - Starter, current supply, CCS

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-B- Large poly V-belt pulley with free-wheel; special tool to use:
adapter - 3400-

Note

The poly V-belt for the large pulley with free-wheel must be longer
to accommodate the larger diameter.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Special tools and workshop equipment required
♦ Adapter - T10474-

♦ Adapter - 3400-

4. Alternator 73
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♦ Torque wrench - V.A.G 1332-

♦ 8 mm hexagon socket or TORX T50 socket

Removing:
– If necessary, remove alternator ⇒ Electrical system; Rep. gr.
27 .
– On some engines, removal is possible with alternator installed;
to do so, slacken and remove poly V-belt.
– Clamp alternator in a vice at securing points.
– If fitted, remove protective cap from poly V-belt pulley with
free-wheel.
– Insert adapter - T10474- or adapter - 3400- -1- into pulley and
attach a ring spanner.
– Insert suitable tool -2- into shaft of alternator.
– Loosen shaft of alternator by turning it clockwise (counterhold
with ring spanner).
– Hold poly V-belt pulley with free-wheel in place with your hand
and turn shaft of alternator until pulley can be removed.
Installing:
Installation is carried out in reverse sequence; note the following:
Modify torque wrench - V.A.G 1332- as follows to fit poly V-belt
pulley with free-wheel:

– Release socket -1- and detach from grip -2-.

– Turn torque wrench grip -2- 180° and insert socket
Protected again.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Set torque wrench to turn anti-clockwise at socket.
with respect to the correctness of information in this document. Copyright by AUDI AG.

– First screw poly V-belt pulley with free-wheel onto shaft of al‐
ternator by hand as far as stop.
– Insert adapter - T10474- -1- into poly V-belt pulley with free-
wheel and attach a ring spanner.

74 Rep. gr.27 - Starter, current supply, CCS

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– Insert suitable tool -2- into shaft of alternator.

– Turn alternator shaft anti-clockwise using torque wrench -
V.A.G 1332- -3- to tighten poly V-belt pulley with free-wheel.
– Clip protective cap onto alternator pulley.
Tightening torque
Component Nm
Poly V-belt pulley with free-wheel to alternator 80

4.16 Checking poly V-belt pulley with free-

wheel
Procedure
• Poly V-belt pulley with free-wheel removed ⇒ page 72 .
– Hold inner ring -2- of poly V-belt pulley securely with thumb
and forefinger of one hand and grasp outer ring -1- with thumb
and forefinger on other hand.
– Hold inner ring tightly and turn outer ring in direction of alter‐
nator rotation.
• If free-wheel is intact, you should not be able to turn outer ring.
– Hold inner ring tightly and turn outer ring in opposite direction
to alternator rotation.
• If free-wheel is intact, you should be able to turn outer ring (it
should resist slightly).
If the free-wheel does not function as described, renew poly V-
belt pulley.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Alternator 75
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92 – Windscreen wash/wipe system

1 Washer fluid hoses

1.1 Disconnecting and connecting washer

fluid hose connectors
Different types of hose connectors are used to connect hoses to
washer fluid pumps and washer jets or as disconnection points.
Non-secured hose coupling
– Pull the two coupling elements apart to separate connection.
– To connect, press the two coupling elements firmly together
until they engage audibly and palpably.

Secured hose coupling with retaining ring

– To separate connection, turn retaining ring -1- 90° -arrow- and
detach hose connection.
– To connect, push on hose connection and turn retaining ring
-1- -arrow- until it engages.

Secured hose coupling with retaining clip version 1

– To separate connection, lift retaining clip -1- by approx. 1 mm
-arrow- and detach hose connection.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– To connect, push on hose connection
permittedand
unlesspress in by
authorised retaining
AUDI AG. AUDI AG does not guarantee or accept any liability
clip until it engages. with respect to the correctness of information in this document. Copyright by AUDI AG.

76 Rep. gr.92 - Windscreen wash/wipe system

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Secured hose coupling with retaining clip version 2

– To separate connection, lift retaining clip -1- -arrow- and de‐
tach hose connection.
– To connect, push on hose connection and press in retaining
clip until it engages.

Hose coupling for headlight washer system with retaining clip

– To separate connection, press retaining clip -1- -arrow- and
detach hose connection.
– To connect, press and hold retaining clip -arrow- and push on
hose connection.
– Check whether connection is properly engaged by pulling on
hose without pressing retaining clip.

Hose connector for headlight washer system with O-type clip

– To separate connection, use side-cutting pliers to sever O-
type clip -1- and detach hose connection. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– To connect, slip a new O-type clip onto hose, attach hose
with respect to the correctness of information in this document. Copyright by AUDI AG.

connection and secure O-type clip using hose clip pliers -

V.A.G 1275- .

Hose coupling for headlight washer system with spring clip

– To separate connection, open spring clip -1- using hose clip
pliers - V.A.G 1921- and detach hose connection.
– To connect, open spring clip using hose clip pliers - V.A.G
1921- and attach hose connection.

1.2 Servicing a smooth washer fluid pipe

Note

Smooth pipes with a diameter of 5x1 mm or 6x1 mm can be serv‐

iced using an EPDM hose (Ethylene Propylene Diene Monomer)
⇒ Electronic parts catalogue .

1. Washer fluid hoses 77

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– Cut the damaged section out of the smooth pipe to be repaired,

making the cuts at right-angles to the pipe.
– Choose an appropriate EPDM hose -2- and cable tie ⇒ Elec‐
tronic parts catalogue .
– Cut the EPDM hose -2- to length such that the ends of the
smooth pipe -1- and -3- can both be slipped roughly 10 mm
into the EPDM hose -2-.

– Secure the repair joint with cable ties -1-.

– Check operation and test for leaks.

1.3 Servicing a washer fluid hose with cor‐

rugated tube

Note

Corrugated tubes can be repaired using a heat-shrink hose ⇒

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Electronic parts catalogue .

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Special tools and workshop equipment required

♦ Hot air blower - VAS 5179- or

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♦ Hot air blower - VAS 1978/14A- from wiring harness repair set
- VAS 1978 B-

♦ Cutting pliers - VAS 6228-

Note

♦ The repair location must not be tensioned or bent.

♦ If the damaged section is longer than 20 mm, a new piece of
corrugated pipe must be usedbyand
Protected the Copying
copyright. procedure described
for private or commercial purposes, in part or in whole, is not
below must be performed twice.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Procedure
– Cut washer fluid hose at point of damage using cutting pliers
- VAS 6228- .
– Select appropriate connecting pieces -2- and -3- and appro‐
priate heat-shrink hose (refer to ⇒ Electronic parts catalogue
(ETKA) ).
– Heat end of corrugated pipe -1- with hot air blower - VAS
5179- .
– Push connecting piece -2- into corrugated pipe -1- -arrow A-.
– Heat end of corrugated pipe -4- with hot air blower - VAS
5179- .
– Push connecting piece -3- into corrugated pipe -4- -arrow B-.

1. Washer fluid hoses 79

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– Cut heat-shrink hose so it covers at least 20 mm

-dimension x- of corrugated pipe on both sides.
– Push heat-shrink hose over corrugated pipe, connect con‐
necting pieces and secure repair location with heat-shrink
hose.
• The heat-shrink hose must be heated starting from the centre
and working outwards until it is sealed tight.
• Set hot air blower to appropriate temperature as indicated in
operating instructions.
• When shrink-fitting, ensure no other wires, plastic components
or insulating materials are damaged by the hot nozzle.
– Check operation and test for leaks.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

80 Rep. gr.92 - Windscreen wash/wipe system

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94 – Lights, bulbs, switches - exterior

1 Safety precautions when handling
gas discharge bulbs
Never renew bulbs if you are not familiar with the necessary pro‐
cedure, safety precautions and tools required.

WARNING

High voltage! Danger to life!

♦ Ensure that any part of the gas discharge headlights
marked with yellow high-voltage warning symbols are de-
energised when you are working on them.
♦ Switch off ignition and all electrical equipment and remove
ignition key.
♦ Do not flash the headlights.
♦ Never operate the gas discharge bulb control unit without
a gas discharge bulb.
♦ The gas discharge bulb may only be operated in the head‐
light housing because of the high voltages (above
28,000 V when the gas discharge bulb is ignited).

WARNING

Risk of injury from burns, UV radiation, dazzling and explosion.

♦ The gas discharge bulb may only be operated in the head‐
light housing because of the high temperatures, the ab‐
sorption of UV radiation and to avoid dazzling.
♦ Never look into the light beam as this could disturb the eye
sight for an extended period of time.
♦ Gas discharge bulbs are pressurised and can burst when
they are renewed.
♦ Always wear safety goggles and gloves when removing
and installing gas discharge bulbs.

WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Observe environmental requirements.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Gas discharge bulbs are hazardous waste. They contain
metallic mercury (Hg) and traces of thallium.
♦ Never break off gas discharge bulbs and do not touch
broken glass part of bulb.
♦ Observe disposal regulations. Gas discharge bulbs
should only be disposed of in the appropriate containers
at an official collection point.

1. Safety precautions when handling gas discharge bulbs 81

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Caution

♦ Do not touch the glass part of the gas discharge bulb with
bare hands. The remaining fingerprint would be evapora‐
ted by the heat of the bulb when it is switched on, become
deposited on the reflector and thus impair the brightness
of the headlight. Wear clean fabric gloves when fitting the
gas discharge bulb.
♦ Only replace defective gas discharge bulbs with gas dis‐
charge bulbs of the same type. The type can be found on
the base of the bulb or on the glass part of the bulb.
♦ When installing, make sure connectors engage properly
and are securely attached.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

82 Rep. gr.94 - Lights, bulbs, switches - exterior

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96 – Lights, bulbs, switches - interior

1 Immobiliser

1.1 General notes

Depending on the vehicle, the immobiliser control unit may be
integrated in the following systems:
♦ Control unit in dash panel insert - J285-
♦ Convenience system central control unit - J393-
♦ Entry and start authorisation control unit - J518-
In addition, the following control units are used for the immobiliser
depending on the vehicle:
♦ Engine control unit - J623- / engine control unit 2 - J624-
♦ Automatic gearbox control unit - J217-
♦ Electric drive control unit - J841-
– To renew control unit, select “Replace control unit” function for
appropriate control unit in “Offboard Diagnostic Information
System Service” ⇒ Vehicle diagnostic tester.

1.2 Defective transponder or loss of key

♦ The transponder is integrated into the ignition key and cannot
be renewed separately.
♦ The complete ignition key must be replaced if the transponder
or sender unit is defective.
– Order a new replacement key or sender unit from your import‐
er (or distribution centre), quoting vehicle identification num‐
ber.
Immobiliser, generation 1, 2, 3 and 4:
– Carry out “Match vehicle keys” or “Vehicle key, adaption, im‐
mobiliser” function in “Offboard Diagnostic Information System
Service” ⇒ Vehicle diagnostic tester.
– All vehicle keys must be adapted.
Immobiliser, generation 5 onwards:
– Carry out “Service immobiliser” function in “Offboard Diagnos‐
tic Information System Service” and use this program to adapt
vehicle keys ⇒ Vehicle diagnostic tester.
– Allbyvehicle
Protected copyright. keys
Copyingmust beoradapted.
for private commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

1.3 Renewing reader coil

with respect to the correctness of information in this document. Copyright by AUDI AG.

Vehicles with mechanical ignition lock:

♦ The reader coil is integrated into the lock cylinder and cannot
be renewed separately.
♦ The complete lock cylinder must be replaced if the reader coil
is defective.
– Order a new lock cylinder from your importer (or distribution
centre), quoting vehicle identification number.

1. Immobiliser 83
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Vehicles with entry and start authorisation switch - E415- :

♦ Reader coil is integrated in entry and start authorisation switch
- E415- and cannot be renewed separately.
♦ The entry and start authorisation switch - E415- must be re‐
newed if reading coil is defective.
Vehicles without mechanical ignition lock:
♦ Reader coil is a separate component and can be renewed
separately.

1.4 Procedure for renewing lock set

Immobiliser, generation 1, 2 and 3:
– Carry out “Match vehicle keys” or “Vehicle key, adaption, im‐
mobiliser” function in “Offboard Diagnostic Information System
Service” ⇒ Vehicle diagnostic tester.
– All vehicle keys must be adapted.
Immobiliser, generation 4:
– Carry out “Enable immobiliser/new identity” or “New identity”
function in “Offboard Diagnostic Information System Service”
⇒ Vehicle diagnostic tester.
– All vehicle keys must be adapted.
Immobiliser, generation 5 onwards:
– Carry out “Service immobiliser” function in “Offboard Diagnos‐
tic Information System Service” and use this program to adapt
vehicle keys ⇒ Vehicle diagnostic tester.
– All vehicle keys must be adapted.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

84 Rep. gr.96 - Lights, bulbs, switches - interior

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2 Towing bracket

2.1 Removing and installing socket for tow‐

ing bracket - version 1
Removing
– Switch off ignition and take out ignition key.
– Unscrew bolts -arrows-.
– Detach socket from retaining plate.

Socket with rear fog light cut-out contact switch - F216- :

– Unplug connector -2- for rear fog light cut-out contact switch -
F216- and press connector -1- out of trailer socket - U10- .

Socket without rear fog light cut-out contact switch - F216- :

– Press multi-pin connector -1- out of socket -2- in direction of
-arrow-.

Version 1:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Release retaining tabs -arrows- and then release the clips
-1- and -3 ... 5-.
– Remove frame from connectors -2-.

2. Towing bracket 85
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Version 2:
– Release retaining tabs -arrows- and then release clips
-1, 2, 3, 4, 6, 7-.
– Remove frame from multi-pin connector -5-.

Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Installation is carried out
with in the toreverse
respect order;
the correctness note the
of information following:
in this document. Copyright by AUDI AG.

Note

Make sure that seals -1- and -3- are not damaged.

– Insert connectors -4- into frame -2- until they audibly engage.

2.2 Removing and installing socket for tow‐

ing bracket - version 2
Removing

Note

Refit cable ties at the same locations when reinstalling.

– Switch off ignition and take out ignition key.

– Open out towing bracket and engage.
– Cut open cable tie -1- and remove bolts -2- and -4-.
– Press socket out of towing bracket -3- in direction of -arrow-.

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– Turn cover cap -1- anti-clockwise -arrow- and detach from

socket -3-.
– Detach rubber cover -2-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Release clips -arrows- and press multi-pinpermitted
connectorunless -2- out by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
of socket -1-. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Release clips -arrows- and detach frame -1- from multi-pin

connector -3-.

Note

Pull frame off carefully so that contacts -2- of multi-pin connector

are not separated from wiring harness.

2. Towing bracket 87
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Installing
Installation is carried out in the reverse order; note the following:
– Frame -1- can only be fitted onto multi-pin connector -3- in one
position.
• Guide pins -4- can be inserted in frame in one position only
(the contacts -2- must be in the frame).
– Slide frame into multi-pin connector until it engages audibly.

2.3 Removing and installing socket for tow‐

ing bracket - version 3
Removing
– Open out towing bracket with electric control and engage in
position ⇒ Owner's Manual for the specific vehicle.
– Switch off ignition and remove ignition key.
– Remove bolts -arrows-.
– Detach socket from retaining plate.
– Detach rubber cover from socket.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Releasepermitted
retaining
unlessclips -arrows-
authorised by AUDI and press
AG. AUDI multi-pin
AG does connector
not guarantee or accept any liability
-1- out ofwith
socket -2-.
respect to the correctness of information in this document. Copyright by AUDI AG.

88 Rep. gr.96 - Lights, bulbs, switches - interior

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– Release clips -arrows- and detach frame -2- from multi-pin

connector -3-.

Note

Pull frame off carefully so that contacts -2- of multi-pin connector

are not separated from wiring harness.

Installing
Installation is carried out in the reverse order; note thebyfollowing:
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Frame -1- can only be fitted onto multi-pin connector -3-tointheone
with respect correctness of information in this document. Copyright by AUDI AG.
position.
• Guide pins -4- can be inserted in frame in one position only
(the contacts -2- must be in the frame).
– Slide frame into multi-pin connector until it engages audibly.

2. Towing bracket 89
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2.4 Pin assignment at socket for towing

bracket
Socket for towing bracket, 13-pin (country-specific version)
1- Terminal BL - turn signal (left-side)
2- Terminal NSL - rear fog light
3- Terminal 31 - earth
4- Terminal BR - turn signal (right-side)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5- Terminal 58 Runless
permitted - tailauthorised
light (right-side)
by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6- Terminal 54 - brake light
7- Terminal 58 L - tail light (left-side)
8- Terminal RF - reversing light
9- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
10 - ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
11 - ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
12 - ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
13 - ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
Socket with rear fog light cut-out contact switch - F216- :
Pin assignment at rear fog light cut-out contact switch - F216-
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐
tions

90 Rep. gr.96 - Lights, bulbs, switches - interior

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97 – Wiring
1 Vehicle diagnostic, testing and infor‐
mation systems

WARNING

♦ Risk of serious injury or death when performing tests or

measurements using a vehicle diagnostic information sys‐
tem. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

♦ Risk of serious injury orcorrectness

death ifofthe airbag is document.
triggered
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the information in this Copyright by AUDI AG.
during a test drive while the vehicle diagnostic information
system is within range of one of the airbags.
♦ When using test equipment while road-testing the vehicle,
have a second person operate the vehicle diagnostic in‐
formation system from the rear seat.

Audi TT and Audi R8

WARNING

♦ Risk of serious injury or death when performing tests or

measurements using a vehicle diagnostic information sys‐
tem.
♦ Risk of serious injury or death if the airbag is triggered
during a test drive while the vehicle diagnostic information
system is within range of one of the airbags.
♦ When using test equipment while road-testing the vehicle,
have a second person operate the vehicle diagnostic in‐
formation system from the front passenger's seat with the
seat in the rearmost position.
♦ The vehicle diagnostic information system -1- must be
placed flat on the front passenger's lap as shown and op‐
erated by this person.

– Connect vehicle diagnostic tester ⇒ page 91 .

1.1 Connecting vehicle diagnostic tester

Special tools and workshop equipment required
♦ Vehicle diagnostic tester with corresponding diagnostic cable
Procedure
– Apply parking brake or operate electromechanical parking
brake.
– Shift gear lever to neutral position or selector lever to position
“P”.

1. Vehicle diagnostic, testing and information systems 91

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– Connect vehicle diagnostic tester to diagnostic connection

-arrow- with diagnostic cable (ignition switched off).
– When using remote diagnosis head - VAS 5054 A- or diagno‐
sis interface - VAS 5055- refer to ⇒ User handbook (installing
and operating) .
– Switch on ignition.
– Switch off all electrical equipment.

Note

If a fault message appears on the screen of the vehicle diagnostic

tester, refer to ⇒ Operating instructions for the appropriate vehicle
diagnostic tester.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

92 Rep. gr.97 - Wiring

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2 Repairing wiring harnesses and con‐

nectors

2.1 General information on repairs to the ve‐

hicle electrical system

Caution

It is very important that the battery be connected and discon‐

nected according to the instructions in the Workshop Manual.

WARNING

Certain tools are equipped with a guard. This is placed over

the end of the tool after use to prevent injury to employees and
to protect the tip of the tool against damage.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Repairing wiring harnesses and connectors 93

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Electrical system; General information - Edition 06.2014

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

94 Rep. gr.97 - Wiring

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♦ For all repairs, observe current notes in relevant Workshop

Manual.
♦ Observe country-specific regulations.
♦ Disconnect battery earth strap before working on electrical
system. Disconnecting the battery earth strap (open circuit)
prevents accidents when working on the electrical system. It
is only necessary to disconnect the battery positive wire when
removing the battery.
♦ Before commencing repair work, always eliminate cause of
damage, e.g. sharp body edges, defective electrical compo‐
nents, corrosion etc.
♦ Further information, for example about installation and remov‐
al of individual components, can be found in the appropriate
Workshop Manual.
♦ Soldering is not permitted for repairs to vehicle wiring.
♦ Only use wiring harness repair set - VAS 1978 B- (and older
versions) for wiring harness and connector repairs on the elec‐
trical system. Only use yellow wires from wiring harness repair
set - VAS 1978 B- .
♦ Repaired wiring harnesses must not be re-incorporated into
the wrapping of the original vehicle wiring harness and must
be marked with yellow tape to indicate that they have been
repaired.
♦ Never repair crimp connectors. Route a new wire along the
defective wire if necessary. After crimping, hot air blower must
be used to shrink-fit crimp connector to prevent moisture from
ingressing.
♦ It is very important to observe the additional information on
repairing wiring harnesses on the airbag and belt tensioner
systems, fibre optic cables, CAN bus wiring, FlexRay wiring
and aerial wiring.
♦ Always check operation after completing repair work. It may
be necessary to interrogate and erase the event memories
and/or reset the systems to basic setting.
♦ Do not loosen earth straps on body if this can be avoided
(danger of corrosion).
♦ Not all wiring cross sections found in the vehicle are contained
in the wiring harness repair set - VAS 1978 B- (and previous
versions). If the wiring cross section required is not contained,
use the next largest cross section.
♦ Heat-resistant wiring is fitted in various places in the vehicle,
primarily in the engine compartment. Heat-resistant wiring can
be identified by its slightly matt and softer insulation. Only re‐
pair these wires using heat-resistant wiring.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Repairing wiring harnesses and connectors 95

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2.2 Wiring harness repair set

2.2.1 Wiring harness repair set - VAS 1978-

Using wiring harness repair set - VAS 1978- makes it possible to
maintain optimum repair standards for repairs to the electrical
system. The tools can be used to repair the electrical connectors
and any open circuits in the wiring. This is done using complete
repair wires with crimped-on contacts which are joined to the wir‐
ing harness of the vehicle with crimp connectors. Crimping pliers
with three different crimp recesses and a hot air blower for shrink‐
ing the crimp connectors ensure a perfect electrical connection.

Note

Additional information:

⇒ Operating instructions Wiring harness repair set - VAS 1978-

2.2.2 Upgrade kit - VAS 1978/50-

The upgrade kit - VAS 1978/50- is required to upgrade the old
wiring harness repair set - VAS 1978- to the same standard as
the wiring harness repair set - VAS 1978A- . The upgrade kit con‐
tains 4 assembly tools and 10 release tools, as well as the new
crimping pliers for crimp connectors with head adapters for 0.35
- 2.5 mm2 -VAS 1978/1-1- , 4.0 - 6.0 mm2 -VAS 1978/2 A- and
head adapter for JPT contacts - VAS 1978/9-1- . Also included
are new stickers, a new set of operating instructions, crimp con‐
nectors for wires with 0.35 mm2 cross section and a roll of black
felt adhesive tape.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.2.3 Wiring harness repair set - VAS 1978A-

Using the new wiring harness repair set - VAS 1978A- makes it
possible to maintain optimum repair standards for repairs to the
electrical system. The new pliers can be used to repair the elec‐
trical connectors and any open circuits in the wiring. This is done
using complete repair wires with crimped-on contacts which are
joined to the wiring harness of the vehicle with four different types
of crimp connectors. New crimping pliers with exchangeable head
adapters and a hot air blower for shrinking the crimp connectors
ensure a perfect electrical connection.

Note

Additional information:

⇒ Operating instructions Wiring harness repair set - VAS 1978A-

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2.2.4 Release tool set - VAS 1978/35-

Release tool set - VAS 1978/35- is used to release various pri‐
mary and secondary locking devices on Group vehicles. The set
contains 26 different tools which can be used to properly release
or fit e.g. round connector systems, flat contacts with one or two
fasteners and seals for individual wires.
For correct release tools for corresponding locking devices, refer
to table in ⇒ Operating instructions for -VAS 1978/35- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.3 Description of tools

2.3.1 Crimping pliers with insert

The crimping pliers (base tool) - VAS 1978/1- with insert for
crimping pliers - VAS 1978/2- are part of the wiring harness repair
set - VAS 1978- and are used to crimp connectors for wiring har‐
ness repairs.
Colour of crimp Colour of crimp re‐ Wire cross section
connector cess
Transparent Yellow 0.35 mm 2 - 0.5
mm 2

Red Red 0.5 mm 2 - 1.0 mm 2

Blue Blue 1.5 mm 2 - 2.5 mm 2
Yellow Yellow 4.0 mm 2 - 6.0 mm 2

Note

♦ Alternatively, the connectors can also be crimped with crimp‐

ing pliers (base tool) - VAS 1978/1-2- in conjunction with head
adapters -VAS 1978/1-1- or -VAS 1978/2A- ⇒ page 100 .
♦ It is very important to ensure that the correct crimp recess is
selected for the crimp connector being used.
♦ Take care not to crimp insulation of wire.

2. Repairing wiring harnesses and connectors 97

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2.3.2 Release tools for contacts

The different release tools can be used to detach different con‐
tacts from connector housings without damaging them irrepara‐
bly.
A selection of release tools is included in wiring harness repair
set - VAS 1978- and wiring harness repair set - VAS 1978A- . The
complete set of release tools is included in release tool set - VAS
1978/35- ⇒ page 97 .

WARNING

Certain tools are equipped with a guard. This is placed over

the end of the tool after use to prevent injury to employees and
to protect the tip of the tool against damage.

Releasing and dismantling connector housings ⇒ page 141

2.3.3 Assembly tools for seals for individual

wires
The assembly tools are used to insert seals for individual wires
all the way into the connector housing without damaging them;
this ensures a complete seal between the individual wire and the
connector housing. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Four assembly tools for seals with
for respect
individual wires are included in
to the correctness of information in this document. Copyright by AUDI AG.

each wiring harness repair set - VAS 1978 B- and previous ver‐
sions.
Fitting seals for individual wires ⇒ page 140

2.3.4 Wire strippers - VAS 1978/3-

Wire strippers - VAS 1978/3- are used to strip wires of their insu‐
lation and cut them properly.
Wire strippers - VAS 1978/3- are included in wiring harness repair
set - VAS 1978 B- and previous versions.
There is an adjustable stop in the jaws of the wire strippers with
which the desired length of insulation to be removed can be set.
Stripping:
– Set adjustable stop in jaws of wire stripper to desired length to
be stripped.

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– Working from the front, insert end of wire into jaws of wire
stripper as far as it will go and press stripper together com‐
pletely.
– Open wire stripper again and take out stripped end of wire.

– If necessary, cut wire using side-cutting function on upper side

of wire strippers.

2.3.5 Hot air blower, 220 V / 50 Hz - VAS

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1978/14-
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Caution

When shrinking crimp connectors, take care not to damage any

other pipes/wires, plastic parts or insulating material with hot
nozzle of the hot air blower.
Always observe operating instructions for hot air blower.

Hot air blower, 220 V / 50 Hz - VAS 1978/14- is used in conjunction

with shrink element for hot air blower - VAS 1978/15- to shrink-fit
the crimp connectors. After crimping, hot air blower must be used
to shrink-fit crimp connector to prevent moisture from ingressing.

Hot air blower, 220 V/50 Hz - VAS 1978/14- is included in wiring

harness repair set - VAS 1978 B- and previous versions.
– Attach shrink element for hot air blower - VAS 1978/15A- to
hot air blower, 220 V/ 50 Hz - VAS 1978/14A- .

Caution

Risk of damage to surrounding components.

♦ When shrinking crimp connectors, take care not to dam‐
age any other pipes/wires, plastic parts or insulating ma‐
terial with hot nozzle of the hot air blower.
♦ Always observe operating instructions for hot air blower.

2. Repairing wiring harnesses and connectors 99

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– Working from centre outwards, use hot air blower to heat crimp
connector in longitudinal direction until it is completely sealed
and adhesive emerges at ends.
• A wire repaired using a single crimp connector must look as
shown in illustration.

2.3.6 Crimping pliers - VAS 1978/1A-

Crimping pliers - VAS 1978/1A- or crimping pliers (base tool) -
VAS 1978/1-2- together with head adapter 0.35 - 2.5 mm² - VAS
1978/1-1- or head adapter 4.0 - 6.0 mm² - VAS 1978/2A- are used
to compress the crimp connectors from the wiring harness repair
sets.
Crimping connectors using crimping pliers - VAS 1978/1A-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

The following head adapters are available for the crimping pliers
with respect to the correctness of information in this document. Copyright by AUDI AG.

(base tool) - VAS 1978/1-2- :

♦ Head adapter 0.35 mm2 - 2.5 mm2 - VAS 1978/1-1-
♦ Head adapter 4.0 mm2 - 6.0 mm2 - VAS 1978/2A-
♦ Head adapter for JPT contacts - VAS 1978/9-1-
The crimping pliers are used in conjunction with head adapter for
JPT contacts - VAS 1978/9-1- to crimp contacts to individual wires
during repairs to wiring with cross sections up to 0.35 mm2.
Changing head adapter:
– Open crimping pliers all the way.

– Unclip both locking pins -arrows- from body of crimping pliers.

– Insert required head adapter from above -arrow- into body of

crimping pliers.

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– Lock head adapter in place by pressing pins -arrows- into body

of crimping pliers.

2.4 Repairing wiring harnesses

Note

Observe general information on repairs to the vehicle electrical

system
⇒ “2.1 General information on repairs to the vehicle electrical
system”, page 93 .

⇒ “2.4.1 Repairing airbag and belt tensioner wiring”, page 101

⇒ “2.4.2 Repairing CAN bus wiring”, page 104
⇒ “2.4.3 Repairing FlexRay wiring”, page 104
⇒ “2.4.4 Repairing a wire of 0.22 mm2 section with a single crimp
connector”, page 105
⇒ “2.4.5 Repairing a wire of 0.35 mm2 section or thicker with a
single crimp connector”, page 107
⇒ “2.4.6 Repairing a wire of 0.22 mm2 section by connecting in
an additional wire”, page 109
⇒ “2.4.7 Repairing a wire of 0.35 mm2 section or thicker by con‐
necting in an additional wire”, page 112

2.4.1 Repairing airbag and belt tensioner wir‐

ing
In addition to the general notes on repairing wiring harnesses,
observe the following instructions for repairing wiring in the airbag
and belt tensioner system:

WARNING

♦ Airbag and belt tensioner system can fail.

♦ Carrying out repair work incorrectly on wiring harnesses
for airbags and belt tensioners can cause a malfunction in
passenger protection systems.
♦ For repairs to airbag and belt tensioner wiring harnesses,
only use contacts, connectors and wiring designed spe‐
cifically for this purpose ⇒ Electronic parts catalogue
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
(ETKA) . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Repairing wiring harnesses and connectors 101

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Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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Note

♦ Wiring for airbag and belt tensioner wiring harness may only
be repaired using wiring harness repair set - VAS 1978 B- and
previous versions.
♦ Observe general information on repairs to the vehicle electri‐
cal system ⇒ page 93 .
♦ Pay attention to stickers on vehicle pointing out components
with high voltage. Remaining voltage must be dissipated be‐
fore commencing repair work ⇒ General body repairs, interior;
Rep. gr. 69 ; Passenger protection .
♦ Do not repair wiring for the airbag and belt tensioner system
at more than two repair locations. Repair locations increase
the resistance in wiring and can be the cause of faults in the
system's self-diagnosis.
♦ To avoid corrosion, the crimp connectors must always be
shrink-fitted when repairing the airbag wiring harness or belt
tensioner wiring harness.
♦ Do not incorporate the repaired wiring back in the wiring har‐
ness in the vehicle, and mark the repair location clearly with
yellow insulating tape.
♦ Repairs in the area around airbags or belt tensioners should
not be performed more than 30 cm from the nearest connector
housing. Following this method and marking the repair with
yellow insulating tape ensures that previous repairs can be
easily identified.
♦ The original wires going to the airbag igniters have a twist
length specification of 20 ± 5 mm. The wiring pairs have stand‐
ard part numbers that ensure this twist length in series pro‐
duction, and it must always be observed when repairing
twisted wires. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ When performing repairs both wires to the airbag igniters
with respect to the must
correctness of information in this document. Copyright by AUDI AG.
be of the same length. When twisting wires -1- and -2-, it is
very important to ensure that twist length A = 20 ±5 mm.
♦ There must be no untwisted section of wire which is longer
than B = 100 mm, e.g. in the vicinity of crimp connectors
-arrow-.
♦ Repair operations must be recorded in the Audi Service
Schedule under “Workshop entries” with a brief outline of the
repair work completed, company stamp and signature.
♦ Any warranty claims made under the AUDI AG factory war‐
ranty are invalid if airbag wiring harness repairs have not been
performed using genuine replacement parts and wiring har‐
ness repair set - VAS 1978 B- .

2. Repairing wiring harnesses and connectors 103

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2.4.2 Repairing CAN bus wiring

♦ Use an unscreened two-wire line -1- and -2- (cross-section
0.35 mm2 or 0.5 mm2) as CAN bus wire.
♦ Refer to the following table for the colour coding of the CAN
bus wiring:
Drive CAN High Orange/black
Convenience CAN High Orange/green
Infotainment CAN High Orange/purple
CAN Low wire (all) Orange/brown
♦ CAN bus wiring can be repaired either using sections of repair
wiring with the correct cross section or with “green/yellow” or
“white/yellow” twisted wires from the Electronic parts cata‐
logue ⇒ Electronic parts catalogue (ETKA) .
♦ Both CAN bus wires must be of the same length when repair‐
ing. When twisting wires -1- and -2-, ensure a twist length of
A = 20 mm.
♦ There must be no untwisted section of wire which is longer
than B = 50 mm, e.g. in the vicinity of crimp connectors
-arrow-.
♦ Apply yellow insulating tape to the repair location to indicate a
previous repair.

2.4.3 Repairing FlexRay wiring

Note

Observe general information on repairs to the vehicle electrical

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

system
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ “2.1 General information on repairs to the vehicle electrical
system”, page 93 .

FlexRay wiring consists of a sheathed pair of wires -1 and 2- with

a cross-section of 0.35 mm2.

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♦ Both wires must be of exactly the same length when repairing.

♦ When twisting the wires -1 and 2-, the twist length specification
-A- = 30 mm must be met.
♦ When making repairs, there must be no untwisted section of
wire which is longer than -B- = 50 mm, e.g. in the vicinity of
crimp connectors -arrow-.
♦ Maximum stripped length of wire -C- = 100 mm.
♦ Protect repair location against environmental effects with suit‐
able measures. This requires a crimp connector with heat-
shrink hose, internal bonding material over untwisted repair
joint and water-tight insulating tape around stripped wire.
♦ The repair location must be marked with appropriate tape e.g.
yellow insulating tape.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Follow the same procedure as you do when repairing one wire
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

if you are repairing both wires.

with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ The two repair locations -arrows- should be located one twist

length -A- = 30 mm away from each other.
♦ Crimping cable ends with connectors should be performed in
the same way.
1 - Repair location in stripped area
2 - Repair location with cable ends with connectors
C - Maximum stripped length = 100 mm

2.4.4 Repairing a wire of 0.22 mm2 section

with a single crimp connector
Procedure
– Release a length of approx. 20 cm of the defective wire on both
sides of the repair joint.

Caution

Risk of damage to electrical wiring.

♦ Take care when releasing wiring from wrapped wiring har‐
nesses.

– If necessary, use a knife to remove wrapping of wiring har‐

ness.
– Use wire stripper - VAS 1978/3- to cut out damaged section of
wiring.

Note

If cutting out the damaged section of wiring makes the two ends
of the original vehicle wire too short for repair with a single crimp
connector, insert a corresponding length of repair wire with two
crimp connectors ⇒ page 109 .

2. Repairing wiring harnesses and connectors 105

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– Set adjustable stop in jaws of wire stripper - VAS 1978/3- to

12 ... 14 mm (length to be stripped).
– Working from the front, insert end of wire into jaws of wire
stripper as far as it will go and press stripper together com‐
pletely.
– Open wire stripper again and take out stripped end of wire.
– Fold back half of the stripped wire ends.
– To repair a 0.22 mm2 wire, take a small transparent crimp
connector out of the wiring harness repair set - VAS 1978 B- .

– To fit crimp connector, use crimping pliers (base tool) - VAS

1978/1-2- with head adapter 0.35 mm² - 2.5 mm² - VAS
1978/1-1- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Slide small transparent crimp connector over both stripped

and folded back ends of original vehicle wire and fasten with
crimping pliers.

Note

Take care not to crimp insulation of wire.

After crimping, hot air blower must be used to shrink-fit crimp

connector to prevent moisture from ingressing.
– Attach shrink element for hot air blower - VAS 1978/15A- to
hot air blower, 220 V/ 50 Hz - VAS 1978/14A- .

Caution

Risk of damage to surrounding components.

♦ When shrinking crimp connectors, take care not to dam‐
age any other pipes/wires, plastic parts or insulating ma‐
terial with hot nozzle of the hot air blower.
♦ Always observe operating instructions for hot air blower.

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– Working from centre outwards, use hot air blower to heat crimp
connector in longitudinal direction until it is completely sealed
and adhesive emerges at ends.
• A wire repaired using a single crimp connector must look as
shown in illustration.

Note

♦ If several wires have to be repaired, make sure crimp connec‐

tors are not directly adjacent to one another. Offset the crimp
connectors slightly to restrict the size of the wiring harness.
♦ If the repair location was previously wrapped, yellow adhesive
tape must be wrapped around this location again on comple‐
tion of repair.
♦ If necessary, secure the repaired wiring harness with a cable
tie to prevent rattling noises when the vehicle is driven.

2.4.5 Repairing a wire of 0.35 mm2 section or

thicker with a single crimp connector
Procedure
– Release a length of approx. 20 cm of the defective wire on both
sides of the repair joint.

Caution

Risk of damage to electrical wiring.

♦ Take care when releasing wiring from wrapped wiring har‐
nesses.

– If necessary, use a knife to remove wrapping of wiring har‐

ness.
– Use wire stripper - VAS 1978/3- to cut
Protected by out damaged
copyright. section
Copying for private or of
commercial purposes, in part or in whole, is not
wiring. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

If cutting out the damaged section of wiring makes the two ends
of the original vehicle wire too short for repair with a single crimp
connector, insert a corresponding length of repair wire with two
crimp connectors ⇒ page 112 .

2. Repairing wiring harnesses and connectors 107

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– Set adjustable stop in jaws of wire stripper - VAS 1978/3- to

6 ... 7 mm (length to be stripped).
– Working from the front, insert end of wire into jaws of wire
stripper as far as it will go and press stripper together com‐
pletely.
– Open wire stripper again and take out stripped end of wire.
– For repair, take a suitable crimp connector out of the wiring
harness repair set - VAS 1978 B- .

Note

♦ It is very important to select the correct crimp connector and

appropriate corresponding crimp recess ⇒ page 97 .
♦ Take care not to crimp insulation of wire.

– Use crimping pliers (base tool) - VAS 1978/1-2- for fitting crimp
connectors.
The following head adapters are available for the crimping pliers
(base tool) - VAS 1978/1-2- :
♦ Head adapter 0.35 mm² - 2.5 mm² - VAS 1978/1-1-
♦ Head adapter 4.0 - 6.0 mm² - VAS 1978/2 A-

– Slide crimp connector over two stripped ends of original vehi‐

cle wire and fasten with crimping pliers.

Note

Take care not to crimp insulation of wire.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

After crimping, hot air blower must be used to shrink-fit crimp

connector to prevent moisture from ingressing.
– Attach shrink element for hot air blower - VAS 1978/15A- to
hot air blower, 220 V/ 50 Hz - VAS 1978/14A- .

Caution

Risk of damage to surrounding components.

♦ When shrinking crimp connectors, take care not to dam‐
age any other pipes/wires, plastic parts or insulating ma‐
terial with hot nozzle of the hot air blower.
♦ Always observe operating instructions for hot air blower.

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– Working from centre outwards, use hot air blower to heat crimp
connector in longitudinal direction until it is completely sealed
and adhesive emerges at ends.
• A wire repaired using a single crimp connector must look as
shown in illustration.

Note

♦ If several wires have to be repaired, make sure crimp connec‐

tors are not directly adjacent to one another. Offset the crimp
connectors slightly to restrict the size of the wiring harness.
♦ If the repair location was previously wrapped, yellow adhesive
tape must be wrapped around this location again on comple‐
tion of repair.
♦ If necessary, secure the repaired wiring harness with a cable
tie to prevent rattling noises when the vehicle is driven.

2.4.6 Repairing a wire of 0.22 mm2 section by

connecting in an additional wire

Note

To repair a 0.22 mm2 wire, a repair wire with a 0.35 mm2 or 0.5
mm2 cross section can be used as the additional wire.

Procedure
– Release a length of approx. 20 cm of the defective wire at two
points on both sides of the repair joint.

Caution
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Risk of damagepermitted
to electrical wiring.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Take care when releasing wiring from wrapped wiring har‐
nesses.

– If necessary, use a knife to remove wrapping of wiring har‐

ness.

2. Repairing wiring harnesses and connectors 109

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– Lay yellow repair wire next to damaged wiring harness and

use wire stripper - VAS 1978/3- to cut repair wire to required
length.
– Cut damaged section out of original vehicle wire.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Set adjustable stop in jaws of wire stripper - VAS 1978/3- to
12 ... 14 mm (length to be stripped).
– Working from the front, insert end of original vehicle wire into
jaws of wire stripper as far as it will go and press wire stripper
together completely.
– Open wire stripper again and take out stripped end of wire.
– Fold back half of the stripped wire ends.
– Repeat procedure at other end of original vehicle wire.

– Set adjustable stop in jaws of wire stripper - VAS 1978/3- to

6 ... 7 mm (length to be stripped).
– Working from the front, insert end of the yellow repair wire into
jaws of wire stripper as far as it will go and press wire stripper
together completely.
– Open wire stripper again and take out stripped end of wire.
– Repeat procedure at other end of repair wire.
– To repair a 0.22 mm2 wire, take a small transparent crimp
connector out of the wiring harness repair set - VAS 1978 B- .

– To fit crimp connectors from wiring harness repair set - VAS

1978 B- , use crimping pliers (base tool) - VAS 1978/1-2- with
head adapter 0.35 mm² - 2.5 mm² - VAS 1978/1-1- .
– Slide small transparent crimp connector over end of original
vehicle wire (stripped and folded back) on one side and over
stripped end of repair wire on the other.

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– Use crimping pliers to fasten crimp connector to both wire

ends.
– Repeat procedure at other end of repair wire.

Note

Take care not to crimp insulation of wire.

After crimping, hot air blower must be used to shrink-fit crimp

connector to prevent moisture from ingressing.
– Attach shrink element for hot air blower - VAS 1978/15A- to
hot air blower, 220 V/ 50 Hz - VAS 1978/14A- .

Caution

Risk of damage to surrounding components.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ When shrinking crimp connectors, take care not to dam‐
with respect to the correctness of information in this document. Copyright by AUDI AG.
age any other pipes/wires, plastic parts or insulating ma‐
terial with hot nozzle of the hot air blower.
♦ Always observe operating instructions for hot air blower.

– Working from centre outwards, use hot air blower to heat crimp
connector in longitudinal direction until it is completely sealed
and adhesive emerges at ends.
• A wire repaired using inserted repair wire and two crimp con‐
nectors must look as shown in illustration.

Note

♦ If several wires have to be repaired, make sure crimp connec‐

tors are not directly adjacent to one another. Offset the crimp
connectors slightly to restrict the size of the wiring harness.
♦ If the repair location was previously wrapped, yellow adhesive
tape must be wrapped around this location again on comple‐
tion of repair.
♦ If necessary, secure the repaired wiring harness with a cable
tie to prevent rattling noises when the vehicle is driven.

2. Repairing wiring harnesses and connectors 111

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2.4.7 Repairing a wire of 0.35 mm2 section or

thicker by connecting in an additional
wire

Note

Repair wires with a cross section of 0.35 mm2 to 6.0 mm2 can be
used for repairs.

Procedure
– Release a length of approx. 20 cm of the defective wire at two
points on both sides of the repair joint.

Caution

Risk of damage to electrical wiring.

♦ Take care when releasing wiring from wrapped wiring har‐
nesses.

– If necessary, use a knife to remove wrapping of wiring har‐

ness.
– Lay yellow repair wire next to damaged wiring harness and
use wire stripper - VAS 1978/3- to cut repair wire to required
length.
– Cut damaged section out of original vehicle wire.

– Set adjustable stop in jaws of wire stripper - VAS 1978/3- to

6 ... 7 mm (length to be stripped).
– Working from the front, insert end of original vehicle wire into
jaws of wire stripper as far as it will go and press wire stripper
together completely.
– Open wire stripper again and take out stripped end of wire.
– Repeat procedure at other end of original vehicle wire.
– For repair, take two suitable crimp connectors out of wiring
harness repair set - VAS 1978 B- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note

♦ It is very important to select the correct crimp connector and

appropriate corresponding crimp recess ⇒ page 97 .
♦ Take care not to crimp insulation of wire.

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– Use crimping pliers (base tool) - VAS 1978/1-2- for fitting crimp
connectors.
The following head adapters are available for the crimping pliers
(base tool) - VAS 1978/1-2- :
♦ Head adapter 0.35 mm² - 2.5 mm² - VAS 1978/1-1-
♦ Head adapter 4.0 - 6.0 mm² - VAS 1978/2 A-
– Slide crimp connector over original vehicle wire on one side
and over repair wire on the other.

– Use crimping pliers to fasten crimp connector to both wire

ends.
– Repeat procedure at other wire ends.

Note

Take care not to crimp insulation of wire.

After crimping, hot air blower must be used to shrink-fit crimp

connector to prevent moisture from ingressing.
– Attach shrink element for hot air blower - VAS 1978/15A- to
hot air blower, 220 V/ 50 Hz - VAS 1978/14A- .

Caution

Risk of damage to surrounding components.

♦ When shrinking crimp connectors, take care not to dam‐
age any other pipes/wires, plastic parts or insulating ma‐
terial with hot nozzle of the hot air blower.
♦ Always observe operating instructions for hot air blower.

– Working from centre outwards, use hot air blower to heat crimp
connector in longitudinal direction until it is completely sealed
and adhesive emerges at ends.
• A wire repaired using inserted repair wire and two crimp con‐
nectors must look as shown in illustration.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Repairing wiring harnesses and connectors 113

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Note

♦ If several wires have to be repaired, make sure crimp connec‐

tors are not directly adjacent to one another. Offset the crimp
connectors slightly to restrict the size of the wiring harness.
♦ If the repair location was previously wrapped, yellow adhesive
tape must be wrapped around this location again on comple‐
tion of repair.
♦ If necessary, secure the repaired wiring harness with a cable
tie to prevent rattling noises when the vehicle is driven.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.5 Repairing fibre optic cables

Caution

The fibre optic cables must not be severely kinked. Bending

radius must not be less than 25 mm.
The fibre optic cables must not located over sharp edges.
The ends of the fibre optic cables must not be made dirty or
touched with bare hands.
The fibre optic cables must not be heated.
Twisting two fibre optic cables or a fibre optic cable with a cop‐
per wire is not permitted.
Protect connector and connecting cable from dust. Use pro‐
tective caps from set.

⇒ “2.5.1 Determining location of fault”, page 114

⇒ “2.5.2 Preparing fibre optic cables with fibre-optic conductor
repair set VAS 6223 ”, page 115
⇒ “2.5.3 Preparing fibre optic cables with fibre-optic conductor
repair set VAS 6223A ”, page 119
⇒ “2.5.4 Separating fibre optic cable from wiring harness connec‐
tor”, page 124

2.5.1 Determining location of fault

Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Procedure
The precise location of the fault is very difficult to find. A damaged
fibre optic cable must be renewed by fitting a new cable parallel
to the defective one.

Note

♦ You can use the “Guided Fault Finding” to find out where (be‐
tween which components) the fibre optic cabling is damaged.
♦ A fibre optic cable that has already been repaired is coloured
“yellow”.

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– Carry out “Loop break diagnosis” function in “Offboard Diag‐

nostic Information System Service” ⇒ Vehicle diagnostic test‐
er.
– Remove components concerned.
– Disconnect connectors from components.
– Prepare fibre optic cable:
♦ ⇒ “2.5.2 Preparing fibre optic cables with fibre-optic conductor
repair set VAS 6223 ”, page 115
♦ ⇒ “2.5.3 Preparing fibre optic cables with fibre-optic conductor
repair set VAS 6223A ”, page 119

2.5.2 Preparing fibre optic cables with fibre-

optic conductor repair set - VAS 6223-
Special tools and workshop equipment required
♦ Fibre-optic conductor repair set - VAS 6223-

♦ Cutting pliers - VAS 6228-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Checking remaining cut indicator

– Start by checking remaining cut indicator:
♦ Cutting unit of pliers for fibre optic cable - VAS 6223/1- can be
used for approx. 1,260 cuts. The cutter is turned for each fur‐
ther cut.
♦ The remaining cut indicator -arrow- shows the last 150 cuts
available.
♦ Once no further cuts are available the cutting unit is blocked.
It must then be renewed ⇒ Operating instructions for pliers for
fibre optic cable - VAS 6223/1- .

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Preparing pliers for fibre optic cable - VAS 6223/1- for use
– Release transport safeguard on cutter by slackening off hex‐
agon socket head bolt -arrow-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Cutting fibre optic cable to length
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Establish length of fibre optic cable required.
– Open pliers for fibre optic cable - VAS 6223/1- and insert fibre
optic cable -1- in cutting point.
– Close cutting pliers to cut fibre optic cable to length.

Stripping
– Open pliers for fibre optic cable - VAS 6223/1- .
• Stripping lever must be in lower position -arrow-.
– Insert fibre optic cable -1- in stripper unit.
• Fibre optic cable must be flush with back of cutting pliers.

– Close pliers for fibre optic cables - VAS 6223/1- as far as fixed
stop and keep closed.
– Swivel up stripping lever -arrow-.
– Open cutting pliers and take out fibre optic cable -1-.
– Detach separated section of insulation from fibre optic cable.

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Precision cutting (cutting end face of fibre optic cable)

– Insert fibre optic cable -1- in cutting point.
• Insulation must make contact with cutting point stop -arrow-.
– Close pliers for fibre optic cable - VAS 6223/1- .

– Press down cutting unit -arrow-.

– Open pliers for fibre optic cable - VAS 6223/1- and take out
fibre optic cable -1-.

Note

Fibre optic cable should only be placed on an absolutely clean

surface.

Activating transport safeguard

– Close pliers for fibre optic cable - VAS 6223/1- .
– Secure hexagon socket head bolt -arrow- for transportation
safeguard at cutter.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Attaching brass pin contact to fibre optic cable

– Open locking lever on pliers for fibre optic cable - VAS 6223/2-
-arrow 1- and -arrow 2-.

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– Insert brass pin contact -1- in mounting.

– Close locking lever on pliers for fibre optic cable - VAS 6223/2-
-arrow-.

– Slide fibre optic cable -2- into brass pin contact -1- as far as
spring-loaded stop.
– Push in fibre optic cable further as far as fixed stop and close
pliers for fibre optic cable - VAS 6223/2- .
– Open pliers for fibre optic cable and take out fibre optic cable
with brass pin contact.

Caution

The fibre optic cables must not be severely kinked. Bending

radius must not be less than 25 mm.

– Check proper attachment of brass pin contact -2- to fibre optic

cable -1-.
• There must be 4 crimping points visible on brass pin.
• It should not be possible to detach brass pin contact from fibre
optic cable by hand.
• End face of fibre optic cable is located 0.01 ... 0.1 mm behind
brass pin contact (visual inspection).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Plug-in couplings are available for connection of fibre optic
cable ⇒ Electronic parts catalogue .
♦ For fitting new fibre optic cable in wiring harness connector,
refer to ⇒ page 124 .

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Fitting corrugated tube onto fibre optic cable

– Cut corrugated tube to appropriate length.
• Use cutting pliers - VAS 6228- or a sharp knife for cutting.
• Do NOT use side-cutters to cut through the corrugated tube.
• The corrugated tube must be cut at the top of the corrugation
-arrow- and not at the bottom.

– Insert fibre optic cable in pliers for corrugated tube installation

- VAS 6223/10- as shown.
– Apply pliers for corrugated tube installation at slot in corruga‐
ted tube.
– Slide pliers for corrugated tube installation along slot on cir‐
cumference of corrugated tube. This will insert the fibre optic
cable into the corrugated tube.

2.5.3 Preparing fibre optic cables with fibre-

optic conductor repair set - VAS 6223A-
Special tools and workshop equipment required
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

♦ Fibre-optic conductor repair set with

- VAS 6223A-
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by AUDI AG.

2. Repairing wiring harnesses and connectors 119

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♦ Cutting pliers - VAS 6228-

♦ Vehicle diagnostic tester

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Caution

The fibre optic cables must not be severely kinked. Bending

radius must not be less than 25 mm.
The fibre optic cables must not located over sharp edges.
The ends of the fibre optic cables must not be made dirty or
touched with bare hands.
The fibre optic cables must not be heated.
Twisting two fibre optic cables or a fibre optic cable with a cop‐
per wire is not permitted.
Protect connector and connecting cable from dust. Use pro‐
tective caps from set.

Mounting tool head for pliers for fibre optic cable - VAS 6223/1-

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– Press out locking pins -arrows-.

– Fit tool head -arrow- and press locking pins back.

Cutting fibre optic cable to length

– Determine required length of fibre optic cable.
– Open pliers for fibre optic cable and insert fibre optic cable
-1- into cutting point.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Close pliers for fibre optic tocable
with respect to cut offibre
the correctness opticincable
information to Copyright by AUDI AG.
this document.
length.

Stripping
– Open pliers for fibre optic cable - VAS 6223/1- .
– Bring stripping lever into lower position -arrow-.
– Insert fibre optic cable into stripping point.
• Fibre optic cable must be flush with back of cutting pliers.

– Close pliers for fibre optic cables as far as fixed stop and keep
closed.
– Swivel stripping lever upwards -arrow- and remove fibre optic
cable.

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Precision cutting (cutting end face of fibre optic cable)

– Insert fibre optic cable -1- into cutting point.
• Insulation must make contact with cutting point stop.

– Close pliers for fibre optic cable - VAS 6223/1- and remove
cable.
– Perform a visual check of cable -1- to ensure that it has been
cut correctly and that there is no burr on end face.

Note

♦ Fibre optic cable should only be placed on an absolutely clean

surface or held by hand.
♦ Use protective cap if there is a danger of end face of fibre optic
cable becoming dirty.

Attaching brass pin contact to fibre optic cable

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Change tool head -arrow-.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Move securing clip on pliers for fibre optic cable -arrow- so that
the word “STIFT” (pin) is visible.

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– Insert a brass pin contact -1- in mounting.

– Close locking lever on pliers for fibre optic cable -arrow-.

– Slide fibre optic cable into brass pin contact -arrow- as far as
spring-loaded stop and close pliers for fibre optic cable .
– Open pliers for fibre optic cable and remove fibre optic cable
with brass pin contact.

Caution

Fibre optic cables must not be kinked or excessively bent (min‐

imum bending radius 25 mm).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Check that brass pin contact -2- is properly attached to fibre
optic cable -1-.
• There must be 4 crimping points visible on brass pin.
• It should not be possible to detach brass pin contact from fibre
optic cable by hand.
• End face of fibre optic cable is located 0.01 ... 0.1 mm behind
brass pin contact (visual inspection).

Note

♦ Plug-in couplings are available for connection of fibre optic

cable ⇒ Electronic parts catalogue .
♦ For fitting new fibre optic cable in wiring harness connector,
refer to ⇒ page 124 .

2. Repairing wiring harnesses and connectors 123

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Fitting corrugated tube onto fibre optic cable

– Cut corrugated tube to appropriate length.
• Use cutting pliers - VAS 6228- or a sharp knife for cutting.
• Do NOT use side-cutters to cut through the corrugated tube.
• The corrugated tube must be cut at the top of the corrugation
-arrow- and not at the bottom.
• When being fitted, corrugated tube must engage audibly in fi‐
bre optic cable housing.

– Insert fibre optic cable into pliers for corrugated tube installa‐
tion - VAS 6223/10- , as shown in illustration.
– Apply pliers for corrugated tube installation at slot in corruga‐
ted tube.
– Slide pliers for corrugated tube installation along slot on cir‐
cumference of corrugated tube. This will insert the fibre optic
cable into the corrugated tube. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.5.4 Separating fibre optic cable from wiring

harness connector
Removing
– Unplug connector for fibre optic cable from appropriate control
unit.
– Release catch in connector for fibre optic cable -arrow-.

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– Pull basic module -2- for fibre optic cable out of connector
housing -1-.

Caution

♦ Mark assignment of fibre optic cable -5- to corresponding

sockets in module -1- with coloured dots.
♦ Pay attention to arrows -3- on basic module for “IN” and
“OUT” assignment.

– Release secondary catch -6- (blue pin) using a small screw‐

driver -arrow-.
– Release retaining tab -2- and pull fibre optic cable -5- with
brass pin -4- out of module -1-.
Installing
Installation is carried out in the reverse order; note the following:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Note
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Seal off open connector plug -2- for fibre optic cable with pro‐
tective cap for cable connector - VAS 6223/9- -item 1-.
♦ Protective cap prevents contamination of or mechanical dam‐
age to end face of fibre optic cable which would impair light
transmission.

– Fit fibre optic cable in accordance with markings.

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2.6 Repairing aerial wires

⇒ “2.6.1 Repair set, aerial cable VAS 6720”, page 126
⇒ “2.6.2 Renewing an entire aerial wire”, page 136

2.6.1 Repair set, aerial cable VAS 6720

Checking aerial wire ⇒ page 126
Changing tool head ⇒ page 126
Cutting aerial wire ⇒ page 127
Stripping screening ⇒ page 127
Stripping outer sleeve ⇒ page 130
Stripping inner insulation ⇒ page 131
Crimping central wire ⇒ page 132
Crimping outer wire ⇒ page 134
Special tools and workshop equipment required
♦ Repair set, aerial cable - VAS 6720-
The repair set, aerial cable - VAS 6720- makes it possible to
maintain optimum repair standards for repairs to aerial wiring RG
174 (blue) and RKT 031 (black). The set includes the necessary
stripping tools and crimping tools for each of the aerial cables. In
addition, the case includes all the individual parts needed to con‐
nect the original connector in nearly production quality. This
requires only the 0-coded connector (green). All other connecting
wires for the various infotainment systems can be found in ETKA
(EL-electrical connection elements) in chart 035-XX. The different
adapter aerial wires are specific to vehicle models and must al‐
ways be ordered separately. All the individual parts are listed in
the chart for re-ordering. The compartments in the case are la‐
belled with the part numbers of the spare materials. The repair
set is based on the existing set of adapters and pliers in VAS
1978B.

Note

Additional information ⇒ Operating manual of Repair set, aerial

cable - VAS 6720-

Checking aerial wire:

Before beginning repairs, determine which aerial wire is affected
using gauge.
♦ -1- System RG 174 = blue
♦ -2- System RTK 031 = grey
The positioners of the tool heads of both systems are colour co‐
ded accordingly.
Changing tool head:
– Select appropriate tool head after checking aerial wire
⇒ page 126 .
– Open pliers completely.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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– Release both locking pins -arrows- from grips of pliers and pull
them out.

– Insert required tool head from above -arrow- into grips.

– Press Protected
pins -arrows- inCopying
by copyright. to lockfor tool
privatehead into grips.
or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Cutting aerial
withwire:
respect to the correctness of information in this document. Copyright by AUDI AG.

– Insert aerial wire -2- into cutting mechanism -1-.

– Close tool and open it again.
– Pull aerial wire out of cutting mechanism.
Stripping screening:

2. Repairing wiring harnesses and connectors 127

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Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Push locating pin -1- into rotary cutter as far as stop.

– Push aerial wire -2- into rotary cutter as far as stop. The entire
locating pin -3- can now be seen again.

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– Push blade holder -1- against shaft of rotary cutter until it en‐
gages. The gap -2- beneath the blade holder is now com‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

pletely closed.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Hold aerial wire securely so that it cannot turn.

– Turn rotary cutter -3- approximately 2 times in direction of ar‐
row until it rotates easily.

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– Pull release pin -1-. The blade holder will be released and will
detach from aerial wire.
– Push locating pin -2- into rotary cutter as far as stop. The aerial
wire will be pressed out of rotary cutter.
– Remove screening from aerial wire.
– Remove any pieces of insulation remaining in rotary cutter.
Stripping outer sleeve:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

130 Rep. gr.97 - Wiring

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Insert aerial wire -2- in retainer -3- into tool head as far as stop
-1-.
– Close tool and open it again.
– Pull out aerial wire -4-.
Stripping inner insulation:

2. Repairing wiring harnesses and connectors 131

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Insert aerial wire -2- in retainer -1- into tool head as far as stop.
– Close tool and open it again.
– Pull out aerial wire -3-.
Crimping central wire:

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Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Select appropriate tool head after checking aerial wire

⇒ page 126 .
– Unfold adjustable positioner -2-.
– Open up positioning piece -3- (it will tilt upward).
– Push inner contact -1- into adjustable positioner as far as stop
and detach positioning piece. The inner contact will be fixed
in place.
– Fold in adjustable positioner; the inner contact -4- will now be
in position in the tool head.

2. Repairing wiring harnesses and connectors 133

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Insert aerial wire -1- into inner contact -2- in tool head (hold
adjustable positioner in place).
– Close tool until it opens by itself.
– Open positioning piece -3- and pull out aerial wire.
Crimping outer wire:

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Push sleeve -2- and outer contact -1- over central wire. The
knurled contact part must be pushed under shielding -3- but
over the aluminium foil.
– Push outer contact -4- on all the way, ensuring that socket/pin
is seated correctly.

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Electrical system; General information - Edition 06.2014

– Push on sleeve -3- as far as outer contact.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Open
permittedtool and
unless unfold
authorised adjustable
by AUDI positioner
AG. AUDI AG -1-. or accept any liability
does not guarantee
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Position attached outer contact -2- in tool head in middle notch
on edge surface -4-.
– Close tool and open it again.
– Pull out aerial wire.

2.6.2 Renewing an entire aerial wire

A repair method has been developed for renewing aerial wires.
Instead of a complete aerial wire, connecting wires of different
lengths and various adapter wires are now available as replace‐
ment parts.
Replacement parts ⇒ Electronic parts catalogue; Special cata‐
logue “Electrical connecting elements”; Accessories; Sub-group
35 from chart 035-20 onwards .

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Note

♦ Do not repair aerial wires. The wiring must be renewed using

connecting wires and adapter wires (available as genuine re‐
placement parts).
♦ These genuine replacement parts are suitable for all wire
cross-sections and aerial wires which have to be renewed.
♦ The replacement wires can be used for all previously fitted
wiring cross-sections on all Audi models.
♦ All adapter wires and connecting wires are suitable for all
transmission and reception signals.
♦ The repair method can also be used for testing and service
installation purposes (e.g. retrofitting).

Special tools and workshop equipment required

♦ -1- Adapter wire for connection to radio; length: approx. 30 cm

♦ -2- Connecting wire; various lengths available

♦ -3- Adapter wire for connection to aerial; length: approx. 30 cm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Procedure permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Example: Aerial wire from radio to aerial defective

– Unplug connectors of defective aerial wire from units.
– Determine routing of defective aerial wire in vehicle and meas‐
ure out overall length of aerial connection to be replaced in
vehicle.

2. Repairing wiring harnesses and connectors 137

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• Total length of aerial connection = length of required adapter

wires -1 and 3- plus connecting wire -2-.
– Subtract 60 cm from total length of aerial connection meas‐
ured to calculate required length of connecting wire needed.
– Obtain necessary adapter wires and connecting wire (with cal‐
culated length) as genuine replacement parts ⇒ Electronic
parts catalogue .
– Cut connectors off defective aerial wire.
• Leave rest of defective aerial wire in vehicle.
– Connect adapter wires to units in vehicle.
– Fit connectors with a piece of foam sheathing to prevent rat‐
tling noise.
– Lay and secure connecting wire parallel to old aerial wire.

Note

Aerial wires must not be kinked or bent excessively. Bending ra‐

dius must not be less than 50 mm.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Attach connecting wire to adapter wires. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– To prevent rattling noises, apply a suitable piece of foam
sheathing to aerial connectors.
– Check operation.

2.7 Repairing connector housings and elec‐

trical connectors

2.7.1 Notes on repairing connector housings

and electrical connectors

Note

♦ Observe general information on repairs to the vehicle electri‐

cal system ⇒ page 93 .
♦ The appropriate crimp contacts are assigned to the connector
housings on the basis of the part number stamped on the con‐
nector housing. ⇒ Electronic parts catalogue; Special cata‐
logue “Electrical connecting elements”; Electrical equipment;
Sub-group 71 from chart 970-00 onwards .
♦ Always renew damaged connector housings.

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2.7.2 Repairing contacts in connector hous‐

ings
Procedure
– If applicable, start by opening or releasing secondary locking
device on connector housing ⇒ page 141 .
– Use appropriate release tool to release connector (primary
locking device) ⇒ page 141 .
– Take hold of wire and pull connector towards rear and out of
connector housing (if applicable with wire seal) -arrow-.

– Cut old connector off original vehicle wiring harness (if appli‐
cable with wire seal).
– Take yellow repair wire with correct connector out of wiring
harness repair set - VAS 1978 B- .
– Release a length of approx. 20 cm of the defective wire on both
sides of the repair joint.

Caution

Risk of damage to electrical wiring.

♦ Take care when releasing wiring from wrapped wiring har‐
nesses.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– If necessary, use a knife to remove wrapping of unless
permitted wiring har‐ by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
ness. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Slide connector of new repair wire into corresponding con‐

nector housing slot until it engages.
– If applicable, attach wire seal to repair wire ⇒ page 140 .

– Use wire stripper - VAS 1978/3- to shorten repair wire and wire
of original vehicle wiring harness as required.
– Strip ends of repair wire and original vehicle wire and crimp
stripped ends of repair wire and wire of original vehicle wiring
harness using crimping pliers and a crimp connector
⇒ “2.4.4 Repairing a wire of 0.22 mm2 section with a single
crimp connector”, page 105 or
⇒ “2.4.5 Repairing a wire of 0.35 mm2 section or thicker with
a single crimp connector”, page 107 .

2. Repairing wiring harnesses and connectors 139

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2.7.3 Fitting seals for individual wires

Procedure

Note

♦ Wire seals prevent water and dirt from ingressing into the con‐
nector housing. They are fitted e.g. in the engine compartment
and must always be re-installed after completing a repair.
♦ As a standard, wire seal is crimped to wire together with con‐
nector. This is not the case with repair wires. Wire seal must
be slipped onto wire before crimping repair wire.
♦ Wire seals must always match the wire cross section of the
repair wire used. The outer diameter of the wire seal depends
on the diameter of the connector housing slot. Always use the
appropriate assembly tool when fitting.

– Attach wire seal -A- to free end of repair wire.

• The small diameter of the wire seal must face the connector
housing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Slide wire seal -A- over repair wire as far as connector housing
and then as far as it will go into connector housing using an
appropriate fitting tool -B-.

– Use wire stripper - VAS 1978/3- to shorten repair wire and wire
of original vehicle wiring harness as required.
– Crimp stripped ends of repair wire and wire of original vehicle
wiring harness using crimping pliers and a crimp connector
⇒ “2.4.4 Repairing a wire of 0.22 mm2 section with a single
crimp connector”, page 105 , or
⇒ “2.4.5 Repairing a wire of 0.35 mm2 section or thicker with
a single crimp connector”, page 107 .

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2.7.4 Repairing connector housings with insu‐

lation displacement technology (IDC)

Note

♦ For technical reasons, connector housings for insulation dis‐

placement technology can only be supplied with the connec‐
tors inserted.
♦ If these connectors are not required, they can be removed in
the same manner as for any other connector housing.
♦ Repair wires which are already fitted with the corresponding
crimped-on connectors are available ⇒ Electronic parts cata‐
logue (ETKA) .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.8 Releasing and dismantling connector

housings

2.8.1 Notes on releasing and dismantling con‐

nector housings

Note

♦ Observe general information on repairs to the vehicle electri‐

cal system ⇒ page 93 .
♦ Always use the release tools intended for this purpose. Never
force connectors out of connector housings.
♦ Always renew damaged connector housings. New connector
housings can be ordered from OTC Kassel.
♦ Small screwdrivers can be used to help release secondary
locking devices.
♦ The contact/pin assignment may be stamped on the secon‐
dary locking device or on the back of the connector housing.
♦ For further information on fitting locations of connectors, refer
to ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.

For correct release tools for corresponding locking devices, refer

to table in ⇒ Operating instructions for -VAS 1978/35- .

2.8.2 Secondary locking device

The secondary locking device is a securing element designed to
secure all the wires in a connector housing. If a connector housing
is fitted with a secondary locking device, this must always be
opened or removed using the specified tool before releasing and
extracting individual crimp connectors.
The secondary locking device is of a different colour to the rest of
the connector housing to aid identification and show how it works.

2. Repairing wiring harnesses and connectors 141

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The types of connector housing shown here are only a selection

designed to illustrate examples of the various operating principles
of the secondary locking devices.
Example 1:
Release housing securing element by removing “comb” -arrow-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Example 2:
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Release housing securing element by opening “flap” -arrow-.

Example 3:
Release housing securing element by disengaging a “slide”
-arrow-.

2.8.3 Primary locking device

The primary locking device engages an individual crimp connec‐
tor in the connector housing.
If housing securing elements (secondary locking devices) are fit‐
ted, they must be released or removed using the specified tool
before releasing the contacts ⇒ page 141 .
The types of primary locking device shown here are only a se‐
lection designed to illustrate examples of the various operating
principles of the primary locking devices.
♦ Round connector systems ⇒ page 143
♦ Flat connector systems ⇒ page 143
♦ Special connector systems ⇒ page 145
For correct release tool for corresponding locking device, refer to
⇒ Operating instructions for -VAS 1978/35- .

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2.8.4 Round connector systems

Note

If housing securing elements (secondary locking devices) are fit‐

ted, they must be released or removed using the specified tool
before releasing the contacts ⇒ page 141 .

– Insert appropriate release tool for connector housing in re‐

lease slot at connector housing.
– Take hold of connector at wire and press it slightly into con‐
nector housing -arrow-.

Note

Pressing connector towards connector housing causes retaining

tabs of connector to be lifted off housing shoulder, enabling them
to be released with release tool.

– At the same time, press release tool towards connector hous‐

ing -arrow- and pull released connector out of connector hous‐
ing.

– After removing connector, release tool can be pulled back out

of connector housing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.8.5 Flat connector systems

Note

If housing securing elements (secondary locking devices) are fit‐

ted, they must be released or removed using the specified tool
before releasing the contacts ⇒ page 141 .

Flat connector system with one retaining tab:

– Insert appropriate release tool for connector housing in re‐
lease slot at connector housing.
– Take hold of connector at wire and press it slightly into con‐
nector housing -arrow-.

Note

Pressing connector towards connector housing causes retaining

tab of connector to be lifted off housing shoulder, enabling it to be
released with release tool.

2. Repairing wiring harnesses and connectors 143

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– At the same time, press release tool towards connector hous‐

ing and pull released connector out of connector housing
-arrow-.
– After removing connector, release tool can be pulled back out
of connector housing.

Flat connector system with two retaining tabs:

– Insert appropriate release tool for connector housing in re‐
lease slot at connector housing.
– Take hold of connector at wire and press it into connector
housing -arrow- as far as stop.

Note

Pressing connector towards connector housing causes retaining

tabs of connector to be lifted off housing shoulder, enabling them
to be released with release tool.

– At the same time, press release tool towards connector hous‐

ing and pull released connector out of connector housing
-arrow-.
– After removing connector, release tool can be pulled back out
of connector housing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Asymmetrical: with respect to the correctness of information in this document. Copyright by AUDI AG.

– Insert appropriate release tool for connector housing in re‐

lease slot at connector housing.
– Take hold of connector at wire and press it slightly into con‐
nector housing -arrow-.

Note

Pressing connector towards connector housing causes retaining

tabs of connector to be lifted off housing shoulder, enabling them
to be released with release tool.

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– At the same time, press release tool towards connector hous‐

ing and pull released connector out of connector housing
-arrow-.
– After removing connector, release tool can be pulled back out
of connector housing.

2.8.6 Special connector systems

Note

If housing securing elements (secondary locking devices) are fit‐

ted, they must be released or removed using the specified tool
before releasing the contacts ⇒ page 141 .

Fast-on contacts:
– Insert appropriate release tool for connector housing in re‐
lease slot at connector housing.
– Take hold of connector at wire and press it slightly into con‐
nector housing.

Note

Pressing connector towards connector housing causes retaining

tabs of connector to be lifted off housing shoulder, enabling them
to be released with release tool.

– At the same time, press release tool towards connector hous‐

ing and pull released
Protected by connector outforofprivate
copyright. Copying connector housing
or commercial purposes, in part or in whole, is not
-arrow-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– After removing connector, release tool can be pulled back out
of connector housing.

2. Repairing wiring harnesses and connectors 145

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GT 150/280 connectors:
– Insert appropriate release tool for connector housing beneath
retaining tab into connector housing.
– Press tool -arrow- in connector housing as far as it will go.

Connector is ejected from connector housing.

– After ejecting connector, release tool can be pulled back out
of connector housing.

Contacts without retaining tabs:

– Insert release tool beneath retaining tab on connector hous‐
ing.
– Lifting it slightly -arrow-, press release tool as far as stop.

Connector is ejected from connector housing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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3 Contact surface cleaning set - VAS

6410-

3.1 Using contact surface cleaning set -

VAS 6410-
Using contact surface cleaning set - VAS 6410- makes it possible
to maintain optimum repair standards for repairs to the electrical
system. The tools can be used to service the areas around the
connectors on wiring harnesses for screw-type connections in
high current circuits (starting and charging current). Contact sur‐
face cleaning set - VAS 6410- has been adapted to the structural
design of the vehicle and ensures that repairs are easy to perform
and are carried out correctly.

Note

The illustrations show just a few examples of repairs.

Contact surface cleaning set - VAS 6410-

3.1.1 Servicing wiring lugs

Special tools and workshop equipment required
♦ VAG 1331

Note

♦ To prevent the screw connection from cracking when the tight‐

ening torque
Protected has been
by copyright. exceeded
Copying due
for private or to a lack
commercial of friction
purposes, inwhole,
in part or in the is not
thread, do not
permitted apply
unless rust
authorised by remover,
AUDI AG. AUDI contact spray
AG does not or grease
guarantee to liability
or accept any
the screw connection.
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ The grey sanding pads can be used for slight impurities and
"soft surfaces". The red sanding pads can be used for more
severe impurities and "hard surfaces".

3. Contact surface cleaning set VAS 6410 147

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WARNING

Risk of injury. Observe warnings and safety regulations

⇒ page 3 .

– Disconnect battery.
– Loosen cap nut and remove wiring lug from screw connection.
– Check wiring lug for corrosion, dirt, etc.
– Select appropriate adapter and corresponding sanding pad.

Note

As an alternative you can also use the sanding block.

Caution

Do not sand away the tin plating to such an extent that the
copper layer underneath becomes visible. This could produce
a galvanic cell which destroys metal and causes faulty repair.

Note

As the thickness of the tin plating varies, it is necessary to clean

the wiring lug in several stages and check it in between.

– Apply adapter to wiring lug and sand corrosion and dirt off by
rotating adapter.
– Check wiring lug and if necessary re-sand.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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– If necessary, remove sanding residue at wiring lug using de‐

burrer.
– Screw wiring lug back on to specified torque ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.

Note

To ensure optimum contact, tighten all screw connections to

specified torque after cleaning.

– Protect connection from corrosion by applying corresponding

anti-corrosion agent ⇒ page 152 .
– Reconnect battery.

WARNING

Risk of injury. Observe warnings and safety regulations

⇒ page 3 .

– Readapt electric windows, enter radio code, set clock and, if

necessary, recode any control units with fault messages.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
3.1.2 Servicing screw connections with respect to the correctness of information in this document. Copyright by AUDI AG.

Special tools and workshop equipment required

♦ VAG 1331

Note

♦ To prevent the screw connection from cracking when the tight‐

ening torque has been exceeded due to a lack of friction in the
thread, do not apply rust remover, contact spray or grease to
the screw connection.
♦ The grey sanding pads can be used for slight impurities and
"soft surfaces". The red sanding pads can be used for more
severe impurities and "hard surfaces".

WARNING

Risk of injury. Observe warnings and safety regulations

⇒ page 3 .

– Disconnect battery.

3. Contact surface cleaning set VAS 6410 149

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– Loosen cap nut and remove wiring lug from screw connection.
– Check screw connection for corrosion, dirt, etc.
– Select appropriate adapter and corresponding sanding pad for
screw connection.

Caution

Do not sand away the tin plating to such an extent that the
copper layer underneath becomes visible. This could produce
a galvanic cell which destroys metal and
Protected by copyright. causes
Copying faulty
for private repair.
or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

As the thickness of the tin plating varies, it is necessary to clean

the wiring lug in several stages and check it in between.

– Apply adapter to screw connection and sand corrosion and dirt

off by rotating adapter.
– Check screw connection and re-sand if necessary.
– Bolt screw connection together with locating element (if fitted)
and tighten to specified torque ⇒ Current flow diagrams, Elec‐
trical fault finding and Fitting locations.

Note

To ensure optimum contact, tighten all screw connections to

specified torque after cleaning.

– Protect connection from corrosion by applying corresponding

anti-corrosion agent ⇒ page 152 .
– Reconnect battery.

WARNING

Risk of injury. Observe warnings and safety regulations

⇒ page 3 .

– Readapt electric windows, enter radio code, set clock and, if

necessary, recode any control units with fault messages.

3.1.3 Cleaning battery terminal clamps and

battery terminals
Special tools and workshop equipment required

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♦ VAG 1331

Note

To prevent the screw connection from cracking when the tight‐

ening torque has been exceeded due to a lack of friction in the
thread, do not apply rust remover, contact spray or grease to the
screw connection.

WARNING

Risk of injury. Observe warnings and safety regulations

⇒ page 3 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Disconnect battery.
– Check battery terminal clamp and battery terminal for corro‐
sion or dirt.
– Clean battery terminal clamp with wire brush of battery termi‐
nal cleaner (rotary motion).

3. Contact surface cleaning set VAS 6410 151

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– Clean battery terminal using bottom end of battery terminal

cleaner (rotary motion).

WARNING

Risk of injury. Observe warnings and safety regulations

⇒ page 3 .

– Reconnect battery and tighten battery terminals to specified

torque.

Note

To ensure optimum contact, tighten all screw connections to

specified torque after cleaning.

3.1.4 Corrosion protection

Caution

A lack of corrosion protection will ultimately cause damage to

the vehicle's electrical system.

Note

♦ All screw connections must be tightened to the specified tor‐

que.
♦ To protect from corrosion, use hose attached to can of anti-
corrosion agent.
♦ Use anti-corrosion wax for cold sections.
♦ Use cavity sealing agent for warm sections.
♦ Capillary attraction causes anti-corrosion agent to be drawn to
the affected areas automatically.

– Hold injector underneath wiring lug and spray all around ter‐
minal.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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– Hold injector above wiring lug and spray terminal and wiring
lug (all around).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Contact surface cleaning set VAS 6410 153

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4 ESD (electrostatic discharge) work‐

place VAS 6613

4.1 Using ESD workplace - VAS 6613-

♦ The ESD (electrostatic discharge) workplace -VAS 6613- is
designed for preventing damage to electronic components
due to static discharge.
♦ Therefore it is possible to perform repairs on extremely sen‐
sitive electronic components and open printed circuit boards.
♦ Details on repairs which must be performed on the ESD (elec‐
trostatic discharge) workplace -VAS 6613- can be found in the
relevant chapter of the appropriate Workshop Manual "Elec‐
trical system".
– For setting up the ESD (electrostatic discharge) workplace,
place the ESD table mat -3- from -VAS 6613- on a dry and
clean table.
– Connect earthing module -2- to one of the snap fasteners on
ESD table mat.
– Then proceed by plugging in connector adapter -1- of earthing
module with adapting connector to an electrical mains socket
equipped with earthing contact or attach crocodile clip to build‐
ing earth strap or water pipe.
– Connect wrist strap -4- to one of the snap fasteners on mat.
– Always wear the wrist strap so that it is in contact with your
wrist - it is not sufficient for it to merely be in contact with your
jacket or shirt sleeve.

Caution

For repairs on extremely sensitive electronic components and

open printed circuit boards always use nonmagnetic tools, e.g.
socket wrench - T10072- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

154 Rep. gr.97 - Wiring

 2005 Audi A4 Quattro
2005 AUDI A4

2005 AUDI

A4

BUZZERS, RELAYS & TIMERS

BUZZERS, RELAYS & TIMERS LOCATION
Component Location
Brake Booster Relay Left side of dash. See Fig. 22 .
Coolant Circulation Pump Relay Left rear of engine compartment. See Fig. 40 .
Front Parking Warning Buzzer Behind center of dash. See Fig. 63 .
Fuel Pump (FP) 2 Relay Left side of dash. See Fig. 64 .
On relay & fuse panel at left side of dash. See Fig.
Horn Relay
84 .
Load Reduction Relay Left side of dash. See Fig. 106 .
Locking Relay For Starter (Clutch Pedal Switch) Left rear of engine compartment. See Fig. 111 .
Motronic Engine Control Module (ECM) Power
Left rear of engine compartment. See Fig. 116 .
Supply Relay
Park/Neutral Position (PNP) Relay Left rear of engine compartment. See Fig. 123 .
Secondary Air Injection (AIR) Pump Relay Left rear of engine compartment. See Fig. 133 .
Starter Interlock Alarm System Relay (A/T) Left rear of engine compartment. See Fig. 143 .
Warning Buzzer (Parking) (Avant) Left side of cargo area. See Fig. 157 .
Warning Buzzer (Parking) (Sedan) Under package shelf. See Fig. 158 .

CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES LOCATION
Component Location
Rear Shade Circuit Breaker Left side of dash. See Fig. 125 .

CONTROL UNITS
CONTROL UNITS LOCATION
Component Location
ABS Control Module (W/EDL) At left side of engine compartment. See Fig. 14 .
Air Bag Control Module Below center console. See Fig. 16 .
Central Control Module (Comfort System) Below driver's seat. See Fig. 33 .
Coolant FC (Fan Control) Control Module Front of engine compartment. See Fig. 41 .
Integrated in driver's door window regulator motor.
Door Control Module (Driver Side)
See Fig. 54 .
Integrated in left rear door window regulator motor.
Door Control Module (Left Rear)
See Fig. 56 .

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Integrated in right front door window regulator

Door Control Module (Passenger Side )
motor. See Fig. 55 .
Integrated in right rear door window regulator
Door Control Module (Right Rear)
motor. See Fig. 57 .
Fresh Air Blower Control Module Below right side of dash. See Fig. 34 .
Headlight Range Control Module Behind right side of dash. See Fig. 80 .
Heated Seat Control Module (Left Rear) Rear of center console. See Fig. 103 .
Heated Seat Control Module (Right Rear) Rear of center console. See Fig. 130 .
Heated Windshield Control Module Rear center of engine compartment. See Fig. 82 .
Instrument Cluster Control Module Behind instrument cluster. See Fig. 39 .
Memory Seat Control Module Under driver's seat. See Fig. 114 .
Left rear of engine compartment, in plenum
Motronic Engine Control Module (ECM)
chamber. See Fig. 115 .
Navigation Control Module W/CD (Avant) Left rear of cargo area. See Fig. 35 .
Navigation Control Module W/CD (Sedan) Left side of trunk. See Fig. 36 .
Parking Aid Control Module (Avant) Left side of cargo area. See Fig. 37 .
Parking Aid Control Module (Sedan) Left side of trunk. See Fig. 38 .
Rear Window Shade Control Module Under package shelf. See Fig. 126 .
Servotronic Control Module At left side of dash. See Fig. 142 .
Steering Column Electronic Systems Control On steering column, behind steering wheel. See Fig.
Module 145 .
Telephone/Telematic Control Module Under passenger's seat. See Fig. 147 .
Throttle Valve Control Module (1.8L Turbo) On throttle body. See Fig. 149 .
Behind intake manifold, on throttle valve housing.
Throttle Valve Control Module (3.0L)
See Fig. 150 .
Transmission Control Module (TCM) (CVT) At rear of transmission. See Fig. 152 .
Transmission Control Module (TCM) (5 Speed
Left rear of engine compartment. See Fig. 151 .
A/T)
Vehicle Electrical System Control Module At left side of dash. See Fig. 156 .

MOTORS
MOTORS LOCATION
Component Location
ABS Hydraulic Unit Left side of engine compartment. See Fig. 15 .
Brake System Vacuum Pump (A/T) Left side of engine compartment. See Fig. 25 .
Leak Detection Pump (LDP) In left rear wheel well. See Fig. 100 .
Lock Unit For Central Locking (Driver's) Rear of driver's door. See Fig. 107 .
Lock Unit For Central Locking (Left Rear) Rear of left rear door. See Fig. 109 .
Lock Unit For Central Locking (Passenger's) Rear of passenger's door. See Fig. 108 .
Lock Unit For Central Locking (Right Rear) Rear of right rear door. See Fig. 110 .
Secondary Air Injection (AIR) Pump Motor (3.0L) Right front of engine compartment. See Fig. 132 .

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SENDING UNITS/SENSORS
SENDING UNITS & SENSORS LOCATION
Component Location
Accelerator Pedal Position Sender 2 At accelerator pedal. See Fig. 136 .
Brake Pressure Sensor 1 Left side of engine compartment. See Fig. 24 .
Camshaft Position (CMP) Sensor (1.8L Turbo) Front of engine. See Fig. 29 .
Camshaft Position (CMP) Sensor 2 (3.0L) Left rear of engine. See Fig. 31 .
Camshaft Position (CMP) Sensor (3.0L) Rear of right cylinder bank. See Fig. 30 .
Camshaft Position (CMP) Sensor 4 (3.0L) Rear of left cylinder head. See Fig. 32 .
Engine Coolant Temperature (ECT) Sensor (1.8L
Rear of engine. See Fig. 59 .
Turbo)
Engine Coolant Temperature (ECT) Sensor (3.0L) Right rear of engine. See Fig. 60 .
Front Air Bag Crash Sensor (Driver's Side) Left front of engine compartment. See Fig. 58 .
Front Air Bag Crash Sensor (Passenger's Side) Right front of engine compartment. See Fig. 124 .
Heated Oxygen Sensor (HO2S) (1.8L Turbo) Right side of engine compartment. See Fig. 81 .
High Pressure Sensor Left side of A/C condenser. See Fig. 83 .
Intake Air Temperature (IAT) Sensor (1.8L Turbo) Left side of engine. See Fig. 96 .
Knock Sensor (KS) 1 (1.8L Turbo) On top of engine. See Fig. 98 .
Knock Sensor (KS) 2 (1.8L Turbo) On top of engine. See Fig. 99 .
Top of windshield, in rearview mirror assembly. See
Light Recognition Sensor
Fig. 105 .
Mass Air Flow (MAF) Sensor (1.8L Turbo) On intake air duct. See Fig. 112 .
Mass Air Flow (MAF) Sensor (3.0L) On air intake duct. See Fig. 113 .
Outside Air Temperature Sensor Behind front bumper. See Fig. 118 .
Oxygen Sensor (O2S) Behind TWC (1.8L Turbo) Right rear of engine compartment. See Fig. 119 .
Oxygen Sensor (O2S) Heater 1 Behind TWC (1.8L
Right rear of engine. See Fig. 122 .
Turbo)
Oxygen Sensor (O2S) Heater (1.8L Turbo) Right side of engine compartment. See Fig. 120 .
Parking Aid Sensor (Left Front) In front bumper. See Fig. 102 .
Parking Aid Sensor (Left Front Center) In front bumper. See Fig. 101 .
Parking Aid Sensor (Left Rear) On rear bumper. See Fig. 138 .
Parking Aid Sensor (Left Rear Center) On rear bumper. See Fig. 139 .
Parking Aid Sensor (Right Front) Front bumper. See Fig. 129 .
Parking Aid Sensor (Right Front Center) On front bumper. See Fig. 128 .
Parking Aid Sensor (Right Rear) On rear bumper. See Fig. 140 .
Parking Aid Sensor (Right Rear Center) On rear bumper. See Fig. 141 .
Rotation Rate Sender Under front of center console. See Fig. 137 .
Sensor (O2S) Heater (3.0L) Right rear of engine. See Fig. 121 .
Side Air Bag Crash Sensor (Driver's Side) At left "B" pillar. See Fig. 42 .
Side Air Bag Crash Sensor (Left Rear) At bottom of left "C" pillar. See Fig. 104 .

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Side Air Bag Crash Sensor (Passenger's Side) At right "B" pillar. See Fig. 43 .
Side Air Bag Crash Sensor (Right Rear) At bottom of right "C" pillar. See Fig. 131 .
Steering Angle Sensor Behind steering wheel. See Fig. 144 .
Throttle Position Sensor (3.0L) On accelerator pedal. See Fig. 148 .
Ultra-Sound Sensor For Anti-Theft In roof console. See Fig. 153 .

SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES LOCATION
Component Location
ABS Hydraulic Unit Left side of engine compartment. See Fig. 15 .
Camshaft Adjustment Valve 1 (Exhaust) (3.0L) Right front of engine. See Fig. 27 .
Camshaft Adjustment Valve 1 (1.8L Turbo) Rear of engine. See Fig. 26 .
Camshaft Adjustment Valve 2 (Exhaust) (3.0L) Left front of engine. See Fig. 28 .
Evaporative Emissions (EVAP) Canister Purge
Right side of engine compartment. See Fig. 61 .
Regulator Valve (1.8L Turbo)
Evaporative Emissions (EVAP) Canister Purge
Right side of engine compartment. See Fig. 62 .
Regulator Valve (3.0L)
Fuel Injector No. 1 (1.8L Turbo) Top Of Engine. See Fig. 44 .
Fuel Injector No. 1 (3.0L) Right side of engine. See Fig. 48 .
Fuel Injector No. 2 (1.8L Turbo) On top of engine. See Fig. 45 .
Fuel Injector No. 2 (3.0L) Right side of engine. See Fig. 49 .
Fuel Injector No. 3 (1.8L Turbo) Top of engine. See Fig. 46 .
Fuel Injector No. 3 (3.0L) Right side of engine. See Fig. 50 .
Fuel Injector No. 4 (1.8L Turbo) Top of engine. See Fig. 47 .
Fuel Injector No. 4 (3.0L) Left side of engine. See Fig. 51 .
Fuel Injector No. 5 (3.0L) Left side of engine. See Fig. 52 .
Fuel Injector No. 6 (3.0L) Left side of engine. See Fig. 53 .
Intake Manifold Change-Over Valve (3.0L) Front of engine. See Fig. 97 .
Recirculating Valve For Turbocharger (1.8L Turbo) Left side of engine. See Fig. 127 .
Secondary Air Injection (AIR) Solenoid Valve (1.8
Left side of engine compartment. See Fig. 134 .
Turbo)
Secondary Air Injection (AIR) Solenoid Valve
Rear of engine. See Fig. 135 .
(3.0L)
Valve 1 For Camshaft Adjustment (3.0L) Right front of engine. See Fig. 154 .
Valve 2 For Camshaft Adjustment (3.0L) Left front of engine. See Fig. 155 .
Wastegate Bypass Regulator Valve (1.8L Turbo) Right front of engine compartment. See Fig. 159 .

SWITCHES
SWITCHES LOCATION

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Component Location
Ambient Temperature Switch Front of vehicle. See Fig. 17 .
Brake Fluid Level Warning Switch On brake fluid reservoir. See Fig. 23 .
Multi-Function Transmission Range (TR) Switch Left side of transmission. See Fig. 117 .

MISCELLANEOUS
MISCELLANEOUS LOCATION
Component Location
Amplifier (Avant) Right side of cargo area. See Fig. 18 .
Amplifier (Sedan) Right side of trunk. See Fig. 19 .
Antenna Splitter Below front passenger's seat. See Fig. 21 .
Antenna (Telephone) Right front of vehicle. See Fig. 20 .
Antenna 2 (Telephone) Under right rear of vehicle. See Fig. 146 .
Diagnostic Connector (DLC) Under left side of dash. See Fig. 1 .
Ignition Coil 1 With Power Output Stage (1.8L
Top of engine. See Fig. 85 .
Turbo)
Ignition Coil 1 With Power Output Stage (3.0L) Right side of engine. See Fig. 89 .
Ignition Coil 2 With Power Output Stage (1.8L
Top of engine. See Fig. 86 .
Turbo)
Ignition Coil 2 With Power Output Stage (3.0L) Right side of engine. See Fig. 90 .
Ignition Coil 3 With Power Output Stage (1.8L
Top of engine. See Fig. 87 .
Turbo)
Ignition Coil 3 With Power Output Stage (3.0L) Right side of engine. See Fig. 91 .
Ignition Coil 4 With Power Output Stage (1.8L
Top of engine. See Fig. 88 .
Turbo)
Ignition Coil 4 With Power Output Stage (3.0L) Left side of engine. See Fig. 92 .
Ignition Coil 5 With Power Output Stage (3.0L) Left side of engine. See Fig. 93 .
Ignition Coil 6 With Power Output Stage (3.0L) Left side of engine. See Fig. 94 .
Induction Coil (Anti-Theft Immobilizer) Right side of steering column. See Fig. 95 .

CONNECTORS
CONNECTORS LOCATION
Component Location
T3a (1.8L Turbo) (3 Pin) Rear of engine compartment. See Fig. 4 .
T3b (1.8L Turbo) (3 Pin) Rear of engine compartment. See Fig. 2 .
T3b (3.0L) (3 Pin) Rear of engine compartment. See Fig. 6 .
T3e (3.0L) (3 Pin) Rear of engine compartment. See Fig. 7 .
T3 (1.8L Turbo) (3 Pin) Rear of engine compartment. See Fig. 3 .
T3 (3.0L) (3 Pin) Rear of engine compartment. See Fig. 5 .

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T4a (3.0L) (4 Pin) Rear of engine compartment. See Fig. 10 .

T4c (3.0L) (4 Pin) Rear of engine compartment. See Fig. 9 .
T4 (1.8L Turbo) (4 Pin) Rear of engine compartment. See Fig. 8 .
T6a (3.0L) (6 Pin) Rear of engine compartment. See Fig. 13 .
T6 (1.8L Turbo) (6 Pin) Rear of engine compartment. See Fig. 11 .
T6 (3.0L) (6 Pin) Rear of engine compartment. See Fig. 12 .

GROUNDS
GROUNDS LOCATION
Component Location
G3 Right side of engine compartment. See Fig. 79 .
G11 Right rear of engine compartment. See Fig. 76 .
G12 Left rear of engine compartment. See Fig. 77 .
G18 (1.8L) Right side of engine. See Fig. 75 .
G18 (3.0L) Left rear of engine. See Fig. 78 .
G26 Left side of engine compartment. See Fig. 74 .
G32 Left kick panel. See Fig. 73 .
G43 Above right kick panel. See Fig. 71 .
G44 Above left kick panel. See Fig. 70 .
G50 Left side of luggage compartment. See Fig. 65 .
G73 Rear of roof. See Fig. 68 .
G77 Left "B" pillar. See Fig. 67 .
G78 Right "B" pillar. See Fig. 66 .
G347 Front of center console. See Fig. 72 .
G610 Under front of center console. See Fig. 69 .

COMPONENT LOCATION GRAPHICS

NOTE: Figures may show multiple component locations. Refer to appropriate table for
proper figure references.

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Fig. 1: Left Side Of Dash

Courtesy of AUDI OF AMERICA, INC.

Fig. 2: Rear Of Engine Compartment

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Fig. 3: Rear Of Engine Compartment

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Fig. 4: Rear Of Engine Compartment

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Fig. 5: Rear Of Engine Compartment

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Fig. 6: Rear Of Engine Compartment

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Fig. 7: Rear Of Engine Compartment

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Fig. 8: Rear Of Engine Compartment

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Fig. 9: Rear Of Engine Compartment

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Fig. 10: Rear Of Engine Compartment

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Fig. 11: Rear Of Engine Compartment

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Fig. 12: Rear Of Engine Compartment

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Fig. 13: Rear Of Engine Compartment

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Fig. 14: Rear Of Engine Compartment

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Fig. 15: Left Side Of Engine Compartment

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Fig. 16: Below Center Console

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Fig. 17: Front Of Vehicle

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Fig. 18: Right Rear Of Vehicle (Avant)

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Fig. 19: Right Side Of Trunk (Sedan)

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Fig. 20: Right Front Of Vehicle

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Fig. 21: Below Front Passenger's Seat

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Fig. 22: Left Side Of Dash

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Fig. 23: Left Rear Of Engine Compartment

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Fig. 24: Left Side Of Engine Compartment

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Fig. 25: Left Side Of Engine Compartment

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Fig. 26: Rear Of Engine (1.8L Turbo)

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Fig. 27: Right Front Of Engine

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Fig. 28: Left Front Of Engine

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Fig. 29: Front Of Engine (1.8L Turbo)

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Fig. 30: Right Rear Of Engine (3.0L)

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Fig. 31: Left Rear Of Engine (3.0L)

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Fig. 32: Left Rear Of Engine (3.0L)

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Fig. 33: Below Driver's Seat

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Fig. 34: Below Right Side Of Dash

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Fig. 35: Left Side Of Cargo Area (Avant)

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Fig. 36: Left Side Of Trunk (Sedan)

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Fig. 37: Left Side Of Cargo Area (Avant)

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Fig. 38: Left Side Of Trunk

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Fig. 39: Left Side Of Dash

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Fig. 40: Left Rear Of Engine Compartment

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Fig. 41: Front Of Engine Compartment

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Fig. 42: Left "B" Pillar

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Fig. 43: Right "B" Pillar

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Fig. 44: Top Of Engine (1.8L Turbo)

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Fig. 45: Top Of Engine (1.8L Turbo)

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Fig. 46: Top Of Engine (1.8L Turbo)

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Fig. 47: Top Of Engine (1.8L Turbo)

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Fig. 48: Right Side Of Engine (3.0L)

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Fig. 49: Right Side Of Engine (3.0L)

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Fig. 50: Right Side Of Engine (3.0L)

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Fig. 51: Left Side Of Engine (3.0L)

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Fig. 52: Left Side Of Engine (3.0L)

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Fig. 53: Left Side Of Engine (3.0L)

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Fig. 54: Driver's Door

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Fig. 55: Passenger's Door

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Fig. 56: Left Rear Door

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Fig. 57: Right Rear Door

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Fig. 58: Left Front Of Engine Compartment

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Fig. 59: Rear Of Engine (1.8L Turbo)

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Fig. 60: Right Rear Of Engine (3.0L)

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Fig. 61: Right Side Of Engine Compartment (1.8L Turbo)

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Fig. 62: Right Side Of Engine Compartment (3.0L)

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Fig. 63: Behind Center Of Dash

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Fig. 64: Under Left Side Of Dash

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Fig. 65: Left Rear Of Vehicle

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Fig. 66: Right "B" Pillar

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Fig. 67: Left "B" Pillar

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Fig. 68: Rear Of Roof

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Fig. 69: Center Of Vehicle

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Fig. 70: Left Kick Panel

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Fig. 71: Right Kick Panel

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Fig. 72: Center Of Vehicle

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Fig. 73: Left Kick Panel

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Fig. 74: Left Side Of Engine Compartment

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Fig. 75: Right Side Of Engine (1.8L Turbo)

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Fig. 76: Right Rear Of Engine Compartment

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Fig. 77: Left Rear Of Engine Compartment

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Fig. 78: Left Rear Of Engine (3.0L)

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Fig. 79: Right Side Of Engine Compartment

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Fig. 80: Behind Right Side Of Dash

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Fig. 81: Right Side Of Engine Compartment (1.8L Turbo)

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Fig. 82: Rear Center Of Engine Compartment

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Fig. 83: Left Side Of A/C Condenser

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Fig. 84: Left Side Of Dash

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Fig. 85: Top Of Engine (1.8L Turbo)

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Fig. 86: Top Of Engine (1.8L Turbo)

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Fig. 87: Top Of Engine (1.8L Turbo)

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Fig. 88: Top Of Engine (1.8L Turbo)

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Fig. 89: Right Side Of Engine (3.0L)

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Fig. 90: Right Side Of Engine (3.0L)

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Fig. 91: Right Side Of Engine (3.0L)

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Fig. 92: Left Side Of Engine (3.0L)

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Fig. 93: Left Side Of Engine (3.0L)

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Fig. 94: Left Side Of Engine (3.0L)

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Fig. 95: Steering Column

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Fig. 96: Left Side Of Engine (1.8L Turbo)

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Fig. 97: Front Of Engine (3.0L)

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Fig. 98: Top Of Engine (1.8L Turbo)

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Fig. 99: Top Of Engine (1.8L Turbo)

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Fig. 100: Left Rear Wheel Well

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Fig. 101: Front Bumper

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Fig. 102: Front Bumper

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Fig. 103: Rear Of Center Console

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Fig. 104: Left "C" Pillar

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Fig. 105: Inside Rearview Mirror

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Fig. 106: Left Side Of Dash

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Fig. 107: Driver's Door

Courtesy of AUDI OF AMERICA, INC.

Fig. 108: Passenger's Door

Courtesy of AUDI OF AMERICA, INC.

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Fig. 109: Left Rear Door

Courtesy of AUDI OF AMERICA, INC.

Fig. 110: Right Rear Door

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 111: Left Rear Of Engine Compartment

Courtesy of AUDI OF AMERICA, INC.

Fig. 112: Right Front Of Engine Compartment (1.8L Turbo)

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 113: Right Side Of Engine Compartment (3.0L)

Courtesy of AUDI OF AMERICA, INC.

Fig. 114: Driver's Seat

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 115: Left Rear Of Engine Compartment

Courtesy of AUDI OF AMERICA, INC.

Fig. 116: Left Rear Of Engine Compartment

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 117: Left Side Of Transmission

Courtesy of AUDI OF AMERICA, INC.

Fig. 118: Front Of Vehicle

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 119: Rear Of Engine Compartment (1.8L Turbo)

Courtesy of AUDI OF AMERICA, INC.

Fig. 120: Right Side Of Engine Compartment (1.8L Turbo)

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 121: Right Rear Of Engine Compartment (3.0L)

Courtesy of AUDI OF AMERICA, INC.

Fig. 122: Right Rear Of Engine (1.8L Turbo)

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 123: Left Rear Of Engine Compartment

Courtesy of AUDI OF AMERICA, INC.

Fig. 124: Right Front Of Vehicle

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 125: Left Side Of Dash

Courtesy of AUDI OF AMERICA, INC.

Fig. 126: Rear Package Shelf (Sedan)

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 127: Left Side Of Engine (1.8L Turbo)

Courtesy of AUDI OF AMERICA, INC.

Fig. 128: Front Bumper

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 129: Front Bumper

Courtesy of AUDI OF AMERICA, INC.

Fig. 130: Rear Of Center Console

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 131: Right "C" Pillar

Courtesy of AUDI OF AMERICA, INC.

Fig. 132: Right Front Of Engine Compartment (3.0L)

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 133: Left Rear Of Engine Compartment

Courtesy of AUDI OF AMERICA, INC.

Fig. 134: Left Side Of Engine Compartment (1.8L Turbo)

Courtesy of AUDI OF AMERICA, INC.

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Fig. 135: Rear Of Engine (3.0L)

Courtesy of AUDI OF AMERICA, INC.

Fig. 136: Top Of Accelerator Pedal

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 137: Below Center Console

Courtesy of AUDI OF AMERICA, INC.

Fig. 138: Rear Bumper

Courtesy of AUDI OF AMERICA, INC.

11:34:56 PM Page 75
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2005 AUDI A4

Fig. 139: Rear Bumper

Courtesy of AUDI OF AMERICA, INC.

Fig. 140: Rear Bumper

Courtesy of AUDI OF AMERICA, INC.

11:34:56 PM Page 76
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2005 AUDI A4

Fig. 141: Rear Bumper

Courtesy of AUDI OF AMERICA, INC.

Fig. 142: Left Side Of Dash

Courtesy of AUDI OF AMERICA, INC.

11:34:56 PM Page 77
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2005 AUDI A4

Fig. 143: Left Rear Of Engine Compartment

Courtesy of AUDI OF AMERICA, INC.

Fig. 144: Steering Column

Courtesy of AUDI OF AMERICA, INC.

11:34:56 PM Page 78
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2005 AUDI A4

Fig. 145: Steering Column

Courtesy of AUDI OF AMERICA, INC.

Fig. 146: Right Rear Of Vehicle

Courtesy of AUDI OF AMERICA, INC.

11:34:56 PM Page 79
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2005 AUDI A4

Fig. 147: Below Passenger's Seat

Courtesy of AUDI OF AMERICA, INC.

Fig. 148: Under Left Side Of Dash

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 149: Left Side Of Engine (1.8L Turbo)

Courtesy of AUDI OF AMERICA, INC.

Fig. 150: Rear Of Engine (3.0L)

Courtesy of AUDI OF AMERICA, INC.

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2005 AUDI A4

Fig. 151: Left Rear Of Engine Compartment (3.0L)

Courtesy of AUDI OF AMERICA, INC.

Fig. 152: Rear Of Transmission (CVT)

Courtesy of AUDI OF AMERICA, INC.

11:34:56 PM Page 82
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2005 AUDI A4

Fig. 153: Front Center Of Roof

Courtesy of AUDI OF AMERICA, INC.

Fig. 154: Right Front Of Engine (3.0L)

Courtesy of AUDI OF AMERICA, INC.

11:34:56 PM Page 83
 2005 Audi A4 Quattro
2005 AUDI A4

Fig. 155: Left Front Of Engine (3.0L)

Courtesy of AUDI OF AMERICA, INC.

Fig. 156: Under Left Side Of Dash

Courtesy of AUDI OF AMERICA, INC.

11:34:56 PM Page 84
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2005 AUDI A4

Fig. 157: Left Side Of Cargo Area

Courtesy of AUDI OF AMERICA, INC.

Fig. 158: Rear Package Shelf (Sedan)

Courtesy of AUDI OF AMERICA, INC.

11:34:56 PM Page 85
 2005 Audi A4 Quattro
2005 AUDI A4

Fig. 159: Right Front Of Engine Compartment (1.8L Turbo)

Courtesy of AUDI OF AMERICA, INC.

11:34:56 PM Page 86
 2005 Audi A4 Quattro
ELECTRICAL Electrical Equipment

27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

BATTERY

General information

The battery is one of the most important electrical components in the modern automobile. A battery that
provides trouble-free service has a great influence on customer satisfaction. To ensure trouble-free service and
optimum service life, batteries must be checked, serviced and maintained as per the instructions in this
information.

Apart from starting the engine, the battery has other tasks. It acts as a buffer and also supplies electrical energy
to the complete vehicle electrical system. In addition, the cyclical and capacity demands on the battery have
increased due to additional safety and convenience features (electrical consumers) being installed.

The automobile battery has undergone many technical changes and improvements, and development of new
battery technologies continues.

A new generation of maintenance free batteries uses physically and constructively optimized, lead-calcium
coated positive electrodes. Advantages include minimal electrolyte consumption and servicing requirements, as
well as improved charge stability over a longer period of time. Simplified checking of these batteries is also
achieved with the charge indicator (magic eye).

Several different types of battery may be installed. Each requires specific servicing.

Warnings and safety measures for lead-acid batteries

When servicing batteries, Technicians must be aware of, and observe the warnings and safety measures
specified in this information.

Fig. 1: Warning Symbols On Batteries

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Explanation of WARNING symbols on batteries

12:15:46 AM
12:15:53 Page 1
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ELECTRICAL Electrical Equipment

CAUTION: 1 - Read and follow all instructions on battery, contained in Repair

Information, Electrical Equipment, and in Owners Manual!

2 - Battery acid can cause severe burns!

 When working with electrolyte always wear eye protection, rubber

gloves and a suitable apron. If electrolyte is spilled on eyes, skin,
clothing (or painted surfaces), flush at once with large quantities of
water.
 Never tip a battery on edge. Electrolyte can spill from the ventilation
openings.

3 - Keep open flames and sparks away and DO NOT smoke near
batteries! .

 Avoid sparks when working with cables and electrical units.

 Always reinstall battery positive (B+) or negative ( - ) terminal covers
if removed during servicing

4 - Always wear eye protection when working with electrolyte!

 If electrolyte gets into eyes, flush with large quantities of water. Seek
medical attention immediately!

5 - Keep children away from batteries!

6 - Dispose of batteries properly!

 Waste batteries must only be disposed of in appropriate waste

disposal sites. Refer to local regulations pertaining to battery
disposal.

7 - Never dispose of batteries in household waste! Batteries contain lead

(Pb), which is toxic.

8 - Danger of explosion!

 Batteries produce explosive gasses while being charged.

 Keep open flames and sparks away and DO NOT smoke near
batteries.
 The battery charger MUST be turned off when connecting or
disconnecting the cables at the battery.
 Battery cell caps must NOT be removed while charging.

 Ensure that battery is charged in a well ventilated area.

12:15:47 AM Page 2
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ELECTRICAL Electrical Equipment

 Avoid short circuits. Always reinstall battery positive (B+) or negative

( - ) terminal covers if removed during servicing.

Smoking, naked flames, fires and sparks:

CAUTION:  Smoking, naked flames and fires are prohibited whilst working; flying
sparks must be avoided.
 Avoid short circuits and sparks when handling cables and electrical
equipment.

Electrolyte:

CAUTION:  Can cause severe injury to the eyes, skin and mucous membranes.
 Inhalation can damage the respiratory system.
 Swallowing is harmful to the digestive system.
 First aid: Rinse eyes and immediately consult first aid station or
inform doctor.

 Never tilt battery. Acid can leak out of the gas vents.
 Soak up spilled electrolyte with binding agent and neutralize any
residual electrolyte.
 Never allow electrolyte to come into contact with hands.
 Avoid contact with skin.

 Never touch mouth, nose or eyes with soiled hands.

 Immediately change any clothing affected by electrolyte and place in
water if necessary.
 Do not eat, drink or store foodstuffs at workplace.
 Wash thoroughly before breaks and on completion of work.

Eye protection and protective clothing:

CAUTION:  Wear safety goggles and an acid-resistant apron or alternatively

electrolyte-proof overalls.
 Wear electrolyte-proof gloves.

Danger of explosion:

CAUTION:  Old batteries (in use for 6 months or more) must be treated with an
anti-static spray (currently "Neostatic Antistatikum HB 155" or
equivalent) prior to handling.

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ELECTRICAL Electrical Equipment

 Sealing plugs must be closed when charging.

 Charging of batteries removed from the vehicle is only permitted in
vented cubicles with extraction system.
 After charging, battery must be left in charging area with extraction
system for an appropriate length of time.

 Batteries must always be transported in conductive metal containers.

 Electrostatically chargeable materials are not to be used for securing
purposes.

Battery handling instructions

NOTE:  Battery terminals must no longer be greased

 To avoid damaging the battery housing, do not use force when attaching
battery terminals; press on by hand only.

Fig. 2: Identifying Battery Terminal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Battery terminal tightening torque - arrow - 7.5 Nm.

 Additional battery terminal tightening torque: 7.5 Nm.

Battery in engine compartment, disconnecting and reconnecting

Should service procedures in this information specify disconnecting and reconnecting the battery, please heed
the following CAUTIONS!:

CAUTION: Before beginning repairs on the electrical system:

 Where applicable, obtain anti-theft radio security code.

 Switch off all electrical consumers.
 Switch the ignition off and remove ignition key.

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ELECTRICAL Electrical Equipment

 Disconnect negative ( - ) battery terminal.

 On vehicles equipped with Audi Telematics by OnStar (R) , switch-off

the emergency (back-up) battery for the Telematic/Telephone Control
Module prior to disconnecting vehicle battery --> 91 -
COMMUNICATION
 After reconnecting vehicle battery, re-code and check operation of
anti-theft radio. Also check operation of clock and power windows
according to Repair Information and/or Owners Manual.
 After reconnecting vehicle battery on vehicles equipped with Audi
Telematics by OnStar (R) , switch-on the emergency (back-up) battery
for the Telematic/Telephone Control Module --> 91 -
COMMUNICATION

Disconnecting

Special tools, testers and auxiliary items required

Fig. 3: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Torque wrench VAG 1331 or (equivalent 5 - 50 Nm)

 Heed CAUTIONS listed above

12:15:47 AM Page 5
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ELECTRICAL Electrical Equipment

Fig. 4: Pushing Cover Over Battery Toward Right And Removing It Upward
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Slide battery cover to right - arrow 1 - and lift off - arrow 2 - (where applicable).

Fig. 5: Locating Battery Ground Strap

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect negative ( - ) terminal - arrow - from battery post.

Reconnecting

 Reconnect negative ( - ) terminal to battery post and tighten to specified torque.

The following steps are required after reconnecting battery:

NOTE:  When reconnecting battery, activate vehicle equipment (radio/radio

navigation system, clock, electric window lifters) in accordance with
Owners Manual.
 On vehicles equipped with Audi Telematics by OnStar (R) , switch on
emergency (back-up) battery --> 91 - COMMUNICATION .
 Further measures after reconnecting the voltage supply, refer to
applicable engine repair information,

12:15:47 AM Page 6
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ELECTRICAL Electrical Equipment

 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V

TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB
 24 - MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 4V
TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT
 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL
INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN
 24 - FUEL INJECTION SYSTEM for 3.2 V6 4V FUEL INJECTION
IGNITION, ENGINE CODE(S): BKH
 24 - MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 4V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BNS
 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BHF
.
 Check proper function of remote control keys; adapt keys if necessary.
Inform customer that all additional keys must also be adapted to ensure
that the remote control works properly Owners Manual.
 After re-connecting battery, the ESP indicator lamp will go out only after
driving a distance of several meters.

Tightening torque

Component - fastener Nm
Battery terminal to battery post - nut 7.5

Battery in luggage compartment, disconnecting and connecting

Should service procedures in this information specify disconnecting and reconnecting the battery, please heed
the following CAUTIONS!:

CAUTION: Before beginning repairs on the electrical system:

 Where applicable, obtain anti-theft radio security code.

 Switch off all electrical consumers.
 Switch the ignition off and remove ignition key.
 Disconnect negative ( - ) battery terminal.

 After reconnecting vehicle battery, re-code and check operation of

anti-theft radio. Also check operation of clock and power windows
according to Repair Information and/or Owners Manual.

Disconnecting

Special tools, testers and auxiliary items required

12:15:47 AM Page 7
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ELECTRICAL Electrical Equipment

Fig. 6: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Torque wrench VAG 1331 or (equivalent 5 - 50 Nm)

 Heed CAUTIONS listed above

Fig. 7: Disconnecting Battery Ground (GND) Strap

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Lift luggage compartment floor covering and secure.

 Disconnect battery negative ( - ) terminal - arrow - from battery post.

Connecting

 Reconnect negative ( - ) terminal to battery post and tighten to specified torque.

The following steps are required after reconnecting battery:

NOTE:  When reconnecting battery, activate vehicle equipment (radio/radio

navigation system, clock, electric window lifters) in accordance with
Owners Manual.
 Further measures after reconnecting the voltage supply, refer to

12:15:47 AM Page 8
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ELECTRICAL Electrical Equipment

applicable engine repair information,

 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V
TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB
 24 - MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 4V
TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT
 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL
INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN
 24 - FUEL INJECTION SYSTEM for 3.2 V6 4V FUEL INJECTION
IGNITION, ENGINE CODE(S): BKH
 24 - MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 4V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BNS
 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BHF
.
 Check proper function of remote control keys; adapt keys if necessary.
Inform customer that all additional keys must also be adapted to ensure
that the remote control works properly Owners Manual.
 After re-connecting battery, the ESP indicator lamp will go out only after
driving a distance of several meters.

Tightening torque

Component - fastener Nm
Battery terminal to battery post - nut 7.5

Battery in engine compartment, removing and installing

Removing

CAUTION:  Prior to handling or servicing batteries, read, understand and

observe the Warning and Safety Measures for lead-acid batteries -->
Warnings and safety measures for lead-acid batteries
 Always wear suitable protective clothing Eye protection and
protective clothing:.

CAUTION: Before beginning repairs on the electrical system:

 Where applicable, obtain anti-theft radio security code.

 Switch off all electrical consumers.
 Switch the ignition off and remove ignition key.
 Disconnect negative ( - ) battery terminal.

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ELECTRICAL Electrical Equipment

 On vehicles equipped with Audi Telematics by OnStar (R) , switch-off

the emergency (back-up) battery for the Telematic/Telephone Control
Module prior to disconnecting vehicle battery --> 91 -
COMMUNICATION
 After reconnecting vehicle battery, re-code and check operation of
anti-theft radio. Also check operation of clock and power windows
according to Repair Information and/or Owners Manual.
 After reconnecting vehicle battery on vehicles equipped with Audi
Telematics by OnStar (R) , switch-on the emergency (back-up) battery
for the Telematic/Telephone Control Module --> 91 -
COMMUNICATION

Special tools, testers and auxiliary items required

Fig. 8: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Torque wrench VAG 1331 or (equivalent 5 - 50 Nm)

Fig. 9: Identifying Plenum Chamber Cover & Removing Rubber Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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ELECTRICAL Electrical Equipment

 Remove rubber seal from plenum chamber cover in direction of - arrow -.

 Remove plenum chamber cover - 1 - from the front.
 Disconnect negative ( - ) terminal - 1 - from battery

Fig. 10: Locating Battery Terminals On Battery

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Then disconnect positive ( + ) terminal - 2 - from battery.

 Remove bolt - 4 - from battery hold-down bracket - 3 -.

NOTE:  On vehicles with suspension cross-brace, hex socket bolt - 4 - must be

removed using an Allen key with ball head.
 Loosen bolt enough so that ball head of Allen key contacts suspension
cross-brace.
 Leave bolt and securing bracket in place and swivel battery out from under
hold-down bracket.

Fig. 11: Identifying Angle Piece Of Central Gas Venting System

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect angled connector of central gas venting system - arrow -.

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ELECTRICAL Electrical Equipment

 Carefully lift battery out of plenum chamber.

CAUTION: When disposing batteries it is absolutely necessary that the disposal

procedures for batteries and sulfuric acid are observed.

Installing

Install in reverse order of removal, noting the following:

NOTE:  Only maintenance-free batteries conforming to standards "TL82506" (as of

December 1997) and "VW75073" (as of August 2001) may be installed.
 Batteries from the Audi parts range feature a base strip adapter for
matching to different retainer flanges. The battery operating instructions
give details of when and how to use the base strip adapter.

Fig. 12: Battery Foot Strip Cut-Out

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Insert battery in battery carrier so that lug at rear of battery carrier - arrow - engages in recess in battery
base strip - 1 -.

 It should no longer be possible to move the battery.

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ELECTRICAL Electrical Equipment

Fig. 13: Center Cut-Out In Battery Foot Strip Aligned With Threaded Hole In Battery Carrier
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 The battery has been properly inserted if the center recess in the battery base strip aligns with the tapped
hole in the battery tray - arrows -.

Fig. 14: Locating Battery Terminals On Battery

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Install battery hold-down bracket - 3 - and fasten with bolt - 4 -.

NOTE:  Lug on battery retainer must engage in recess on battery base strip.

Reconnect battery in the following sequence with ignition and electrical equipment switched off:

 First connect positive ( + ) terminal - 2 - to battery post and torque nut to specification.
 Then connect negative ( - ) terminal - 1 - to battery post and torque nut to specification.
 Connect hose for central gas venting system; see notes --> Batteries with central gas venting.
 Check firm attachment of battery following installation --> Battery installation, checking.

The following steps are required after reconnecting battery:

12:15:47 AM Page 13
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ELECTRICAL Electrical Equipment

NOTE:  When reconnecting battery, activate vehicle equipment (radio/radio

navigation system, clock, electric window lifters) in accordance with
Owners Manual.
 On vehicles equipped with Audi Telematics by OnStar (R) , switch on
emergency (back-up) battery --> 91 - COMMUNICATION .
 Further measures after reconnecting the voltage supply, refer to
appropriate engine repair information, RG 24.
 Check proper function of remote control keys; adapt keys if necessary.
Inform customer that all additional keys must also be adapted to ensure
that the remote control works properly Owners Manual.
 After re-connecting battery, the ESP indicator lamp will go out only after
driving a distance of several meters.

Tightening torques

Component - fastener Nm
Battery hold-down bracket - nut 12
Battery terminal to battery post - nut 7.5

Battery in luggage compartment, removing and installing

CAUTION:  Prior to handling or servicing batteries, read, understand and

observe the Warning and Safety Measures for lead-acid batteries -->
Warnings and safety measures for lead-acid batteries
 Always wear suitable protective clothing Eye protection and
protective clothing:.

CAUTION: Before beginning repairs on the electrical system:

 Where applicable, obtain anti-theft radio security code.

 Switch off all electrical consumers.
 Switch the ignition off and remove ignition key.
 Disconnect negative ( - ) battery terminal.

 After reconnecting vehicle battery, re-code and check operation of

anti-theft radio. Also check operation of clock and power windows
according to Repair Information and/or Owners Manual.

Removing

Special tools, testers and auxiliary items required

12:15:47 AM Page 14
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ELECTRICAL Electrical Equipment

Fig. 15: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Torque wrench VAG 1331 or (equivalent 5 - 50 Nm)

Fig. 16: Removing/Install Battery From Battery Console Retaining Strip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Lift luggage compartment floor covering and secure.

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ELECTRICAL Electrical Equipment

 Remove formed insert behind battery - 5 - upward - arrow -.

 Disconnect negative ( - ) terminal - 6 - from battery
 Fold positive terminal cover - 2 - upward.

 Then disconnect positive ( + ) terminal - 1 - from battery.

 Disconnect central gas venting system hose - 7 -.
 Remove bolt - 4 - from battery hold-down bracket - 3 -.
 Remove battery from battery console retaining strip.

 Remove battery from luggage compartment.

CAUTION: When disposing batteries it is absolutely necessary that the disposal

procedures for batteries and sulfuric acid are observed.

Installing

NOTE:  Only maintenance-free batteries conforming to standards "TL82506" (as of

December 1997) and "VW75073" (as of August 2001) may be installed.
 Batteries from the Audi Parts Program have a bottom strip-adapter for
adapting to different grip channels. Whether and how bottom strip-adapter
is used, refer to operating instructions for battery.

Fig. 17: Identifying Battery Clamping Strip And Battery Holder Mount
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Insert battery in battery holder.

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ELECTRICAL Electrical Equipment

 Battery clamping strip - 1 - must engage in battery holder mount - 2 -.

 It should no longer be possible to move the battery.

Fig. 18: Removing/Install Battery From Battery Console Retaining Strip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Position battery hold-down bracket - 3 -.

 Lug on battery retainer must engage in recess on battery base strip.

 Hand tighten bolt - 4 -.

Reconnect battery in the following sequence with ignition and electrical equipment switched off:

 First connect positive ( + ) terminal - 1 - to battery post and torque nut to specification.
 Close positive terminal cover - 2 -.
 Then connect negative ( - ) terminal - 6 - to battery post and torque nut to specification.
 Connect hose for central gas venting system; see notes --> Batteries with central gas venting.

 Check firm attachment of battery following installation --> Battery installation, checking.

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The following steps are required after reconnecting battery:

NOTE:  When reconnecting battery, activate vehicle equipment (radio/radio

navigation system, clock, electric window lifters) in accordance with
Owners Manual.
 Further measures after reconnecting the voltage supply refer to applicable
engine repair information,
 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V
TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB
 24 - MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 4V
TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT
 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL
INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN
 24 - FUEL INJECTION SYSTEM for 3.2 V6 4V FUEL INJECTION
IGNITION, ENGINE CODE(S): BKH
 24 - MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 4V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BNS
 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BHF
.
 Check proper function of remote control keys; adapt keys if necessary.
Inform customer that all additional keys must also be adapted to ensure
that the remote control works properly Owners Manual.
 After re-connecting battery, the ESP indicator lamp will go out only after
driving a distance of several meters.

Tightening torques

Component - fastener Nm
Battery hold-down bracket - nut 12
Battery terminal to battery post - nut 7.5

Battery installation, checking

Battery must not be moveable after battery hold-down bracket and bolt is installed.

CAUTION: If battery is not secured properly, the following will result:

 Shortened battery service life due to vibration damage.

 Battery cell and plate damage.
 Electrolyte leakage due to battery case damage.
 Poor collision safety.

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Batteries with central gas venting

CAUTION:  Ensure venting system hose is always attached to battery.

 On batteries with central gas venting hose/pipe, ensure that hose
does not become disconnected. Only then is the battery able to vent
freely.

NOTE:  The latest generation of batteries is equipped with a central gas venting
system and a fine-mesh "flame trap". Function: The gases produced
during charging escape through a central opening in the top of the battery
cover. The fine-mesh flame trap which prevents ignition of the flammable
gas in the battery is also located here. The flame trap comprises a small
round fiberglass mat approx. 15 mm in diameter and 2 mm thick. It
operates in a manner similar to a valve, i.e. it allows the gas produced in
the battery by gassing to escape.

Battery with charge indicator (magic eye), checking

Fig. 19: Locating Magic Eye

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The charge indicator - arrow - provides information on the electrolyte level and charge level of the battery to be
tested.

Three different colored indications are possible:

color indicator Battery status

Green  Battery adequately charged.
Black  Not charged or inadequately charged.
Colorless or yellow  Critical electrolyte level reached; topping up with distilled water essential.

NOTE:  If a battery is more than 5 years old and the indicator is colorless, replace

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battery.

Test sequence

NOTE:  When recharging the battery, and during driving, air bubbles may form
under the "magic eye". They distort the color displayed by the magic eye.
 If batteries are fitted with sealing plugs for production reasons, these are
covered with plastic foil.
 Prior to visual inspection, use screwdriver handle to tap gently and
carefully on "magic eye" to disperse any bubbles.
 Observe color of charge indicator --> Battery with charge indicator (magic
eye), checking.

Visual inspection

Visually inspect battery before performing measurements, e.g. no-load voltage, specific gravity of electrolyte or
battery test.

CAUTION:  Prior to handling or servicing batteries, read, understand and

observe the Warning and Safety Measures for lead-acid batteries -->
Warnings and safety measures for lead-acid batteries
 Always wear suitable protective clothing Eye protection and
protective clothing:.

 Check for the following:

 Battery housing damage. Electrolyte can leak out if the housing is damaged.
 Battery posts (battery cable terminals) damaged. Proper contact of connections is not ensured if battery
posts are damaged. This may then result in cable burn-out and electrical system malfunctions.
 Batterys original sealing plugs fitted. The sealing plugs must be fitted with an O-ring. Only use sealing
plugs of same type (same as original equipment) if originals are lost or damaged.

No-load voltage, checking

Special tools, testers and auxiliary items required

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Fig. 20: Identifying Multimeter V.A.G 1526B

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Multimeter VAG 1526 B , Fluke 83 or equivalent

Test requirements

 Always heed the following, otherwise correct measurement is not guaranteed.

NOTE:  If no load voltage measurement is carried out with the battery installed in
vehicle, disconnect negative ( - ) battery terminal.
 The battery must not be loaded by connected power consumers for at
least 2 hours before making measurements.
 The battery must not be charged for at least 2 hours before making the
measurements.

CAUTION:
 On vehicles equipped with Audi Telematics by OnStar (R) , switch-off
the emergency (back-up) battery for the Telematic/Telephone Control
Module prior to disconnecting vehicle battery --> 91 -
COMMUNICATION
 After reconnecting vehicle battery, re-code and check operation of
anti-theft radio. Also check operation of clock and power windows
according to Repair Information and/or Owners Manual.
 After reconnecting vehicle battery on vehicles equipped with Audi
Telematics by OnStar (R) , switch-on the emergency (back-up) battery
for the Telematic/Telephone Control Module --> 91 -
COMMUNICATION

CAUTION:  Switch off all electrical consumers.

 Switch the ignition off and remove ignition key.

 Disconnect negative ( - ) terminal from battery post.

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Battery in engine compartment --> Battery in engine compartment, disconnecting and reconnecting

Battery in luggage compartment --> Battery in luggage compartment, disconnecting and connecting

 Measure voltage between battery posts.

 Battery is OK if measuring instrument reading is 12.5 V or above.

 The battery no-load voltage must at no time be less than 12.5 Volts, otherwise the battery must be
recharged immediately --> Battery, charging.

 Repeat voltage measurement between terminals.

 Battery no-load voltage must not be less than 12.5 Volts.

 If no-load voltage is not OK, replace battery.

Install in reverse order of removal, noting the following:

 Reconnect battery. Required steps:

Battery in engine compartment Reconnecting

Battery in luggage compartment Connecting

Electrolyte level - batteries with charge indicator (magic eye), checking

Fig. 21: Locating Magic Eye

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Electrolyte level on batteries with charge indicator - arrow - can be established from the color indication.
Three different colored displays are possible:

color indicator Battery status

Green  Battery adequately charged.

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Black  Not charged or inadequately charged.

Colorless or  Critical electrolyte level reached; topping up with distilled water essential,
yellow procedure --> Electrolyte level - batteries with sealing plugs, checking

Electrolyte level - batteries with sealing plugs, checking

CAUTION:  Prior to handling or servicing batteries, read, understand and

observe the Warning and Safety Measures for lead-acid batteries
Smoking, naked flames, fires and sparks:.
 Always wear suitable protective clothing Eye protection and
protective clothing:.
 Only use flashlight to illuminate inside of battery casing.
 Never illuminate inside of battery casing with a naked flame.

 Keep naked flames and burning cigarettes away from batteries.

 When disposing of batteries, always pay attention to the appropriate
regulations for batteries and sulfuric acid.
 Proper battery sealing plugs must be used to ensure differing battery
cover systems are sealed correctly. Use genuine sealing plugs of
same construction if lost or damaged.
 The plugs must be installed with an O-ring seal.

Special tools, testers and auxiliary items required

Fig. 22: Battery fill bottle VAS 5045

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Battery filler bottle VAS 5045

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Fig. 23: Identifying Commercially Available Hydrometer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hydrometer (commercially available)

The correct electrolyte level is an important factor in ensuring long battery service life.

 On batteries with visible min. and max marks it is sufficient to perform visual inspection from outside to
check electrolyte level.

 The electrolyte level must be above the minimum marking but not exceed the max marking.

 On batteries on which the min. and max marks are difficult to see, or on which the electrolyte level
cannot be seen because of the opacity of the battery housing, remove the sealing plugs.
 Check the electrolyte level by making a visual inspection of the inside of the battery.

 The electrolyte level must coincide with the internal level mark (plastic web). This corresponds to the
max marking on the outside.

Electrolyte level too low

If the electrolyte level is too low, drying-out of the cell plates will reduce the capacity (power) of the battery.
The cell plates must be fully covered by electrolyte (sulfuric acid/water mixture) in order to prevent corrosion
of plates, plate bridges and cell connectors. Such corrosion would impair battery operation and make the battery
unusable.

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Fig. 24: VAS 5045 Battery Filling Bottle

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 If electrolyte level is too low, use battery filler bottle VAS 5045 to add distilled water until max mark is
reached.

NOTE:  Filler neck of battery filler bottle VAS 5045 is designed to prevent over-
filling of battery cell and electrolyte spills. When the maximum filling level
is reached, the flow of distilled water into the battery cell is cut off.
 Use distilled water only, this prevents contamination of the battery
electrolyte and the associated increase in self discharge.
 Screw sealing plugs of battery cells back in again.

CAUTION:  Battery openings must be fitted with the correct plugs to ensure that
battery cover (different types!) is properly secured. Always use
correct sealing plugs (same as original equipment) in the event of
loss or damage.
 The plugs must be equipped with an O-ring seal.

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Fig. 25: Identifying Commercially Available Hydrometer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Electrolyte level too high

If the electrolyte level is too high (overfilled), escaping electrolyte (sulfuric acid/water mixture) will cause
damage outside the battery.

 If the electrolyte level is above the inner level mark (the plastic web) or the outer max mark, it is essential
to drain some off.
 Remove the battery cell sealing plugs.
 Use a commercially available hydrometer to drain off the sulfuric acid until it has fallen to the level of the
plastic web or the max mark as appropriate.
 Screw sealing plugs of battery cells back in again.

CAUTION:  Battery openings must be fitted with the correct plugs to ensure that
battery cover (different types!) is properly secured. Always use
correct sealing plugs (same as original equipment) in the event of
loss or damage.
 The plugs must be equipped with an O-ring seal.

Electrolyte specific gravity - batteries with sealing plugs, checking

CAUTION:  Prior to handling or servicing batteries, read, understand and

observe the Warning and Safety Measures for lead-acid batteries
Smoking, naked flames, fires and sparks:.
 Always wear suitable protective clothing Eye protection and

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protective clothing:.
 When disposing of batteries, always pay attention to the appropriate
regulations for batteries and sulfuric acid.
 Proper battery sealing plugs must be used to ensure differing battery
cover systems are sealed correctly. Use genuine sealing plugs of
same construction if lost or damaged.

 The plugs must be installed with an O-ring seal.

Special tools, testers and auxiliary items required

Fig. 26: Identifying Commercially Available Hydrometer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hydrometer (commercially available)

NOTE:  The electrolyte specific gravity test in conjunction with the battery test
provides specific information on battery condition.
 The temperature of the battery electrolyte must be at least 10 ° C.
 Electrolyte specific gravity can be checked immediately after charging
battery.

Test sequence

 Remove all battery plugs (battery cell sealing plugs).

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Fig. 27: Hydrometer Specific Gravity Reading

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Immerse end of hydrometer in a cell and extract sufficient electrolyte so that float swims free in the
electrolyte.

 The greater the specific gravity of the electrolyte drawn in, the higher the float will ride.
 The specific gravity in kg/dm 3 (specific gravity of electrolyte) can be read off the scale - arrow - on the
hydrometer.

 Take reading on hydrometer and compare to values given in table:

Charge condition in normal climatic zones specific gravity of electrolyte in kg/dm 3

discharged 1.12
half charged 1.20
well charged 1.28

Charge level in tropical countries specific gravity of electrolyte in kg/dm 3

discharged 1.08
half charged 1.16
fully charged 1.23

The specific gravity in normal climatic zones must be at least 1.24 kg/dm 3 . If specific gravity is too low in all
battery cells:

 Charge battery and then repeat electrolyte specific gravity test.

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Example 1:

Battery cell: 1 2 3 4 5 6
specific gravity per cell in kg/dm 3 1.24 1.25 1.25 1.10 1) 1.24 1.25

1) Specific gravity in cell 4 is too low (deviation is greater than 0.03 kg/dm 3 ).

* specific gravity in cell 4 is too low (deviation greater than 0.03 kg/dm 3 )

Example 2:

Battery cell: 1 2 3 4 5 6
specific gravity per cell in kg/dm 3 1.26 1.26 1.25 1.14 1) 1.18 1) 1.24

1) Specific gravity in cell 4 and 5 is too low (deviation is greater than 0.03 kg/dm 3 ).

* specific gravity in cells 4 and 5 is too low (deviation greater than 0.03 kg/dm 3 )

If specifications are not obtained:

 Replace battery.

NOTE:  The measured values for the electrolyte specific gravity of the individual
battery cells must NOT deviate by more than 0.03 kg/dm 3 , otherwise
battery has to be replaced.
 Reinstall battery sealing plugs.

CAUTION:  Battery openings must be fitted with the correct plugs to ensure that
battery cover (different types!) is properly secured. Always use
correct sealing plugs (same as original equipment) in the event of
loss or damage.
 The plugs must be equipped with an O-ring seal.

Battery, testing

CAUTION:  Prior to handling or servicing batteries, read, understand and

observe the Warning and Safety Measures for lead-acid batteries
Smoking, naked flames, fires and sparks:.
 Always wear suitable protective clothing Eye protection and
protective clothing:.
 DO NOT battery test batteries which are gassing. Otherwise there is a
risk of explosion.

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 The following notes and procedures must be followed to ensure

correct measurements.

 When disposing of batteries, always pay attention to the appropriate

regulations for batteries and sulfuric acid.

NOTE:  In order to better determine a batterys overall condition, it is

recommended to always perform the battery test in conjunction with the
electrolyte specific gravity test
 Always follow the battery tester operating instructions.
 It is not necessary to remove battery from vehicle or disconnect battery
terminals.

Special tools, testers and auxiliary items required

Fig. 28: Battery VAS Tester

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Battery Test Kit Midtronics MCR 340V (VAG tester illustrated here for reference only).

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

 Check no-load voltage --> No-load voltage, checking

 Connect tester cable clamps to battery terminal MCR 340V Instruction Manual Tester leads must be
securely fastened and make proper contact with the battery posts.
 Select test mode "IN-VEHICLE" or "OUT-OF-VEHICLE" (refer to MCR 340V Instruction Manual).
 Select battery type (AGR or conventional) (refer to MCR 340V Instruction Manual).

 Set tester to "Warranty Test" (refer to MCR 340V Instruction Manual).

 Perform battery test by setting load current on tester according to battery (DIN) capacity (refer to MCR
340V Instruction Manual).

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NOTE:  Use print function of MCR 340V where test results are required for
warranty claims.

Battery test results:

Battery Tester Display /

Required action
Printout
Good Battery None
Good - Recharge Charge battery where necessary --> Battery, charging
Use inCHARGE Charge battery --> Battery, charging
Replace battery --> Battery in engine compartment, removing and
Replace Battery
installing
Replace battery --> Battery in engine compartment, removing and
Bad Cell - Replace
installing

Battery, charging

CAUTION:  Prior to handling or servicing batteries, read, understand and

observe the Warning and Safety Measures for lead-acid batteries
Smoking, naked flames, fires and sparks:.
 Always wear suitable protective clothing Eye protection and
protective clothing:.

Danger of explosion!

 Batteries produce explosive gasses while being charged.

 Keep open flames and sparks away and DO NOT smoke near
batteries.
 The battery charger MUST be turned off when connecting or
disconnecting the cables at the battery.
 Battery cell caps must NOT be removed while charging.

 "Boosting" a sulfated battery a high charging rate can cause an

explosion.
 Ensure that battery is charged in a well ventilated area.
 Precision tools must not be kept in the same room where batteries
are being charged. Tools may corrode due to chemical reaction.

Special tools, testers and auxiliary items required

 Battery Charging Station: Midtronics INC-940.

NOTE:

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 Before charging, battery must have a minimum temperature of 10 degrees

Celsius (50 degrees Fahrenheit).
 It is not necessary to remove battery from vehicle or disconnect battery
terminals.
 Charging voltage must not exceed 14.4V.
 Always follow the battery charger operating instructions.
 After charging, confirm battery no load voltage and electrolyte specific
gravity before reuse in vehicle.

CAUTION: Before beginning repairs on electrical system

 Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Fig. 29: Pushing Cover Over Battery Toward Right And Removing It Upward
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Slide battery cover to right - arrow 1 - and lift off - arrow 2 - where applicable.

Battery in engine compartment:

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Fig. 30: Identifying Battery Terminals, Nuts, And Terminal Clamps

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Connect battery charger to battery, positive to positive ( + ) - 2 - , negative to negative ( - ) - 1 -.

Battery in engine compartment:

Fig. 31: Identifying Battery Charger Connected To Battery

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clamps - arrow - and open cover - 2 - over positive terminal.
 Connect positive battery charger clamp - 3 - to positive ( + ) terminal - 4 - and to negative battery charger
clamp - 5 - to negative terminal - 1 - (VAS 5900 charger shown for illustration purposes only).

All:

 Switch on battery charger.

CAUTION: If battery begins gassing (boiling) violently when charging, REDUCE

charging rate immediately.

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 Adjust charging rate according to battery capacity (refer to Midtronics INC-940 Instruction Manual).

Charging totally discharged batteries

 Batteries which have not been used for lengthy periods, e.g. in vehicles which have not been driven, are
subject to self-discharge.
 A battery is considered to be totally discharged if the no-load voltage has dropped below 11.6 V. Initial
battery damage can occur between 12.2 and 11.6 V. Measuring no-load voltage --> No-load voltage,
checking.
 In a totally discharged battery the electrolyte (sulfuric acid/water mixture) is reduced to almost all water,
as the sulfuric acid content is heavily reduced. At temperatures below zero, the battery may freeze and the
cause the housing to burst.
 Totally discharged batteries become sulphated, i.e. all the plate surfaces of such batteries become hard.
The electrolyte has a slightly milky appearance (instead of being clear).

 If totally discharged batteries are charged directly after being discharged, the sulphation dissipates.
 If this is not done, the plates become even harder and their ability to absorb charge is impaired. This
results in reduced power output.

Procedure for charging exhausted batteries (sulphated)

Totally discharged batteries (that are also sulphated) must be charged as follows using a low charging current:

 Set charging current to approx. 5 % of battery capacity, i.e. for a 60 Ah battery the charging current is
approx. 3 A.
 Charging battery --> Battery, charging.

 The charging voltage (U max ) must not exceed 14.4 V.

CAUTION: Never "quick charge" a totally discharged battery. Effective charging will
not take place, despite what appears to be a sufficient voltage applied.
Batteries loaded in this manner may be incorrectly evaluated as OK and
battery damage may result.

Quick-charging

CAUTION:  Prior to handling or servicing batteries, read, understand and

observe the Warning and Safety Measures for lead-acid batteries
Smoking, naked flames, fires and sparks:.
 Always wear suitable protective clothing Eye protection and
protective clothing:.

Danger of explosion!

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 Batteries produce explosive gasses while being charged.

 Keep open flames and sparks away and DO NOT smoke near
batteries.
 The battery charger MUST be turned off when connecting or
disconnecting the cables at the battery.
 Battery cell caps must NOT be removed while charging.

 "Boosting" a sulfated battery a high charging rate can cause an

explosion.
 Ensure that battery is charged in a well ventilated area.
 Precision tools must not be kept in the same room where batteries
are being charged. Tools may corrode due to chemical reaction.

CAUTION:  Battery must not be connected to vehicle electrical system when

quick charging. Where applicable, disconnect battery in engine
compartment --> Battery in engine compartment, disconnecting and
reconnecting. Where applicable, disconnect battery in luggage
compartment --> Battery in luggage compartment, disconnecting and
connecting.
 Never quick-charge a totally discharged battery. Effective charging
will not take place.

NOTE:  The battery temperature must be at least 10 ° C.

 Quick-charging of batteries should only be performed in exceptional
circumstances (e.g. boost starting) as rapid charging may cause damage.

BATTERY INTERRUPT IGNITER N253 - AUDI RS4

Battery Interrupt Igniter N253 - Audi RS4, removing and installing

Battery Interrupt Igniter N253 must be replaced if faulty or damaged.

 Battery Interrupt Igniter N253 , replacing --> 69 - PASSENGER PROTECTION - AIRBAGS, SEAT
BELTS .

GENERATOR (GEN)

Generator (GEN) - 4-cylinder 1.8L Turbo engine, removing and installing

Special tools, testers and auxiliary items required

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Fig. 32: Identifying Drip Tray V.A.G 1306

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Drip tray VAG 1306 or drip tray for workshop crane VAS 6208

Fig. 33: Identifying Hose Clip Pliers Vag 1921

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hose clip pliers VAG 1921

Fig. 34: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

CAUTION: The cooling system is pressurized when the engine is warm. Wear gloves
and other protection and carefully release system pressure if necessary,
before performing repairs.

 Open filler cap for coolant expansion tank.

 Remove engine cover.
 Lift vehicle.

Fig. 35: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners - 1 - and - 2 - and remove front noise insulation.

Fig. 36: Locating Retaining Clip And Engine Coolant Temperature (ECT) Sensor
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Place drip tray VAG 1306 or drip tray for workshop crane VAS 6208 below engine.

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 Pull off retaining clip - 1 - and pull out Engine Coolant Temperature (ECT) Sensor (on Engine) G83 - 2 -.
 Drain coolant from radiator only.

Fig. 37: Identifying Top Coolant Hose At Coolant Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect top coolant hose from coolant pipe - arrow -.

Fig. 38: Identifying Coolant Fan Control Module

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove radiator fan control module - arrow - and set aside.

CAUTION: Before removing ribbed belt, mark direction of rotation. Belt damage will
result if not reinstalled in proper direction.

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Fig. 39: Identifying Ribbed Belt Tensioner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Relieve ribbed belt tension by turning tensioner in direction of - arrow -.

 Remove ribbed belt from generator pulley.
 Release pressure from the tensioner.

Fig. 40: Identifying Electrical Harness Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 -.

NOTE:  Electrical connections - 2 - and - 3 - not applicable to US/CDN models.

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Fig. 41: Identifying Upper And Lower Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove top and bottom bolts - arrows - and swing generator forward.

Fig. 42: Generator Electrical Connector And Terminal B+

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 2 -.

 Remove 30 ( B+ ) terminal - 1 -.
 Remove generator.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Before installing the ribbed belt, ensure that all subassemblies
(generator, a/c compressor etc.) are securely mounted and turn
freely.
 When installing belt, ensure correct seating in the belt pulleys!
 Reinstall all hose clamps, harness retainers and replace all removed
cable ties as originally installed in production.

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Fig. 43: Ribbed Belt, Seated Correctly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Note running direction of ribbed belt as previously marked and route as illustrated.
 Top up coolant --> 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s) AMB -
 19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE
MECHANICAL, ENGINE CODE(S): AMB
 19 - ENGINE - COOLING SYSTEM for 2.0 LITER 4-CYL. 4V TURBO ENGINE
MECHANICAL, ENGINE CODE(S): BPG, BWT
 19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL,
ENGINE CODE(S): AVK, BGN
 19 - ENGINE - COOLING SYSTEM for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE
(S): BKH
 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE
CODE(S): BNS
 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE
CODE(S): BHF
.
 Reconnect battery. Required steps Reconnecting.
 Start engine and check belt running.

Tightening Torques (1.8L)

Tightening Torques

Component - fastener Nm
Generator (GEN) to engine - bolt 23
Terminal 30/B+ to generator - nut 16

Generator (GEN) - 4-cylinder 2.0L Turbo FSI engine, removing and installing

Special tools, testers and auxiliary items required

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Fig. 44: Locking Tool T40098

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Locking pin T40098 or equivalent

Fig. 45: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

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Fig. 46: Removing Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove engine cover - arrows -.

CAUTION: Before removing ribbed belt, mark direction of rotation. Belt damage will
result if not reinstalled in proper direction.

Fig. 47: Pivoting Belt Tensioner For Ribbed Belt To Relieve Tension On Ribbed Belt
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Relieve ribbed belt tension by turning tensioner in direction of - arrow - and lock in place using locking
pin T40098.
 Remove ribbed belt.

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Fig. 48: Separating Electrical Connector From Charge Air Pressure Sensor G31 & Removing Left
Charge Air Hose
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove air hose - 2 - at intake manifold.

NOTE:  Disregard - 1 -.

Fig. 49: Identifying Upper And Lower Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove top and bottom bolts - arrows - and swing generator forward.

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Fig. 50: Generator Electrical Connector And Terminal B+

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 2 -.

 Remove D+ terminal - 1 -.
 Remove generator.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Before installing the ribbed belt, ensure that all subassemblies
(generator, a/c compressor etc.) are securely mounted and turn
freely.
 When installing belt, ensure correct seating in the belt pulleys!
 Reinstall all hose clamps, harness retainers and replace all removed
cable ties as originally installed in production.

Fig. 51: Ribbed Belt, Seated Correctly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Note running direction of ribbed belt as previously marked and route as illustrated.

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 Top up coolant --> 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection Ignition, Engine Code(s): BPG -
 19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE
MECHANICAL, ENGINE CODE(S): AMB
 19 - ENGINE - COOLING SYSTEM for 2.0 LITER 4-CYL. 4V TURBO ENGINE
MECHANICAL, ENGINE CODE(S): BPG, BWT
 19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL,
ENGINE CODE(S): AVK, BGN
 19 - ENGINE - COOLING SYSTEM for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE
(S): BKH
 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE
CODE(S): BNS
 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE
CODE(S): BHF
.
 Reconnect battery. Required steps Reconnecting.
 Start engine and check belt running.

Tightening Torques (2.0L)

Tightening Torques

Component - fastener Nm
Generator (GEN) to engine - bolt 23
Terminal 30/B+ to generator - nut 16

Generator (GEN) - 3.0L 6-cylinder engine, removing and installing

Special tools, testers and auxiliary items required

Fig. 52: Ribbed Belt Installation Tool 3299 With Tensioner Claw 3299/1
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Ribbed Belt Installation Tool 3299 with tensioner claw 3299/1

Fig. 53: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

Fig. 54: Removing Front Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove front engine cover - arrows -.

CAUTION: Before removing ribbed belt, mark direction of rotation. Belt damage will
result if not reinstalled in proper direction.

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Fig. 55: Swinging Ribbed Belt Tensioner To Release Tension On Ribbed Belt
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Relieve ribbed belt tension by turning tensioner in direction of - arrow -.

 Remove ribbed belt from power steering pump pulley.
 Lift vehicle.

Fig. 56: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners - 1 - and - 2 - and remove front noise insulation.

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Fig. 57: Starter Wiring Bracket Cable Ties

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove cable ties - arrows - , unclip cover for starter cable guide harness and remove harness from
guide.

Vehicles with automatic transmission:

Fig. 58: Unscrewing Nut For Clamp For ATF Lines

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nuts - 1 - and - 2 -.

 Remove bracket for ATF lines.

All models:

 Unclip refrigerant line from bracket at sump.

 Disconnect electrical connections at generator.
 Remove bolts - arrows -.

Fig. 59: Identifying Bolts And Generator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Remove generator.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Before installing the ribbed belt, ensure that all subassemblies
(generator, a/c compressor etc.) are securely mounted and turn
freely.
 When installing belt, ensure correct seating in the belt pulleys!
 Reinstall all hose clamps, harness retainers and replace all removed
cable ties as originally installed in production.

Fig. 60: Identifying Belt Path

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Note running direction of ribbed belt as previously marked and route as illustrated.

1. Generator (GEN)
2. Ribbed belt
3. Power steering pump
4. Air conditioner compressor
5. Crankshaft
6. Tensioning roller

 Reconnect battery. Required steps Reconnecting.

 Start engine and check belt running.

Tightening torques

Component - fastener Nm
M8 22

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Generator to engine bracket - bolts M10 45

Terminal 30/B+ to generator - nut 16
Bracket for refrigerant line to sump - bolt 10
Bracket for starter wire to engine console - bolt 10

Generator (GEN) - 3.2L 6-cylinder FSI engine, removing and installing

Special tools, testers and auxiliary items required

Fig. 61: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

Fig. 62: Identifying Front Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove front engine cover - arrows -.

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Fig. 63: Identifying Bolts & Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove air guides - 1 - and - 2 -.
 Lift vehicle.

Fig. 64: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners - 1 - and - 2 - and remove front noise insulation.

 Remove front bumper cover --> 63 BUMPER .
 Bring lock carrier into service position --> 50 BODY, FRONT .

CAUTION: Before removing ribbed belt, mark direction of rotation. Belt damage will
result if not reinstalled in proper direction.

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Fig. 65: Pivoting Tensioning Device To Relieve Tension On Ribbed Belt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Relieve ribbed belt tension by turning tensioner in direction of - arrow -.

 Remove ribbed belt from generator pulley.
 Allow tensioner to return to operating position.

Fig. 66: Identifying Bolts, Electrical Connections, And Generator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bolts - arrows -.

 Disconnect electrical connections - 1 - and - 2 - from Generator.
 Remove Generator.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Before installing the ribbed belt, ensure that all subassemblies
(generator, a/c compressor etc.) are securely mounted and turn
freely.

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 When installing belt, ensure correct seating in the belt pulleys!

 Reinstall all hose clamps, harness retainers and replace all removed
cable ties as originally installed in production.

Fig. 67: Placing Ribbed Belt Over Belt Pulley

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Note running direction of ribbed belt as previously marked and route as illustrated.

1. Generator (GEN)
2. Idler
3. Coolant pump
4. Power steering pump
5. Air conditioning compressor
6. Tensioning roller
7. Crankshaft

 Reinstall lock carrier --> 50 BODY, FRONT .

 Reconnect battery. Required steps Reconnecting.
 Start engine and check belt running.
 Reinstall front bumper cover --> 63 BUMPER .

Tightening Torques (3.2L)

Tightening Torques

Component - fastener Nm
Generator to engine bracket - bolt 22
Terminal 30/B+ to generator - nut 16

Generator (GEN) - 4.2L 8-cylinder engine (Audi S4), removing and installing

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Special tools, testers and auxiliary items required

Fig. 68: Identifying Drip Tray V.A.G 1306

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Drip tray VAG 1306 or drip tray for workshop crane VAS 6208

Fig. 69: Identifying Old Oil Collecting And Extracting Device V.A.G 1782
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Oil drain appliance VAG 1782 or UL approved equivalent

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Fig. 70: Identifying Hose Clip Pliers Vag 1921

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hose clip pliers VAG 1921

Fig. 71: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Fig. 72: Identifying Torque Wrench V.A.G. 1332

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

 Use oil drain appliance VAG 1782 (or UL approved equivalent) to draw power steering hydraulic fluid
from power steering from reservoir.

CAUTION: The cooling system is pressurized when the engine is warm. Wear gloves
and other protection and carefully release system pressure if necessary,

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before performing repairs.

 Open filler cap for coolant expansion tank.

 Lift vehicle
 Remove right front wheel.

Fig. 73: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners - 1 - and - 2 - and remove front noise insulation.

Fig. 74: Removing Right Air Guide In Front Of Auxiliary Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove air guide - arrow - from right auxiliary radiator.

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Fig. 75: Removing Left Air Guide In Front Of Auxiliary Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove air guide - arrow - from left auxiliary radiator.

Fig. 76: Removing Drain Plug On Coolant Thermostat Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Place drip tray VAG 1306 or drip tray for workshop crane VAS 6208 beneath engine.
 Remove drain plug - arrow - at thermostat housing and drain engine coolant.

Fig. 77: Disconnecting Lower Coolant Hose From Radiator

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release and pull off bottom coolant hose from radiator - arrow - and drain remaining engine coolant.

Fig. 78: Disconnecting Hydraulic Lines To Cooling Coil At Left Rear Of Bumper
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Place oil drain appliance VAG 1782 underneath.

 Remove hydraulic hoses - arrows - at rear of lock carrier to power steering cooling line.

Fig. 79: Removing Cover In Engine Compartment (Right Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove right engine compartment cover - 1 -.

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Fig. 80: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air guide.
 Remove air guide - 2 -.

Fig. 81: Disconnecting Top Coolant Hose From Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove top coolant hose - arrow - from radiator.

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Fig. 82: Removing Cover In Engine Compartment (Left Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove left engine compartment cover - 1 -.

Fig. 83: Removing Electrical Harness Connectors And From Bracket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove electrical connections - 1 - and - 2 - from retainer and disconnect them.

 Set aside harness toward lock carrier.

Fig. 84: Disconnecting Electrical Harness Connector For Headlights At Both Sides Of Vehicle
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections for left and right headlamps - arrow -.

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Fig. 85: Disconnecting Electrical Harness Connector For Left/Right Airbag Sensors On Lock Carrier
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections for both left and right airbag sensors - arrow - on lock carrier.
 Set aside harness toward lock carrier.
 Remove hood release cable from lock carrier --> 55 HOOD, LIDS

Fig. 86: Disconnecting Electrical Harness Connector For Right Fan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - arrow - for right radiator fan.

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Fig. 87: Removing Left/Right Air Guides At Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows - and remove right and left radiator air guides.

Fig. 88: Removing Power Steering Hydraulic Oil Cooling Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Unclip temperature sensor - 1 - from retainer and set aside.

 Remove power steering cooling line - arrows -.

Fig. 89: Removing Coolant Fan Control (FC) Control Module J293 From Radiator
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screw - arrow - and remove cooling fan control module.

CAUTION:  In order not to damage the condensor and refrigerant lines/hoses,

ensure refrigerant lines are not excessively bent or tensioned in the
following procedures.
 Do not open refrigerant circuit!

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Fig. 90: Disconnecting Electrical Harness Connector At High Pressure Sensor G65
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 - at High Pressure Sensor G65.

 Remove screws - arrows -.
 Remove condensor with refrigerant lines attached and lower downward.

Fig. 91: Removing Bolts At Left/Right Side Of Bumper

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws at lock carrier left and right - arrows -.

 Remove front hood sealing gasket from lock carrier and fenders.

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Fig. 92: Removing Bolts At Impact Absorbers At Left/Right

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bolts at impact absorbers - arrows - (left and right).

NOTE:  Use an assistant to remove lock carrier in the following step.

 Remove lock carrier and tilt aside (secure against falling).

Fig. 93: Removing Hose Clamps And Disconnecting Coolant Hose

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release hose clamp - 2 - and remove coolant hose from right coolant pipe.
 Release hose clamp - 1 - and remove coolant hose from coolant pipe.

NOTE:  Engine shown removed in illustration for clarity.

CAUTION: Before removing ribbed belt, mark direction of rotation. Belt damage will
result if not reinstalled in proper direction.

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Fig. 94: Loosening Tensioning Bolt And Ribbed Belt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Relieve ribbed belt tension by loosening tensioner bolt - arrow -.

 Remove ribbed belt from generator pulley.

Fig. 95: Removing Tensioning Roller

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bolts - arrows - and remove tensioner.

Fig. 96: Removing Generator Bolts

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bolts - arrows -.

 Remove generator from bracket and pull forwards.

NOTE:  If generator is difficult to remove from mounting, reinstall mounting bolts

loosely and carefully strike bolt heads with hammer in order to loosen
mounting threaded bushings.

Fig. 97: Disconnecting Coolant Hose On Generator, Electrical Connector & Removing Electrical Wire
On Generator
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release hose clamp - 3 - and remove coolant hose from generator.

 Disconnect electrical connection - 1 -.
 Remove nut - 2 - and terminal eyelet from generator.
 Remove generator.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Before installing the ribbed belt, ensure that all subassemblies
(generator, a/c compressor etc.) are securely mounted and turn
freely.
 When installing belt, ensure correct seating in the belt pulleys!
 Reinstall all hose clamps, harness retainers and replace all removed
cable ties as originally installed in production.

 To aid in installation, drive generator mounting bushings back into mounting flanges approx. 4mm.

CAUTION: Tight generator mounting bushings must be made to move freely in order

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to ensure sufficient clamping force at the specified bolt torque.

Fig. 98: Placing Ribbed Belt Over Belt Pulley In Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Note running direction of ribbed belt as previously marked and route as illustrated.

1. Generator (GEN)
2. Ribbed belt
3. Idler
4. Vibration damper
5. Tensioning roller

 Tension ribbed belt by rotating tensioner counterclockwise with torque wrench until 70 Nm is achieved.

Fig. 99: Positioning Torque Wrench On Belt Tensioner Hex Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hold and simultaneously tighten tensioner bolt - arrow - to 22 Nm.

 Reinstall lock carrier and related assemblies --> 50 BODY, FRONT .
 Reinstall front bumper --> 63 BUMPER .

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 Top up coolant --> 4.2 Liter V8 5V Engine Mechanical, Engine Code(s): BHF -
 19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE
MECHANICAL, ENGINE CODE(S): AMB
 19 - ENGINE - COOLING SYSTEM for 2.0 LITER 4-CYL. 4V TURBO ENGINE
MECHANICAL, ENGINE CODE(S): BPG, BWT
 19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL,
ENGINE CODE(S): AVK, BGN
 19 - ENGINE - COOLING SYSTEM for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE
(S): BKH
 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE
CODE(S): BNS
 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE
CODE(S): BHF
.

 Refill power steering fluid reservoir --> 48 - STEERING

CAUTION: Power steering pump must NOT be allowed to run dry. Damage will result.

 Reconnect battery. Required steps Reconnecting.

 Start engine and check belt running.
 Check and adjust headlamps if necessary --> 00 - TECHNICAL DATA

Tightening Torques (4.2L - S4)

Tightening Torques

Component - fastener Nm
Coolant pipes to generator - bolt 9
Terminal 30/B+ to generator - nut 16
Generator (GEN) to engine bracket - bolt 22
Tensioning roller to engine - bolt 22

Generator (GEN) - 4.2L 8-cylinder FSI engine (Audi RS4), removing and installing

Special tools, testers and auxiliary items required

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Fig. 100: Identifying Old Oil Collecting And Extracting Device V.A.G 1782
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 oil drain appliance VAG 1782 or UL approved equivalent

Fig. 101: Drip Tray For VAS 6100, VAS 6208

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Workshop crane drip tray VAS 6208 or drip tray VAG 1306

Fig. 102: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Fig. 103: Identifying Torque Wrench V.A.G. 1332

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

 Disconnect battery --> Battery in luggage compartment, disconnecting and connecting.

 Use oil drain appliance VAG 1782 (or UL approved equivalent) to draw power steering hydraulic fluid
from power steering from reservoir.

CAUTION: The cooling system is pressurized when the engine is warm. Wear gloves
and other protection and carefully release system pressure if necessary,
before performing repairs.

 Open filler cap for coolant expansion tank.

 Lift vehicle
 Remove right front wheel.

Fig. 104: Removing Quick-Release Fasteners, Screws And Noise Insulation

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners - 1 - and - 2 - and remove front noise insulation.

 Remove right front wheelhouse liner --> 66 EXTERIOR EQUIPMENT .
 Remove front bumper cover --> 63 BUMPER Front bumper cover, removing and installing.

Fig. 105: Removing Right Air Guide In Front Of Auxiliary Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove right air duct - arrow - in front of auxiliary radiator.

 Place oil drain appliance VAG 1782 (or UL approved equivalent) under engine.
 Drain engine oil.

Fig. 106: Removing Bolts On Oil Cooler Lines At Upper Part Of Oil Pan
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows - at oil cooler lines on upper part of oil pan.

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 Remove oil lines from upper part of oil pan.

Fig. 107: Removing Left Air Guide In Front Of Auxiliary Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove left air duct - arrow - in front of auxiliary radiator.

Fig. 108: Removing Bolt On Auxiliary Cooler Upper Bracket, At Left Of Lock Carrier
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrow - at upper left auxiliary radiator bracket at lock carrier.
 Place workshop crane drip tray VAS 6208 or VAG 1306 under engine.

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Fig. 109: Removing Drain Plug On Coolant Thermostat Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove drain plug - arrow - at coolant regulator housing and drain coolant at engine.

Fig. 110: Removing Drain Plug On Front Coolant Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Also remove drain plug - arrow - at front coolant pipe and drain remaining coolant.

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Fig. 111: Removing Coolant Hose Downward From Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Loosen hose clamp - arrow - and remove lower coolant hose from radiator.
 Place oil extractor VAG 1782 under engine.

Fig. 112: Disconnecting Hydraulic Lines To Cooling Coil At Left Rear Of Bumper
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect hydraulic lines to rear left radiator coil on lock carrier - arrows -.

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Fig. 113: Identifying Bolts & Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove air duct - 1 - and - 2 -.

Fig. 114: Disconnecting Top Coolant Hose From Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Detach upper coolant hose - arrow - from radiator.

Fig. 115: Removing Cover In Engine Compartment (Left Side)

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove cover - 1 - at left of engine compartment.

Fig. 116: Removing Electrical Harness Connectors From Bracket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove electrical connections - 1 - and - 2 - from retainer and disconnect.

 Set aside harness toward lock carrier.

Fig. 117: Disconnecting Electrical Harness Connector For Headlights At Both Sides Of Vehicle
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections for left and right headlamps - arrow -.

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Fig. 118: Disconnecting Electrical Harness Connector For Left/Right Airbag Sensors On Lock Carrier
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections for left and right airbag sensors - arrow - at lock carrier.
 Set aside harness toward lock carrier.
 Remove hood cable at lock carrier --> 55 HOOD, LIDS .

Fig. 119: Disconnecting Electrical Harness Connector For Right Fan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection for right radiator fan - arrow -.

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Fig. 120: Removing Bolts On Left/Right Air Guides At Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows - at left and right air ducts on radiator.

CAUTION:  In order not to damage the condensor and refrigerant lines/hoses,

ensure refrigerant lines are not excessively bent or tensioned in the
following procedures.
 Do not open refrigerant circuit!

Fig. 121: Disconnecting Electrical Harness Connector At High Pressure Sensor G65
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 - for High Pressure Sensor G65.

 Remove screws - arrows -.
 Remove condenser and swing downward with refrigerant lines connected.

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Fig. 122: Removing Right Coolant Hose

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove right coolant hose - arrow - at radiator.

Fig. 123: Removing Bolts At Left/Right Side Of Bumper

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows - at left and right lock carriers.

 Remove engine compartment seat at lock carrier and fender edges.

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Fig. 124: Removing Bolts At Impact Absorbers At Left/Right

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws on left and right shock absorbers - arrows -.

NOTE:  Use an assistant to remove lock carrier in the following step.

 Remove lock carrier and tilt aside (secure against falling).

CAUTION: Before removing ribbed belt, mark direction of rotation. Belt damage will
result if not reinstalled in proper direction.

Fig. 125: Releasing Ribbed Belt Tension

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Relieve ribbed belt tension by pivoting tensioner in direction of - arrow -.

NOTE:  Ensure lever axle is long enough so that it can be completely inserted in
tensioner.
 Remove ribbed belt from generator pulley.
 Release tensioner.

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Fig. 126: Removing Bolts & Ribbed Belt Tensioner At Upper Part Of Oil Pan
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bolts - arrows -.

 Remove tensioner - 1 - at upper part of oil pan.

Fig. 127: Removing Bolts And Coolant Hose From Coolant Pipe Bracket And Generator
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Remove bolt - 2 - on coolant pipe bracket.

 Loosen hose clamp and remove coolant hose - 1 - to generator.
 Remove bolts - 3 - and - 4 -.
 Remove generator from bracket and pull forward.

NOTE:  If generator is difficult to remove from mounting, reinstall mounting bolts

loosely and carefully strike bolt heads with hammer in order to loosen
mounting threaded bushings.

Fig. 128: Identifying Coolant Hose, Electrical Connector, Bolt & Heat Shield
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove coolant hose - 1 - from generator.

 Disconnect electrical connection - 5 -.
 Remove screw - 4 - and remove heat shield.

CAUTION: Ensure coolant pipes do not slip out, otherwise O-rings on removed
coolant pipes must be replaced. Re-tighten bracket - 3 - after removing

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heat shield if necessary.

 Remove nut - 2 - and terminal 30 ( B+ ) eyelet from generator.

 Remove generator.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Before installing the ribbed belt, ensure that all subassemblies
(generator, a/c compressor etc.) are securely mounted and turn
freely.
 When installing belt, ensure correct seating in the belt pulleys!
 Reinstall all hose clamps, harness retainers and replace all removed
cable ties as originally installed in production.

 To aid in installation, drive generator mounting bushings back into mounting flanges approx. 4mm.

CAUTION: Tight generator mounting bushings must be made to move freely in order
to ensure sufficient clamping force at the specified bolt torque.

Fig. 129: Placing Ribbed Belt Over Belt Pulley In Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Note running direction of ribbed belt as previously marked and route as illustrated.

1. Generator
2. Ribbed belt
3. Idler pulley
4. Vibration damper
5. Tensioning roller

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 Install lock carrier with attachments --> 50 BODY, FRONT .

 Install front bumper cover --> 63 BUMPER Front bumper cover, removing and installing.
 Before starting engine for first time, fill hydraulic oil in power steering reservoir.

CAUTION: Power steering pump must NOT be allowed to run dry. Damage will result.

 Fill engine oil and check oil level.

 Top up coolant --> 4.2 Liter V8 5V Engine Mechanical, Engine Code(s): BNS -
 19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE
MECHANICAL, ENGINE CODE(S): AMB
 19 - ENGINE - COOLING SYSTEM for 2.0 LITER 4-CYL. 4V TURBO ENGINE
MECHANICAL, ENGINE CODE(S): BPG, BWT
 19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL,
ENGINE CODE(S): AVK, BGN
 19 - ENGINE - COOLING SYSTEM for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE
(S): BKH
 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE
CODE(S): BNS
 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE
CODE(S): BHF
.
 Reconnect battery. Required steps Connecting
 Start engine and check belt routing.

 Check and adjust headlamps --> 00 - TECHNICAL DATA .

Tightening Torques (4.2L - RS4)

Tightening Torques

Component - fastener Nm
Coolant pipe bracket to generator - bolt 9
Terminal 30/B+ to generator - nut 16
Generator to engine - bolts 22
Tensioner to upper part of oil pan - bolts 9

STARTER

Starter - 1.8L 4-cylinder Turbo engine, removing and installing

Special tools, testers and auxiliary items required

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Fig. 130: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Fig. 131: Identifying Torque Wrench V.A.G. 1332

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

 Lift vehicle.

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Fig. 132: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners - 1 - and - 2 - and remove front noise insulation.

Fig. 133: Identifying Line, Connector Terminal, Clamp, And Insulator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nut at starter solenoid terminal B+ - 2 - and remove connector eyelet from terminal.
 Disconnect electrical connection for terminal 50 - 1 -.
 Remove insulator from positive connection on starter where applicable.
 Remove harness clamp - 4 -.

 Remove bolt - 3 - from engine block to starter bracket, and remove bracket.

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Fig. 134: Identifying Bolts And Starter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bolts - 1 - and - 2 -.

 Remove starter from below.

Installing

Install in reverse order of removal, noting the following:

 Reconnect battery. Required steps Reconnecting.

Tightening torques

Component - fastener Nm
M10 45
Starter to transmission bracket - bolt M12 65
Terminal B+ to starter - nut 16

Starter - 2.0L 4-cyl Turbo FSI engine, removing and installing

Special tools, testers and auxiliary items required

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Fig. 135: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Fig. 136: Identifying Torque Wrench V.A.G. 1332

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

 Lift vehicle.

Fig. 137: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners - 1 - and - 2 - and remove front noise insulation.

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Fig. 138: Removing Left/Right Heat Shields For Drive Axles

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove heat shield - 1 - for right drive shaft.

Fig. 139: Identifying Bolts And Starter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bolts - 1 - and - 2 -.

Fig. 140: Identifying Starter, Electrical Connector & Nuts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Remove starter and swing aside.

 Disconnect electrical connection for terminal 50 - 3 -.
 Remove nut - 1 - for harness clamp.
 Remove nut at starter solenoid terminal B+ - 2 - and remove connector eyelet from terminal.

 Remove starter.

Installing

Install in reverse order of removal, noting the following:

 Reconnect battery. Required steps Reconnecting.

Tightening torques

Component - fastener Nm
Starter to transmission - bolt 65
Terminal B+ to starter - nut 16

Starter - 3.0L 6-cylinder engine, removing and installing

Special tools, testers and auxiliary items required

Fig. 141: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

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Fig. 142: Identifying Torque Wrench V.A.G. 1332

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

 Lift vehicle.
 Remove right front wheel.
 Remove generator --> Generator (GEN) - 3.0L 6-cylinder engine, removing and installing.

Fig. 143: Identifying Heat Shield For Right Drive Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove heat shield for right drive shaft - arrows -.

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Fig. 144: Identifying Cable For Terminals, Heat Shield From Solenoid Switch, And Starter
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nut at starter solenoid terminal B+ - 2 - and remove connector eyelet from terminal.
 Disconnect electrical connection for terminal 50 - 1 -.
 Remove solenoid heat shield - 3 -.
 Remove bolts - arrows - and remove starter.

Installing

Install in reverse order of removal, noting the following:

 Install generator Installing

 Reconnect battery. Required steps Reconnecting.

Tightening torques

Component - fastener Nm
Starter to engine - bolt 45
Terminal B+ to starter - nut 16
Drive shaft heat shield to transmission - bolt 23

Starter - 3.2L 6-cylinder FSI engine, removing and installing

Special tools, testers and auxiliary items required

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Fig. 145: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Fig. 146: Identifying Torque Wrench V.A.G. 1332

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

 Lift vehicle.
 Remove right front wheel.

NOTE:  Secure brake disc with a wheel bolt.

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Fig. 147: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners - 1 3 - and remove front and rear noise insulation.

Fig. 148: Drive Axle Heat Shield

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove right drive shaft heat shield - arrow -.

Vehicles with automatic transmission

 Remove right drive axle from transmission axle flange.

Continued for all:

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Fig. 149: Identifying Bolts, Starter Solenoid Terminal, And Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nut at starter solenoid terminal B+ - 2 - and connection for terminal 50 - 3 -.

 Remove bolts - 1 - and - 4 -.

Vehicles with automatic transmission

 Remove starter towards rear of wheel housing.

Vehicles with standard transmission

 Remove starter from between transmission and subframe.

NOTE:  For clarity, subframe shown removed in illustrations.

Installing

Install in reverse order of removal, noting the following:

 Reinstall right drive axle from transmission axle flange. Refer to appropriate automatic transmission
repair information, RG 40.
 Reconnect battery. Required steps Reconnecting.

Tightening torques

Component - fastener Nm
Stater to transmission - bolt 65
Terminal B+ to starter - nut 16
Drive shaft heat shield to transmission - bolt 23

Starter - 4.2L 8-cylinder engine (Audi S4), removing and installing

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Special tools, testers and auxiliary items required

Fig. 150: Identifying 10-222A Engine Support Bridge With 10-222A/8 Bracket For Engine
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Engine support bridge 10-222 A

Fig. 151: Identifying Special Tools - Shackle 10 - 222 A/12

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Shackle (set) 10-222 A/12

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Fig. 152: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Fig. 153: Identifying Torque Wrench V.A.G. 1332

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

Fig. 154: Removing/Installing Rear Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Unclip engine cover - arrows -.

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Fig. 155: Securing Shackle 10-222 A/12 To Right Rear Engine Lifting Eyelet
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Attach shackle 10-222 A/12 to right rear lifting fixture on engine.

NOTE:  Disregard - 1 -.

Fig. 156: Engaging Shackle 10-222 A/12 On Spindle Of Engine Support Bridge 10-222 A
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Assemble support bracket 10-222 A and place across fenders as illustrated.

 Attach shackle to lifting spindle.
 Turn lifting spindle to apply slight lifting tension to engine.
 Lift vehicle.

 Remove right front wheel.

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Fig. 157: Removing Quick-Release Fasteners, Screws And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners - 1 - , remove bolts - 2 - and remove noise insulation.

Fig. 158: Removing Nuts For Left/Right Stabilizer Mounts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove anti-roll bar bracket nuts - 1... 4 -.

Fig. 159: Removing Wiring Harness Bracket At Right Engine Mount Plate
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Remove nut - arrow - and remove harness retainer from mounting.

Fig. 160: Identifying Nuts, Bolts, And Right Side Engine Mount Carrier
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nut - 3 -.
 Remove bolts - 1 - and - 2 - and remove right side engine mount carrier.

Fig. 161: Removing Refrigerant Line On Bracket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove right refrigerant line mounting - arrow -.

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Fig. 162: Disconnecting Electrical Harness Connector At Right Engine Mount

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 -.

 Remove bolts - arrows -.
 Remove right engine mount with bracket.

Fig. 163: Drive Axle Heat Shield

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Vehicles with manual transmission:

 Remove right drive shaft heat shield - arrow -.

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Fig. 164: Identifying Ground (GND) Wire, Wires, Nuts, Bolts & Starter
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove ground cable - 5 -.

 Remove nut at starter solenoid terminal B+ - 3 - and connection for terminal 50 - 4 -.
 Remove nut - 1 - and bolt - 2 -.
 Remove starter.

Fig. 165: Removing Left/Right Heat Shields For Drive Axles

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Vehicles with automatic transmission:

 Remove heat shield - 1 - for drive shaft (right-side).

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Fig. 166: Identifying Ground (GND) Wire, Starter Electrical Wires, Bolts & Starter
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove earth cable - 1 -.

 Remove nut at starter solenoid terminal B+ - 3 - and connection for terminal 50 - 4 -.
 Remove bolts - 2 - and - 5 -.
 Remove starter.

Installing

Install in reverse order of removal, noting the following:

 Install engine mounting and tighten subframe --> 40 - FRONT SUSPENSION .

 Install anti-roll bar --> 40 - FRONT SUSPENSION .
 Reconnect battery. Required steps Reconnecting.

Tightening torques

Component - fastener Nm
Starter to transmission - bolt 65
Terminal B+ to starter - nut 16
Ground cable to starter - bolt 22
Engine support to cylinder block - bolt 42 1)
Drive shaft heat shield to transmission - bolt 23

1) Insert with locking compound; locking compound.

Starter - 4.2L 8-cylinder FSI engine (Audi RS4), removing and installing

Special tools, testers and auxiliary items required

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Fig. 167: Identifying 10-222A Engine Support Bridge With 10-222A/8 Bracket For Engine
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Engine Support Bridge 10-222A

Fig. 168: Insert Pad For Front Fender T40045

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Insert Pad For Front Fender T40045

Fig. 169: Identifying Special Tools - Shackle 10 - 222 A/12

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Shackle (set) 10-222 A/12

Fig. 170: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Fig. 171: Identifying Torque Wrench V.A.G. 1332

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

NOTE:  When installing, reinstall all cable ties that were loosened or cut during
removal in the same locations.
 Disconnect battery --> Battery in luggage compartment, disconnecting and
connecting.

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Fig. 172: Pulling Rear Engine Cover Off

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove rear engine cover by pulling up in direction of - arrows -.

Fig. 173: Removing Cover In Engine Compartment (Left Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove left engine compartment cover - 1 -.

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Fig. 174: Identifying Bolts & Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove air duct - 1 - and - 2 -.
 Remove engine compartment seal at lock carrier and fender edges.

Fig. 175: Inserting Insert Pad For Front Fender T40045 On Both Sides Between Fender Mounting Flange
And Body Panel Underneath
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 To avoid damaging bolted fender edges with Engine Support Bridge 10-222A , place Insert Pad For Front
Fender T40045 - arrows - on both sides between bolted fender edges and panel underneath.

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Fig. 176: Locating Engine Support Spindles At Rear Of Crossbar

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Place Engine Support Bridge 10-222A on bolted fender edges. Locate engine support spindles at rear of
crossbar as illustrated.
 Install Shackles 10-222A/12 at engine support bridge spindles.
 Pre-tension engine slightly with engine support bridge spindles.
 Lift vehicle.

Fig. 177: Removing Quick-Release Fasteners, Screws And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove right front wheel.

 Release fasteners - 1 - , remove screws - 2 - and remove front noise insulation.

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Fig. 178: Removing Nuts For Left/Right Stabilizer Mounts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove left and right stabilizer bar mount nuts - 1 - and - 2 -.

 Swing stabilizer bar down.

Fig. 179: Removing Wiring Harness Bracket At Right Engine Mount Plate
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove wiring harness bracket at right engine console - arrows -.

Fig. 180: Identifying Nuts, Bolts, And Right Side Engine Mount Carrier

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nut - 3 -.
 Remove bolts - 1 - and - 2 - and remove right engine console.

Fig. 181: Disconnecting Electrical Harness Connector At Right Engine Mount

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connector at right engine mount - 1 -.

 Remove screws - arrows - using a hex socket head wrench with ball head.

Fig. 182: Identifying Engine Mount Nut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove engine mount nut - 1 - at right engine support.

 Remove engine mount and engine support.

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Fig. 183: Removing Left/Right Heat Shields For Drive Axles

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove right driveshaft heat shield - arrow -.

Fig. 184: Identifying Screws, Nuts, And Starter Heat Shield

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 2 - and - 4 - at starter heat shield.

 Remove nut - 3 - and screw - 1 -.
 Remove starter forward.

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Fig. 185: Identifying Electrical Connection, Locking Mechanism, Nut, Ground Wire, And Cable Ties
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release electrical connection - 2 - by pushing locking mechanism - arrow A - and pressing catch down -
arrow B -.
 Remove nut - 1 - and remove terminal 30 ( B+ ) eyelet.
 Remove ground wire - 4 -.
 Cut through cable ties - 3 -.

 Remove starter.

Installing

Install in reverse order of removal, noting the following:

NOTE:  When installing, install cable ties at same location.

 Install engine console and tighten subframe --> 40 - FRONT SUSPENSION .
 Install stabilizer --> 40 - FRONT SUSPENSION .
 Connect battery. Required steps Connecting.

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Tightening torques

Component - fastener Nm
Starter to transmission - bolt 65
Terminal B+ to starter - nut 16
Ground cable to starter - bolt 22
Engine support to cylinder block - bolt 42 1)
Heat shield for half-shaft to transmission - bolt 23

1) Insert with locking compound; locking compound.

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90 INSTRUMENTS
INSTRUMENT CLUSTER

General information

The instrument cluster contains an electronic speedometer, tachometer, liquid crystal (LCD) displays for
odometer, trip odometer, digital clock with date, as well as analog coolant temperature and fuel level gauges.
Control and warning lamps are situated within the speedometer and tachometer faces. Automatic transmission
models also contain an LCD gear indicator display.

A "Drivers Information System" LCD is located between the tachometer and speedometer. Displayed
information includes an auto check system, outside air temperature, automatic transmission range, radio
frequency and selectable trip computer functions.

The optional Navigation system display is also included in the Drivers Information System (where applicable).

Instrument cluster, disposal

NOTE:  Instrument cluster LCD display contains mercury.

 Faulty instrument clusters (not covered by new vehicle warranty) may
need to be disposed of as hazardous waste. Always heed state/local
regulations concerning disposal of hazardous waste.

On Board Diagnostic (OBD), function

The instrument cluster is controlled by an internal microprocessor with On Board Diagnostic (OBD) capability.
If malfunctions occur in monitored sensors and components, Diagnostic Trouble Codes (DTC) will be stored in
memory.

Troubleshoot instrument cluster malfunctions and perform OBD program functions using VAS 5051/5052 tester
in mode "Guided Fault Finding".

VAS 5051/5052 connected and in mode "Guided Fault Finding":

 Enter appropriate model, equipment and model year information and press ">" to confirm.

After the DTC memory of all control modules has been checked:

 Press "Go to" "Go to" button

 Select: "Function / Component Selection"
 Select: "Body (Repair 01; 27; 50 - 97)"
 Select: "Electrical Equipment (Repair 01; 90 - 97)"

 Select: "01 - On Board Diagnostic (OBD) capable systems"

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 Select: "Instrument Cluster"

 Select appropriate option
 Follow tester prompts.

Message "dEF" in trip recorder display

If the instrument cluster control module detects a DTC in permanent memory, letters "dEF" will appear in the
trip recorder display.

 If "dEF" is displayed, Replace instrument cluster --> Instrument cluster, removing and installing.

Instrument cluster, removing and installing

Special tools, testers and auxiliary items required

Fig. 186: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hook 3370

Removing

NOTE:  Do not disassemble instrument cluster.

 Instrument clusters contain no field serviceable components. Should
malfunctions occur, replace complete instrument cluster.
 If instrument cluster is to be replaced, connect VAS 5051/5052 and initiate
OBD program option "Instrument cluster, replacing" --> On Board
Diagnostic (OBD), function

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

 Pull steering wheel with adjusting mechanism fully out and move it downward.

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NOTE:  For clarity, steering wheel is shown removed in the following illustrations.

Fig. 187: Pulling Off Bottom Cover Towards Rear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull off bottom cover - 1 - towards rear - arrows -.

Fig. 188: Locating Screws

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

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Fig. 189: Pulling Off Left Instrument Panel Cover Using Special Hook 3370
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove left instrument panel side cover - arrow - using hook 3370.

Fig. 190: Reaching Through Opening Above Fuse Panel And Pushing Out Instrument Cluster
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Reach through opening - arrow A - above fuse panel and push out instrument cluster in direction of -
arrow B -.

Fig. 191: Identifying Securing Bracket Of Connectors

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disengage lock on electrical connectors - arrow - and disconnect.

 Remove instrument cluster from instrument panel opening.

Installing

Install in reverse order of removal, noting the following:

 After installation, perform functional test of instrument cluster.

 If instrument cluster is replaced, continue to follow VAS 5051/5052 tester prompts in conjunction with

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OBD program option "Instrument cluster, replacing" --> On Board Diagnostic (OBD), function

Instrument cluster, rear view

NOTE:  Do not disassemble instrument cluster.

 Instrument clusters contain no field serviceable components. All indicator
warning lamps are Light Emitting Diodes (LED).

Fig. 192: Instrument Cluster, Rear View

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Should malfunctions occur, replace complete instrument cluster.

A - 32-pin multi-pin connector, green

B - 32-pin multi-pin connector, blue

Instrument cluster multi-pin connector assignments

Fig. 193: Identifying Multi-Pin Connector 32-Pin, Blue

Courtesy of VOLKSWAGEN UNITED STATES, INC.

32-pin multi-pin connector, blue

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1. Washer fluid low

2. Coolant level low
3. Fuel gauge sensor
4. Coolant temperature
5. Push button circuit 2 Navigation system
6. Push button circuit 3 Navigation system
7. Push button circuit x Telematics
8. Menu switch
9. Vacant
10. Front hood switch
11. Fuel gauge sensor 2
12. Menu switch (Out A)
13. Vacant
14. Vacant
15. Vacant
16. FDR/TCS (= ESP)
17. Convenience CAN-Bus High
18. Convenience CAN-Bus Low
19. Infotainment CAN-Bus Low
20. Infotainment CAN-Bus High
21. Ambient temp. (input)
22. S contact
23. Oil level / oil temperature
24. Self-levelling suspension
25. Menu switch (enter)
26. Vacant
27. Vacant
28. Menu switch (Out B)
29. Vacant
30. Transponder 2
31. Transponder 1
32. Terminal 31 (sensor)

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Fig. 194: Identifying Green 32-Pin Multi-Pin Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

32-pin multi-pin connector, green

1. Terminal 58d
2. Terminal 30
3. Terminal 15
4. Vacant
5. Speedometer (input)
6. Speedometer (output 2)
7. Airbag (inverted)
8. Turn signal (right-side)
9. Brake fluid low
10. Turn signal (left-side)
11. Turn signal (trailer)
12. Powertrain CAN-Bus Low
13. Powertrain CAN-Bus High
14. Terminal 61 (generator charge warning)
15. Vacant
16. Oil pressure 2
17. Terminal 58s
18. Terminal 31 load
19. Terminal 31 load
20. Vacant
21. Speedometer (output 1)
22. ABS warning
23. K wire
24. CAN-Bus drive (display)

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25. Tank flap switch

26. CAN-Bus diagnosis Low
27. CAN-Bus diagnosis (display)
28. CAN-Bus diagnosis High
29. HRC (headlamp range control)
30. Safety belt buckle
31. External buzzer
32. Brake pad wear

Fuel Level Sensor G - front-wheel drive, multi-pin connector assignments

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Preparations

Fuel level sensor is located under the floor covering in the luggage compartment.

 Remove luggage compartment floor lining.

 If necessary, fold right backrest of rear seat bench forwards.

Fig. 195: Unbolting Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows - and remove access panel.

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Fig. 196: Identifying Electrical 4-pin Harness Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully unlock and disconnect 4-pin connector - arrow -.

Fig. 197: Identifying Terminal Assignment Of The 4-Pin Connector On Fuel Gauge Sender
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pin assignment for 4-pin connector at fuel level sensor

1. Fuel pump positive ( + )

2. Sensor to fuel gauge
3. Sensor Ground (GND) ( - )
4. Fuel pump Ground (GND) ( - )

Fuel Level Sensor G , Fuel Level Sensor 2 G169 - quattro, multi-pin connector assignments

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Preparations

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 Remove rear seat bench --> 72 - SEAT - FRAMES .

Fuel Level Sensor G

Fig. 198: Removing Cover Bolts For Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows - and remove right access panel.

Fig. 199: Identifying Electrical 4-pin Harness Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully release and disconnect 4-pin connector - arrow - (right-side).

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Fig. 200: Identifying Terminal Assignment Of The 4-Pin Connector On Fuel Gauge Sender
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assignment of 4-pin connector at fuel level sensor.

1. Fuel pump positive ( + )

2. Sensor to fuel gauge
3. Sensor Ground (GND) ( - )
4. Fuel pump Ground (GND) ( - )

Fuel Level Sensor 2 G169

Fig. 201: Removing Cover Bolts For Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows - and remove left access panel.

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Fig. 202: Disconnecting Electrical Harness Connector At Left Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully release and disconnect 4-pin connector - arrow - (left-side).

Fig. 203: Identifying Terminal Assignment Of The 4-Pin Connector On Fuel Gauge Sender
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assignment of 4-pin connector at fuel level sensor 2

1. Vacant
2. Sensor to fuel gauge
3. Sensor Ground (GND) ( - )
4. Vacant

Engine Coolant Temperature (ECT) Gauge Sensor G2 - 1.8L 4-cylinder Turbo engine, multi-pin connector assignments

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Preparations

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Fig. 204: Removing Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners and remove engine cover - arrows -.

Fig. 205: Disconnecting Connector At Coolant Temperature Sensor G2/G62

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - arrow - at sensor.

Fig. 206: Coolant Temperature Sensor Terminals

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Pin assignment for 4-pin connector at Engine Coolant Temperature (ECT) Gauge Sensor G2 G2

1. Wiring from sensor to instrument cluster (temperature gauge)

2. Ground (GND) ( - )

Engine Coolant Temperature (ECT) Sensor G62 - 2.0L 4-cylinder Turbo FSI engine, multi-pin connector assignments

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Preparations

Location: on rear right of engine.

Fig. 207: Disconnecting Electrical Harness Connector From Engine Coolant Temperature (ECT) Sensor
G62
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection at sensor - 1 -.

Fig. 208: Identifying 2-Pin Electrical Harness Connector & Terminals

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Pin assignment for 2-pin connector on Engine Coolant Temperature (ECT) Sensor G62

1. Wiring from sensor to instrument cluster (temperature gauge)

2. Ground (GND) ( - )

Engine Coolant Temperature (ECT) Gauge Sensor G2 - 3.0L 6-cylinder engine, multi-pin connector assignments

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Preparations

Fig. 209: Removing Rear Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove rear engine cover - arrows -.

Fig. 210: Identifying Holding Plate, Intake Air Hose, Hose & Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bolts for solenoid valve retaining plate - 3 - - arrows -.

 Remove air intake hose - 1 - at Mass Air Flow (MAF) Sensor G70.

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 Remove hose - 4 - at air duct - 2 -.

Fig. 211: Removing Bolt And Disconnect Air Duct At Throttle Valve Control Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bolt - arrow - and pull off air duct - 2 - at throttle valve control module J338.
 Where applicable, remove hose - 1 - at air duct.

NOTE:  For illustration purposes the air duct is shown from the rear with the
engine removed.

Fig. 212: Disconnecting Electrical Harness Connector At Engine Coolant Temperature (ECT) Sensor -
G2-/-G62-
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 2 - at sensor.

NOTE:  Disregard - 1 -.

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Fig. 213: Coolant Temperature Sensor Terminals

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pin assignment for 4-pin connector at Engine Coolant Temperature (ECT) Gauge Sensor G2

1. Wiring from sensor to instrument cluster (temperature gauge)

2. Ground (GND) ( - )

Engine Coolant Temperature (ECT) Sensor G62 - 3.2L 6-cylinder FSI engine, multi-pin connector assignments

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Preparations

Fig. 214: Identifying Front Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove front engine cover - arrows -.

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Fig. 215: Disconnecting Electrical Connector, Retaining Clip And Engine Coolant Temperature (ECT)
Sensor G62
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection at sensor - 2 -.

NOTE:  Disregard - 1 -.

Fig. 216: Identifying 2-Pin Electrical Harness Connector & Terminals

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pin assignment for 2-pin connector on Engine Coolant Temperature (ECT) Sensor G62

1. Ground (GND) ( - )
2. Wiring from sensor to instrument cluster (temperature gauge)

Engine Coolant Temperature (ECT) Sensor G62 - 4.2L 8-cylinder engine (Audi S4), multi-pin connector assignments

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Preparations

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Fig. 217: Removing/Installing Rear Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove rear engine cover - arrows -.

Fig. 218: Identifying Electrical Connection At Sensor

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 - at sensor.

NOTE:  Illustration shows engine removed.

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Fig. 219: Coolant Temperature Sensor Terminals

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pin assignment for 4-pin connector at Engine Coolant Temperature (ECT) Sensor G62 - through 05.05

3 - Ground (GND) ( - )

4 - Wiring from sensor to instrument cluster (temperature gauge)

Fig. 220: Identifying 2-Pin Electrical Harness Connector & Terminals

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pin assignment for 2-pin connector at Engine Coolant Temperature (ECT) Sensor G62 - from 06.05

1. Ground (GND) ( - )
2. Wiring from sensor to instrument cluster (temperature gauge)

Engine Coolant Temperature (ECT) Sensor G62 - 4.2L 8-cylinder engine (Audi RS4), multi-pin connector assignments

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Preparations

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Fig. 221: Removing Quick-Release Fasteners, Screws And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners - 1 - and - 2 - and remove front noise insulation.

Fig. 222: Disconnecting Electrical Connector On Engine Coolant Temperature (ECT) Sensor G62
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 - at sensor.

NOTE:  Engine Coolant Temperature (ECT) Gauge Sensor G62 is accessible from
lower right with engine installed.
 Engine shown removed for clarity.

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Fig. 223: Identifying 2-Pin Electrical Harness Connector & Terminals

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pin assignment for 2-pin connector at Engine Coolant Temperature (ECT) Gauge Sensor G62

1. Wiring from sensor to instrument cluster (temperature gauge)

2. Ground (GND) ( - )

Radio Frequency Controlled Clock Receiver J489 , removing and installing

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

NOTE:  J489 only where applicable.

Removing

 Remove rear bumper cover --> 63 BUMPER .

Fig. 224: Identifying Electrical Connection, Receiver, And Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Disconnect electrical connection - 3 - at receiver - 2 -.

 Remove bolts - 1 - and remove receiver.

Installing

Install in reverse order of removal, noting the following:

 Install rear bumper cover: --> 63 BUMPER .

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92 WINDSHIELD WIPER WASHER SYSTEM

WINDSHIELD WIPER SYSTEM

Windshield wiper system, removing and installing

Special tools, testers and auxiliary items required

Fig. 225: Identifying Pry Lever 80-200

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Removal lever 80-200

Fig. 226: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Removing

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Fig. 227: Identifying Plenum Chamber Cover & Removing Rubber Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove rubber seal of plenum chamber cover in direction of - arrow -.

 Remove plenum chamber cover - 1 - to front.

Wiper arms, removing

 Actuate touch-wipe function and allow wiper motor to move to end position.

Fig. 228: Removing Securing Clips And Cowl

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use screwdriver to pry off caps - 3 -.

 Loosen nuts - 4 - (do not remove).
 Loosen wiper arms - 2 - from wiper shaft by tilting slightly.
 Remove nuts completely and remove wiper arms.

NOTE:  Should wiper arms be difficult to remove, use appropriate puller.

 Remove retaining clips - 1 - and detach cowl panel grille - 5 -.

Wiper assembly, removing

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Fig. 229: Removing Screws And Cover From E-Box In Plenum Chamber
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove cover for electronics box in plenum chamber - arrows -.

Fig. 230: Identifying Wiper Linkage And Wiper Frame

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pry off wiper linkage - 2 - from ball head using lever 80-200.
 Remove crank from wiper motor.
 Unclip pipe/hose guides at wiper frame.
 Remove bolts - arrows - and detach entire wiper frame - 1 -.

 Disconnect electrical connection.

Wiper motor, removing fom frame

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Fig. 231: Identifying Wiper Motor And Wiper Frame

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bolts - arrows - and remove wiper motor from wiper frame.

Installing

Install in reverse order of removal, noting the following:

Fig. 232: Identifying Wiper Motor And Wiper Frame

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Secure wiper motor without crank to wiper frame - arrows -.

 Reconnect electrical connectors at wiper motor.
 Fit wiper motor with wiper frame in vehicle and loosely install bolts.

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Fig. 233: Pressing Wiper Linkage In To Stop And Tightening Bolts In Sequence
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Press wiper linkage in to stop in direction of - arrow - and tighten bolt - 1 -.

 Then tighten bolts - 2 - and - 3 - in sequence.
 Actuate touch-wipe function and allow wiper motor to move to end position.

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Fig. 234: Identifying Crank, Wiper Frame, And Nut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Check and if necessary, align crank - 1 - with wiper frame.

 Angle a = 2 degrees

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 Hold crank in position and hand-tighten nut - 2 - so setting is not altered.

 Then brace crank with an open-end wrench and tighten nut fully.
 Switch on ignition.
 Actuate touch-wipe function and allow wiper motor to move to end position.

 Check that angle - a - is attained; re-align if necessary.

NOTE:  Shown with wiper frame removed for illustration purposes.

 Set wiper blades to park position --> Windshield wiper blade park position,
adjusting.

Tightening torques

Component - fastener Nm
Wiper crank to wiper motor - nut 18
Wiper motor to wiper frame - bolt 9
Wiper frame to plenum chamber - bolt 8

Windshield wiper blade park position, adjusting

Procedure

 Switch on ignition.
 Actuate touch-wipe function and allow wiper motor to move to end position.
 Switch off ignition.

Fig. 235: Checking Windshield Wiper Blade Tips Position

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Position wiper blades on windshield and align as follows:

 Dimension - a - = 24 mm.

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 Dimension - b - = 44 mm.

NOTE:  The figures given here are the distances between wiper blades and cowl
panel grille of plenum chamber at bottom edge of windshield.
 Tighten nuts for wiper arms.
 Switch on ignition.
 Actuate touch-wipe function and allow wiper motor to move to end
position.
 Switch off ignition.
 If necessary, re-align wiper arms and tighten nuts again.

Tightening torque

Component - fastener Nm
Wiper arm - nut 21

Windshield wiper blade - through 10.04, replacing

Removing

 Lift wiper arm off windshield.

Fig. 236: Identifying Linkage, Wiper Blade, And Wiper Arm

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Press release button at linkage - arrow -.

 Remove wiper blade - 2 - from wiper arm - 1 - downwards.

Installing

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Fig. 237: Identifying Wiper Blade And Arm

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 When installing wiper blade - 2 - on drivers side, ensure blade engages in lug and retainer at spoiler
engages in wiper blade.
 Lock wiper blade by pressing release button.

Windshield wiper arm - through 10.04, assembly

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Fig. 238: Windshield Wiper Arm - Through 10.04, Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Wiper blade mount

 For drivers side (with spoiler)

 Removing and installing --> Windshield wiper blade mount - through 10.04, removing and installing

2 - Release button

3 - Spacer

 Removing and installing --> Windshield wiper blade mount - through 10.04, removing and installing

4 - Wiper arm

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Windshield wiper blade mount - through 10.04, removing and installing

Removing

 Lift wiper arm off windshield.

Fig. 239: Identifying Linkage, Wiper Blade, And Wiper Arm

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Press release button at linkage - arrow -.

 Remove wiper blade - 2 - from wiper arm - 1 - downwards.

Fig. 240: Identifying Release Button, And Wiper Arm

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release the retaining lug on release button - arrow 1 -.

 Pivot the release button upwards.
 Pull release button out of wiper arm - arrow 2 -.

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Fig. 241: Pressing Sides Of Wiper Mounting Inwards And Removing Wiper Mounting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Press the sides of wiper mounting - 1 - inwards - arrows -.

 Remove wiper mounting from wiper arm - 2 -.

Fig. 242: Identifying Retaining Lugs, And Wiper Arm

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Press the spacer together at retaining lugs - 1 -.

 Remove spacer from wiper arm - 2 -.

Installing

Install in reverse order of removal.

Windshield wiper blade - from 11.04, replacing

Removing

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Fig. 243: Identifying Retaining Clip, Wiper Arm, And Wiper Blade
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Slide clip - 2 - off wiper arm - 3 - in direction of - arrow -.

 Remove wiper blade - 1 - downwards from wiper arm.

Installing

Fig. 244: Identifying Wiper Blade And Retaining Clip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Insert joint of wiper arm in guide on wiper blade - arrow 1 -. Ensure joint is inserted fully in guide.
 Secure wiper blade by fitting retaining clip - arrow 2 -.

WINDSHIELD WASHER SYSTEM

Washer fluid reservoir - Audi A4 S4, removing and installing

Top section of reservoir, removing

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Fig. 245: Removing Cover In Engine Compartment (Left Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove left engine cover - 1 -.

Fig. 246: Identifying Nut, Bolt, Overflow Hose, And Reservoir

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Where applicable, remove overflow hose - 2 - from reservoir - 3 -.

 Remove nut - 1 - and bolt - 4 -.
 Pull top section of reservoir upwards out of bottom section.

Bottom section of reservoir, removing

 Remove left front wheel.

 Remove left front wheel housing liner --> 66 EXTERIOR EQUIPMENT .

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Fig. 247: Removing Bottom Section Of Reservoir

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bottom section of reservoir - 2 - - arrows -.

 Swivel bottom section of reservoir slightly to rear.

NOTE:  If it is not possible to swivel bottom section of reservoir, remove bolt - 4 -

and detach cross member - 1 -.
 Where applicable, detach overflow hose - 3 - from reservoir section.

Fig. 248: Identifying Electrical Connections, Hose Connector, And Fluid Pipe
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections - 2... 4 -.

 Press release tab and pull off hose connector - 1 -.
 Pull off washer fluid pipe - 5 -.

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 Remove washer fluid reservoir downwards.

Installing

Install in reverse order of removal, noting the following:

NOTE:  Clean thread of bolts from remnants of locking fluid using wire brush.
Then apply locking fluid and fit bolts. Locking fluid.
 Clean tapped holes from remnants of self-locking bolts or locking fluid
(e.g. using a thread tap). Otherwise the bolts can shear off if they have to
be removed again later.
 When installing, ensure that the water hose audibly engages in the
connection on the washer fluid pump.

Fig. 249: Identifying Bolt Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Tighten bolts in sequence - 1... 3 -.

Tightening torques

Component - fastener Nm
self-locking bolt M6 18 1) 2)
Top section of reservoir to body nut 5.5
Bottom section of reservoir to body - screw 7


1) Replace bolt.

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
2) Insert with locking compound; locking compound.

Washer fluid reservoir - Audi RS4, removing and installing

Top section of reservoir, removing

Fig. 250: Removing Cover In Engine Compartment (Left Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove left engine cover - 1 -.

Fig. 251: Identifying Nut, Bolt, Overflow Hose, And Reservoir

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Where applicable, remove overflow hose - 2 - from reservoir - 3 -.

 Remove nut - 1 - and bolt - 4 -.
 Pull top section of reservoir upwards out of bottom section.

Bottom section of reservoir, removing

 Upper part of reservoir removed.

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 Remove left front wheel.

 Remove left front wheel housing liner --> 66 EXTERIOR EQUIPMENT .

Fig. 252: Identifying Screws, Crossbar, Electrical Connection, Washer Fluid Line, And Washer Fluid
Reservoir
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows A -.

 Remove screws - arrows B - and remove crossbar - 4 -.
 Disconnect electrical connection - 1 - and remove washer fluid line - 2 - from retainer.
 Pivot lower part of washer fluid reservoir - 3 - slightly toward rear.

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Fig. 253: Identifying Hose, Clamp, And Electrical Connections

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release clamp and remove hose - 2 -.

 Remove hose - 1 -.
 Disconnect electrical connections - 3 - and - 4 -.
 Remove washer fluid reservoir downward.

Installing

Install in reverse order of removal, observing the following:

NOTE:  Clean screw threads installed with locking compound using a wire brush.
Then insert screws with locking compound. Locking compound.
 Threaded holes that had self-locking screws or screws installed with
locking compound must be cleaned (e.g. with a thread tap). Otherwise
screws may shear off when reinstalled.
 When positioning hose, ensure it engages audibly in washer fluid pump
connection.

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Fig. 254: Identifying Screw Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Tighten screws in sequence - 1 to 5 -.

 Install upper part of reservoir.

Tightening torques

Component - fastener Nm
Upper part of reservoir to self-locking bolt M6 18 1) 2)
Body Nut 5,5
Lower part of washer fluid reservoir to chassis 5,5

1) Replace bolt.


2) Insert with locking compound; locking compound.

Windshield washer spray jets, removing and installing

Removing

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Fig. 255: Unclipping Base Of Spray Jet From Bottom Of Hood

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Unclip base of spray jet (bottom) from front hood - arrow -.

Fig. 256: Identifying Hose, And Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove hose - 1 - from spray jet.

 Where applicable, disconnect electrical connection - 2 -.

Installing

Install in reverse order of removal, noting the following:

 When positioning hose, ensure it engages audibly in spray nozzle connection.

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Fig. 257: Locating Oval Opening For Spray Individual Nozzles

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Place spray nozzles in hood so that oval opening - arrow - for individual spray nozzles face windshield.
 When installing hose, ensure hose audibly engages in the connection on spray jet.

Windshield washer spray jets, adjusting

Special tools, testers and auxiliary items required

Fig. 258: Identifying Adjustment Tool T10127 Equipped With Needle 3125/ 5 A
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Adjusting tool T10127 fitted with needle 3125/5 A

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Fig. 259: Identifying Windshield Dimensions

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Adjustment

NOTE:  The adjustment dimensions indicate the values for a moving vehicle, i.e.
the spray from the jets is slightly offset when the vehicle is stationary.
 Use water-soluble pen to mark the four points on windshield:
 Dimension - a - = 250... 275 mm
 Dimension - b - = 465... 490 mm
 Dimension - c - = 270 415 mm
 Dimension - d - = 140... 225 mm
 Align individual washer jets with these points using adjusting tool.

REAR WINDOW WIPER WASHER SYSTEM

Rear window wiper/washer, assembly

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Fig. 260: Rear Window Wiper/Washer, Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Connecting pipe

 For spray jet

2 - Nut, 12 Nm

3 - Spray jet

 Removing and installing --> Rear window washer spray jet, removing and installing
 Adjusting --> Rear window washer spray jet, adjusting

4 - Cap for rear wiper

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5 - Wiper arm

 Removing and installing --> Rear window wiper arm, removing and installing

6 - Wiper blade

 Replacing --> Rear window wiper blade, replacing

Rear window washer spray jet, removing and installing

Removing

Fig. 261: Identifying Wiper Arm, Spray Jet, And Cap

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully pry apart ends of cap - 3 - and remove from wiper arm - 1 -.
 Carefully pull spray jet - 2 - off connecting pipe.

Installing

Install in reverse order of removal, noting the following:

 Insert spray jet with spray opening pointing into recess on wiper arm.

Rear window washer spray jet, adjusting

Special tools, testers and auxiliary items required

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Fig. 262: Identifying Adjustment Tool T10127 Equipped With Needle 3125/ 5 A
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Adjusting tool T10127 fitted with needle 3125/5 A

Procedure

Fig. 263: Identifying Windshield Wiper Dimensions

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Adjust washer jets using adjusting tool T10127 so that water jets spray rear window at points indicated
above wiper.

 Dimension - a - = approx. 125 mm

 Dimension - b - = approx. 295 mm
 Dimension - c - = approx. 5 mm

Rear window wiper arm, removing and installing

Removing

 Switch on ignition.
 Actuate rear wiper and allow wiper arm to move to end position.

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CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Fig. 264: Identifying Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully pry cap apart slightly - arrows - and lift off.

Fig. 265: Identifying Spray Jets And Hex Head Nuts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully detach spray jet - 2 -.

 Loosen nut - 1 - (do not remove).
 Loosen wiper arms from wiper shaft by tilting slightly, remove nut and remove wiper arm.

Installing

Install in reverse order of removal, noting the following:

 Adjust wiper arm --> Rear window wiper arm park position, adjusting.

Tightening torque

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Component Nm
Nut for wiper arm 12

Rear window wiper arm park position, adjusting

Fig. 266: Identifying Dimensions For Wiper Blade On Rear Window

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Procedure

 Apply wiper arm with wiper blade fitted at wiper shaft and align wiper blade on rear window as follows.

 Dimension - a - = 15... 20 mm

NOTE:  The dimension indicates distance between tip of wiper blade and bottom
edge of window.
 Switch on ignition.
 Actuate rear wiper and allow wiper arm to move to end position.
 Check setting of wiper arm again; correct as necessary.

Tightening torque

Component Nm
Nut for wiper arm 12

Rear window wiper blade, replacing

Removing

 Lift wiper arm off rear window.

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Fig. 267: Identifying Retaining Clips, Wiper Blade, And Wiper Arm
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clips - arrows - using a screwdriver and take wiper blade - 2 - out of wiper arm - 1 -.

Installing

Install in reverse order of removal, noting the following:

 The wiper blade can only be fitted in one position.

 The wiper blade must engage audibly in the wiper arm.

Rear window wiper motor, assembly

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Fig. 268: Rear Window Wiper Motor, Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Nut, 8 Nm

2 - Wiper motor

 Removing and installing --> Rear window wiper motor, removing and installing

3 - Rubber grommet

4 - Washer fluid hose

Rear window wiper motor, removing and installing

Removing

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 Remove wiper arm --> Rear window wiper arm, removing and installing.
 Remove lower rear lid trim --> 70 - INTERIOR TRIM .

Fig. 269: Identifying Electrical Connection, Washer Fluid Hose, And Nuts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 2 -.

 Disconnect washer fluid hose - 1 - from connecting pipe for spray jet.
 Loosen nuts - arrows - and detach wiper motor.

Installing

Install in reverse order of removal, noting the following:

 Carefully insert rubber grommet into hole in rear window.

 Fluid hose must audibly engage in spray jet connection.

 Switch on ignition.
 Actuate rear wiper and allow wiper motor to move to end position.

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

 Install lower rear lid trim --> 70 - INTERIOR TRIM .

 Adjust wiper arm --> Rear window wiper arm park position, adjusting.

Component - fastener Nm
Wiper motor to rear lid - nut 8

Washer fluid reservoir, removing and installing

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NOTE:  The combined windshield washer fluid reservoir for front and rear
windshield washer system is located in engine compartment at front left.
Removing and installing on A4 and S4 --> Washer fluid reservoir - Audi A4
S4, removing and installing. Removing and installing on RS4 --> Washer
fluid reservoir - Audi RS4, removing and installing

HEADLAMP WASHER SYSTEM - THROUGH 10.04

Headlamp washer spray jets, removing and installing

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Removing

 Remove front bumper cover --> 63 BUMPER .

Fig. 270: Pulling Up On Spray Jet Covers At Bumper And Carefully Disengaging Mounts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull cover of spray jet upwards away from bumper cover and carefully disengage retainers - arrow -.

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Fig. 271: Identifying Washer Fluid Hose, And Spray Jet Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release clamp and remove hose - 3 -.

 Remove screws - 1 - and - 2 - and detach spray jet.

Installing

Install in reverse order of removal, noting the following:

 Install front bumper cover --> 63 BUMPER .

Tightening torque

Component - fastener Nm
Spray jet to bumper cover - screw 3

Headlamp washer spray jets, adjusting

NOTE:  Washer jets are pre-set at the factory and do not have to be adjusted
following installation.

Washer fluid reservoir, removing and installing

NOTE:  The washer fluid reservoir supplies both the windshield and the headlamp
washer systems; it is located in the engine compartment (front left).
Removing and installing on A4 and S4 --> Washer fluid reservoir - Audi A4
S4, removing and installing. Removing and installing on RS4 --> Washer
fluid reservoir - Audi RS4, removing and installing.

HEADLAMP WASHER SYSTEM - FROM 11.04

Headlamp washer spray jets, removing and installing

Removing

 Remove front bumper cover --> 63 BUMPER .

NOTE:  To protect the bumper cover, place a cloth under pliers before taking hold
of the spray jet.

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Fig. 272: Pulling Cover Of Spray Jet Upwards Away From Bumper Cover And Carefully Disengaging
Retainers
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull cover - 1 - of spray jet - 2 - upwards away from bumper cover and carefully disengage retainers in
direction of - arrow -.

Fig. 273: Identifying Hose, Spray Jet, And Screws

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release clamp and remove hose - 1 - at spray jet - 2 -.

 Remove screws - arrows - and detach spray jet.

Installing

Install in reverse order of removal, noting the following:

 Install front bumper cover --> 63 BUMPER .

Tightening torque

Component - fastener Nm
Spray jet to bumper cover - screw 3

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Headlamp washer spray jets, adjusting

NOTE:  Washer jets are pre-set at the factory and do not have to be adjusted
following installation.

Washer fluid reservoir, removing and installing

NOTE:  The washer fluid reservoir supplies both the windshield and the headlamp
washer systems; it is located in the engine compartment (front left).
Removing and installing on A4 and S4 --> Washer fluid reservoir - Audi A4
S4, removing and installing. Removing and installing on RS4 --> Washer
fluid reservoir - Audi RS4, removing and installing.

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94 LIGHTS, SWITCHES - EXTERIOR

HALOGEN HEADLAMPS - THROUGH 10.04

General information

Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of
the standard or optional headlamp or lighting system. Always read the owners manual and review applicable
headlamp system functions.

NOTE:  Additional information:

Owners Manual

Self Study Program - Course Number 991103 "2002 Audi A4 Technical Features"

Wiring Diagrams Component Locations

CAUTION: Before beginning repairs on electrical system

 Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

On Board Diagnostic (OBD), functions

Headlamp system functions are controlled by the Vehicle Electrical System Control Module J519 which has On
Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes
(DTC) will be stored in memory.

Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing
and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".

Halogen headlamps, assembly

NOTE:  After performing any repairs or service that could affect headlight aim,
check/adjust aim.

12:18:30 AM
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Fig. 274: Halogen Headlamps, Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Trim cover

2 - Headlamp housing

3 - Vent element

4 - Turn signal/parking lamp bulb

 12 V, 27/7 W
 Orange
 Replacing --> Turn signal/parking lamp bulb, replacing

5 - Bulb holder

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 For turn signal/parking lamp bulb

6 - Housing cover

 For low beam headlamps

7 - Left Low Beam Headlamp M29 , Right Low Beam Headlamp M31 - bulb

 H7 - 12 V, 55 W
 Replacing --> Low Beam Headlamp M29 / M31 - bulb, replacing

8 - Housing cover

 For high beam headlamps

9 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb

 H7 - 12 V, 55 W
 Replacing --> High Beam Headlamp M30 / M32 - bulb, replacing

10 - Screw - 6 Nm

11 - Vent element

12 - Screw - 6 Nm

13 - Stop bolt

 For aligning headlamp housing with body contour

 Must make contact with lock carrier

Headlamps, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Left headlamp

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Fig. 275: Removing Cover In Engine Compartment (Left Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove left engine cover - 1 -.

Right headlamp

Fig. 276: Removing Cover In Engine Compartment (Right Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove applicable right engine cover - 1 -.

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Fig. 277: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
 Remove air duct - 2 -.

Fig. 278: Locating Screws And Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Both sides, continued

 Use adhesive tape to mask area beneath headlamp to prevent damage to paintwork.
 Remove screws - 1 - and - 5 -.
 Loosen screws - 2 - and - 4 - (do not remove).
 Where applicable, remove cable tie.

 Disconnect electrical connection - 3 -.

 Remove headlamp from body towards front.

Installing

Install in reverse order of removal, noting the following:

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Fig. 279: Locating Vent Elements On Underside Of Headlamp

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Check whether both vent elements have been inserted on underside of headlamp - detail -.
 Slide headlamp horizontally onto lower headlamp mounting as far as it will go.

Fig. 280: Locating Screws And Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Position stop screw - 1 - so it makes contact with lock carrier.

 Use stop screw to align headlamp with body contours (gap widths).

NOTE:  Pay attention to area around fender opening when aligning headlamp.
 Tighten screws - 2... 5 -.
 Following installation, check and adjust headlamps if necessary --> 00 -
TECHNICAL DATA .

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Tightening torque

Component - fastener Nm
Headlamp to lock carrier - screw 6

Headlamps, adjusting

Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and
specifications --> 00 - TECHNICAL DATA .

Headlamps, service preparation

The following engine-dependent procedures are required in order to replace certain headlamp bulbs.

Preparation - vehicles with 1.8L 4-cylinder Turbo engine

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Procedure

Fig. 281: Removing Cover In Engine Compartment (Right Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove right engine cover - 1 -.

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Fig. 282: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
 Remove air duct - 2 -.

Fig. 283: Disconnect Wires/Unplug Connectors

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections:

1. at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80

2. at Mass Air Flow (MAF) Sensor G70
3. at Wastegate Bypass Regulator Valve N75

 Disconnect hoses - 4... 7 -.

 Disconnect hose leading to secondary air pump.
 Seat aside wiring.
 Release fasteners at air cleaner housing - 8 -.

 Remove air cleaner housing.

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NOTE:  The vacuum line leading to combination valve for secondary air is clipped
onto the underside of the air intake hose.

Install in reverse order of removal.

Preparation - vehicles with 3.0L 6-cylinder engine

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Procedure

Fig. 284: Removing Cover In Engine Compartment (Right Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove right engine cover - 1 -.

Fig. 285: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.

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 Remove air duct - 2 -.

Fig. 286: Identifying Lines And Air Cleaner Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull off lines and disconnect electrical connections:

1. at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80

2. vacuum hose at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80
3. at Mass Air Flow (MAF) Sensor G70

 Pull off hose connections and set aside lines - 4 - and - 5 -.

 Remove air cleaner housing - arrows -.

Install in reverse order of removal.

Low Beam Headlamp M29 / M31 - bulb, replacing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Left headlamp:

 Remove headlamp --> Headlamps, removing and installing.

Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine:

 Preparation.

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Right headlamp - vehicles with 3.0L 6-cylinder engine:

 Preparation.

Both sides, continued

Fig. 287: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp
Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clip - arrow - and detach housing cover for low beam from headlamp housing.

Fig. 288: Identifying Electrical Connection, Retaining Clip, And Bulb

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 2 - at low beam bulb.

 Disengage retaining clip - 1 - and remove bulb - 3 - from housing.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the

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smallest amount of moisture and/or contaminants from fingers that

evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Insert bulb and secure with retaining clip.

 Secure housing cover with retaining clip.

High Beam Headlamp M30 / M32 - bulb, replacing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Left headlamp

Fig. 289: Removing Cover In Engine Compartment (Left Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove left engine cover - 1 -.

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Fig. 290: Disconnecting Electrical Connections From Retainer And Removing Retainer
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections - 1 - and - 2 - from retainer.

 Unclip retainer for connectors and pull off upwards - arrow -.

Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine:

 Preparation.

Right headlamp - vehicles with 3.0L 6-cylinder engine:

 Preparation.

Fig. 291: Releasing Retaining Clip And Detaching Housing Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Both sides, continued:

 Release retaining clip - arrow - and detach housing cover for high beam headlamp bulb from headlamp
housing.

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Fig. 292: Disconnecting Electrical Connection, Releasing Retaining Clip, And Removing Bulb
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 3 - at high beam headlamp bulb.

 Release retaining clip - 2 - and remove bulb - 1 - from housing.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Secure bulb with retaining clip.

 Secure housing cover with retaining clip.

Turn signal/parking lamp bulb, replacing

Removing

 Remove headlamp --> Headlamps, removing and installing.

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Fig. 293: Identifying Bulb Holder

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Turn bulb holder - arrow - counter-clockwise and remove from housing.

 Pull bulb out of bulb holder.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Fit new bulb in housing.

 Install headlamp Installing.

Headlamp securing lugs, servicing

NOTE:  If headlight securing lugs break due to application of excessive force, it

may still be possible to service headlight in a cost effective manner
(though headlight housing must not be damaged).
 Different repair sets are available for left and right headlight.

Procedure

 Remove headlamp with broken retaining tab --> Headlamps, removing and installing.

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Fig. 294: Exploded View Of Headlamp Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove remains of broken lug - 3 - and - 4 - on headlamp housing.

 Attach lug - 2 - from repair kit to edge of headlight housing and secure it with two screws - 1 -.

Tightening torque

Component Nm
Headlamp to lock carrier 6

HALOGEN HEADLAMPS - FROM 11.04

General information

Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of
the standard or optional headlamp or lighting system. Always read the owners manual and review applicable
system functions.

NOTE:  Additional information:

Owners Manual

Self Study Program - Course Number 991503 "The 2005 Audi A4"

Wiring Diagrams Component Locations

CAUTION: Before beginning repairs on electrical system

 Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

On Board Diagnostic (OBD), functions

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ELECTRICAL Electrical Equipment

Headlamp system functions are controlled by the Vehicle Electrical System Control Module J519 which has On
Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes
(DTC) will be stored in memory.

Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing
and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".

Halogen headlamps, assembly

NOTE:  After performing any repairs or service that could affect headlight aim,
check/adjust aim.

Fig. 295: Halogen Headlamps, Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Headlamp housing

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 Removing and installing --> Headlamps, removing and installing

2 - Screw - 4.5 Nm

3 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb

 H7 - 12 V, 55 W
 Replacing --> High Beam Headlamp M30 / M32 - bulb, replacing

4 - Housing cover

 For high beam/parking lamps

5 - Bulb holder

 For bulb for parking lamps

6 - Left Parking Lamp M1 , Right Parking Lamp M3 - bulb

 12 V, 5 W
 W5W, Longlife - white
 Replacing --> Parking Lamp M1 / M3 - bulb, replacing

7 - Screw - 4.5 Nm

8 - Housing cover

 For low beam headlamps

9 - Left Low Beam Headlamp M29 , Right Low Beam Headlamp M31 - bulb

 H7 - 12 V, 55 W
 Replacing --> Low Beam Headlamp M29 / M31 - bulb, replacing

10 - Bulb holder

 For turn signal lamp bulb

11 - Left Front Turn Signal Lamp M5 , Right Front Turn Signal Lamp M7 - bulb

 12 V, 21 W
 Replacing --> Front Turn Signal Lamp M5 / M7 - bulb, replacing

12 - Trim cover

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Headlamps, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

 Remove front bumper cover --> 63 BUMPER .

Fig. 296: Locating Screws

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screw - 3 -.
 Loosen screws - 1 - and - 2 - (do not remove).
 Remove headlamp from body towards front.
 Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

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Fig. 297: Checking Adjusting Nut Of Adjuster For Freedom Of Movement

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Check adjusting nut - 1 - of adjuster for freedom of movement - arrows -.

 Screw in adjusting nut as far as it will go, but do not tighten.

Fig. 298: Locating Screws

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Insert headlamp and tighten screws - 1... 3 - two complete turns.

 Install front bumper cover --> 63 BUMPER .
 Align headlamp with body contours and front bumper cover (note gap widths).
 Tighten screws in sequence - 2 - , - 1 - and - 3 -.

NOTE:  When screws are tightened the adjusting nut of the adjuster element

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automatically rotates against the mounting point of the headlamp housing

and fixes it in place.
 Check gaps; if necessary, repeat procedure for installing headlamp.
 Following installation, check and adjust headlamps if necessary --> 00 -
TECHNICAL DATA .

Tightening torque

Component - fastener Nm
Headlamp to lock carrier - screw 4.5

Headlamps, adjusting

Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and
specifications --> 00 - TECHNICAL DATA .

Low Beam Headlamp M29 / M31 - bulb, replacing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Fig. 299: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
 Remove air duct - 2 -.

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Fig. 300: Locating Retaining Tab

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining tab - arrow - and detach housing cover from headlamp housing.

Fig. 301: Identifying Bulb, Spring Clips, And Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bulb - 2 - from spring clips - arrows -.

 Disconnect electrical connection - 1 - at low beam bulb.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

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 Insert bulb into housing.

 Position bulb at lower spring clip.
 Push bulb beyond resistance of upper spring clips into housing.
 Reconnect electrical connection and close housing cover.

High Beam Headlamp M30 / M32 - bulb, replacing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Fig. 302: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
 Remove air duct - 2 -.

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Fig. 303: Releasing Retaining Clip And Detaching Housing Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clip - arrow - and detach housing cover for high beam/parking lamps from headlamp
housing.

Fig. 304: Identifying Bulb, Spring Clips, And Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bulb - 1 - from spring clips - arrows -.

 Disconnect electrical connection - 2 - at high beam headlamp bulb.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Insert bulb into housing.

 Position bulb at lower spring clip.
 Push bulb beyond resistance of upper spring clips into housing.
 Plug in connector and close housing cover.

 Secure housing cover with retaining clip.

Parking Lamp M1 / M3 - bulb, replacing

Removing

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 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Fig. 305: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
 Remove air duct - 2 -.

Fig. 306: Releasing Retaining Clip And Detaching Housing Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clip - arrow - and detach housing cover for high beam/parking lamp from headlamp
housing.

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Fig. 307: Identifying Bulb, Spring Clips, And Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove high beam headlamp bulb - 1 - from spring clips - arrows -.

NOTE:  Disregard - 2 -.

Fig. 308: Pulling Bulb Holder From Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull bulb holder - 1 - from housing - arrow -.

 Pull bulb out of bulb holder.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water

12:18:31 AM Page 26
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intrusion will damage headlamp.

 Insert new bulb in bulb holder.

 Press parking lamp bulb holder into reflector until felt to engage.
 Position high beam headlamp bulb at lower spring clip.
 Push high beam headlamp bulb into housing (overcome resistance of upper spring clips).

 Close housing cover.

 Secure housing cover with retaining clip.

Front Turn Signal Lamp M5 / M7 - bulb, replacing

Removing

Left headlamp

 Remove washer fluid reservoir --> Washer fluid reservoir - Audi A4 S4, removing and installing.

Right headlamp

 Lift vehicle.
 Remove right front wheel.

Fig. 309: Loosening Left/Right Wheelhousing Liners In Front Area

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

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 Remove forward portion of wheel housing liner.

Fig. 310: Turning Bulb Holder Counter-Clockwise And Pulling From Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Continuation for all:

 Turn bulb holder - 3 - counter-clockwise - arrow - and pull out from housing.
 Screw bulb out of holder.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing bulb holder, ensure proper seating. Water intrusion
will damage headlamp.

 Fit new bulb in bulb holder.

 Markings - 1 - and - 2 - must be opposite each other when inserting bulb holder into housing.

Left headlamp

 Install washer fluid reservoir --> Washer fluid reservoir - Audi A4 S4, removing and installing.

Right headlamp

 Install wheel housing liner --> 66 EXTERIOR EQUIPMENT .

Headlamp securing lugs, servicing

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NOTE:  If headlight securing lugs break due to application of excessive force, it

may still be possible to service headlight in a cost effective manner
(though headlight housing must not be damaged).
 Different repair sets are available for left and right headlight.

Procedure

 Remove headlamp with broken lug --> Headlamps, removing and installing.
 Remove remains of broken lugs from headlamp housing.

Fig. 311: Locating Lugs, And Screws For Headlamp Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Fit lugs - 2 - and - 3 - from repair kit on headlamp housing and secure with screws - 1 - and - 4 -.

Tightening torque

Component - fastener Nm
Headlamp to lock carrier - screw 4.5

HEADLAMPS WITH HIGH INTENSITY GAS DISCHARGE (HID) LAMPS - THROUGH 10.04

General information

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on

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parts of HID headlamp components marked with yellow "HIGH

VOLTAGE" warning symbols.
 The physical and mechanical properties of HID bulbs are very
sensitive. Internal pressure of HID glass bulb may exceed 100 bar (in
operation). Bulb temperature may exceed 700 degrees Celsius.
 Danger of explosion and burning.

 The control modules for HID lamps must never be operated

(headlamps turned on) without an HID lamp.
 HID bulbs must only be operated (headlamps turned on) when
installed in the headlamp housing.
 Always wear safety glasses and gloves when removing and installing
HID bulb.
 Never look directly at an operating HID bulb. The UV emissions of an
HID bulb are approximately 2.5 times that of a comparable halogen
bulb..

Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of
the standard or optional headlamp or lighting system. Always read the owners manual and review applicable
system functions.

NOTE:  Additional information:

Owners Manual

Self Study Program - Course Number 991103 "2002 Audi A4 Technical Features"

Wiring Diagrams Component Locations

CAUTION: Before beginning repairs on electrical system

 Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

On Board Diagnostic (OBD), functions

Headlamp system functions are controlled by the Vehicle Electrical System Control Module J519 which has On
Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes
(DTC) will be stored in memory.

Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing
and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".

Headlamps with High Intensity Gas Discharge (HID) Lamps, assembly

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NOTE:  After performing any repairs or service that could affect headlight aim,
check/adjust aim.

Fig. 312: Headlamps With High Intensity Gas Discharge (Hid) Lamps, Assembly
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Screw - 1.5 Nm

2 - High intensity gas discharge (HID) lamp control module

 For vehicles through approx. 09.01

 Left High Intensity Gas Discharge (HID) Lamp Control Module J343
 Right High Intensity Gas Discharge (HID) Lamp Control Module J344
 Removing and installing --> High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 -
through approx. 09.01, removing and installing

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3 - Headlamp housing

4 - Vent element

 2x

5 - Turn signal/parking lamp bulb

 12 V, 27/7 W
 Orange
 Replacing --> Turn signal/parking lamp bulb, replacing

6 - Bulb holder

 For turn signal

7 - High intensity gas discharge (HID) low beam headlamp bulb

 Where applicable - vehicles through approx. 09.01

 35 W, D2S
 Replacing --> HID low beam headlamp bulb - through approx. 09.01, replacing

8 - Housing cover

 For low beam headlamps

9 - High intensity gas discharge (HID) low beam headlamp lamp bulb

 Where applicable - vehicles from approx. 09.01

 35 W, D1S
 Replacing --> HID low beam headlamp bulb - from approx. 09.01, replacing

10 - Housing cover

 For high beam headlamps

11 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb

 H7 - 12 V, 55 W
 Replacing --> High Beam Headlamp M30 / M32 - bulb, replacing

12 - Headlamp beam adjustment motor

 Left Headlamp Beam Adjustment Motor V48

 Right Headlamp Beam Adjustment Motor V49

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 Removing and installing --> Headlamp Beam Adjustment Motor V48 / V49, removing and installing

13 - O-ring

 For headlamp beam adjustment motor

14 - 6 Nm

15 - Stop bolt

 For aligning headlamp housing with body contour

 Must make contact with lock carrier

16 - Trim cover

17 - Adapter lead

 For vehicles from approx. 09.01

 Removing and installing --> High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 -
from approx. 09.01, removing and installing

18 - High intensity gas discharge (HID) lamp control module

 For vehicles from approx. 09.01

 Left High Intensity Gas Discharge (HID) Lamp Control Module J343
 Right High Intensity Gas Discharge (HID) Lamp Control Module J344
 Removing and installing --> High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 -
from approx. 09.01, removing and installing

19 - Screw - 1.5 Nm

Headlamps, removing and installing

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

Left headlamp

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Fig. 313: Removing Cover In Engine Compartment (Left Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove left engine cover - 1 -.

Fig. 314: Removing Cover In Engine Compartment (Right Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Right headlamp

 Remove right engine cover - 1 -.

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Fig. 315: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
 Remove air duct - 2 -.

Both sides, continued:

 Use adhesive tape to mask area beneath headlamp to prevent damage to paintwork.

Fig. 316: Locating Screws And Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 1 - and - 5 -.

 Loosen screws - 2 - and - 4 - a few turns but do NOT remove completely.
 Where applicable, cut through cable tie.
 Disconnect electrical connection - 3 -.

 Remove headlamp from body towards front.

Installing

Install in reverse order of removal, noting the following:

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Fig. 317: Locating Vent Elements On Underside Of Headlamp

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Check whether both vent elements have been inserted on underside of headlamp - detail -.
 Slide headlamp horizontally onto lower headlamp mounting as far as it will go.

Fig. 318: Locating Screws And Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Position stop screw - 1 - so that it makes contact with lock carrier.

 Use stop screw to align headlamp with body contours (gap widths).

NOTE:  Pay attention to area around fender panel opening when aligning
headlamp.
 Tighten screws - 2... 5 -.
 Reconnect battery. Required steps Reconnecting.

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 Following installation, check and adjust headlamps if necessary --> 00 -

TECHNICAL DATA .

Tightening torque

Component Nm
Headlamp to lock carrier 6

Headlamps, adjusting

Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and
specifications --> 00 - TECHNICAL DATA .

Headlamps, service preparation

The following engine-dependent procedures are required in order to replace certain headlamp bulbs.

Preparation - vehicles with 1.8L 4-cylinder Turbo engine

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Procedure

Fig. 319: Removing Cover In Engine Compartment (Right Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove right engine cover - 1 -.

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Fig. 320: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
 Remove air duct - 2 -.

Fig. 321: Disconnect Wires/Unplug Connectors

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections:

1. at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80

2. at Mass Air Flow (MAF) Sensor G70
3. at Wastegate Bypass Regulator Valve N75

 Disconnect hoses - 4... 7 -.

 Disconnect hose leading to secondary air pump.
 Set aside wiring.
 Release fasteners at air cleaner housing - 8 -.

 Remove air cleaner housing.

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NOTE:  The vacuum line leading to combination valve for secondary air is clipped
onto the underside of the air intake hose.

Install in reverse order of removal.

Preparation - vehicles with 3.0L 6-cylinder engine

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Procedure

Fig. 322: Removing Cover In Engine Compartment (Right Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove cover (right-side) - 1 - in engine compartment.

Fig. 323: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.

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 Remove air duct - 2 -.

Fig. 324: Identifying Lines And Air Cleaner Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull off lines / disconnect electrical connections:

1. at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80

2. vacuum hose at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80
3. at Mass Air Flow (MAF) Sensor G70

 Pull off hose connections, set aside hoses and remove air cleaner housing - arrows -

NOTE:  Disregard - 4 - and - 5 -.

Install in reverse order of removal.

Preparation - 4.2L 8-cylinder engine

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Procedure

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Fig. 325: Removing Cover In Engine Compartment (Right Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove right engine cover - 1 -.

Fig. 326: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
 Remove air duct - 2 -.

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Fig. 327: Identifying Electrical Harness Connectors, Secondary Air Injection (AIR) Pump Hose, Air
Guide Hose & Mass Air Flow (MAF) Sensor
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 2 - at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1
N80.
 Disconnect electrical connection - 3 - at Mass Air Flow (MAF) Sensor G70.
 Disconnect hose - 1 - to secondary air pump.
 Remove air intake hose - 4 - at Mass Air Flow (MAF) Sensor G70.

 Set aside wiring harness at air cleaner housing.

 Release fastener - arrow - and remove air cleaner housing together with Mass Air Flow (MAF) Sensor
G70.

Install in reverse order of removal.

HID low beam headlamp bulb - through approx. 09.01, replacing

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.
 The physical and mechanical properties of HID bulbs are very
sensitive. Internal pressure of HID glass bulb may exceed 100 bar (in
operation). Bulb temperature may exceed 700 degrees Celsius.
 Danger of explosion and burning.

 The control modules for HID lamps must never be operated

(headlamps turned on) without an HID lamp.
 HID bulbs must only be operated (headlamps turned on) when
installed in the headlamp housing.
 Always wear safety glasses and gloves when removing and installing
HID bulb.
 Never look directly at an operating HID bulb. The UV emissions of an
HID bulb are approximately 2.5 times that of a comparable halogen
bulb..

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

Left headlamp

 Remove headlamp --> Headlamps, removing and installing.

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Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine:

 Preparation.

Right headlamp - vehicles with 3.0L 6-cylinder engine:

 Preparation.

Right headlamp - vehicles with 4.2L 8-cylinder engine:

 Preparation.

Both sides, continued:

Fig. 328: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp
Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clip - arrow - and detach housing cover for low beam from headlamp housing.

Fig. 329: Locating Connector And Retaining Clip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove connector - 1 - at HID headlamp bulb by turning counter-clockwise.

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 Release retaining clip - arrows - and pull HID headlamp bulb from housing.

Faulty HID headlamp bulb disposal --> HID headlamp bulb, disposal

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Insert new HID headlamp bulb in housing.

NOTE:  Heed installation position: lug at top of bulb holder must engage in recess
of HID headlamp bulb.
 Secure HID headlamp bulb with retaining clip.
 Secure housing cover with retaining clip.
 Reconnect battery. Required steps Reconnecting.

HID headlamp bulb, disposal

NOTE:  HID headlamp bulbs contain mercury.

 Faulty HID headlamp bulbs (not covered by new vehicle warranty) may
need to be disposed of as hazardous waste. Always heed state/local
regulations concerning disposal of hazardous waste.

HID low beam headlamp bulb - from approx. 09.01, replacing

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.
 The physical and mechanical properties of HID bulbs are very
sensitive. Internal pressure of HID glass bulb may exceed 100 bar (in
operation). Bulb temperature may exceed 700 degrees Celsius.
 Danger of explosion and burning.

 The control modules for HID lamps must never be operated

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(headlamps turned on) without an HID lamp.

 HID bulbs must only be operated (headlamps turned on) when
installed in the headlamp housing.
 Always wear safety glasses and gloves when removing and installing
HID bulb.
 Never look directly at an operating HID bulb. The UV emissions of an
HID bulb are approximately 2.5 times that of a comparable halogen
bulb..

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

Left headlamp

 Remove headlamp --> Headlamps, removing and installing.

Right headlamp - 1.8L 4-cylinder Turbo engine:

 Preparation.

Right headlamp - 3.0L 6-cylinder engine:

 Preparation.

Right headlamp - 4.2L 8-cylinder engine:

 Preparation.

Both sides, continued:

Fig. 330: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp
Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Release retaining clip - arrow - and detach housing cover for low beam from headlamp housing.

Fig. 331: Identifying Retaining Clip, HID Headlamp Bulb, And Electrical Connection
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clip - 2 - and remove HID headlamp bulb - 3 - from housing.
 Disconnect electrical connection - 1 -.

Faulty HID headlamp bulb disposal --> HID headlamp bulb, disposal

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Insert new HID headlamp bulb in housing.

NOTE:  Heed installation position: lug at top of bulb holder must engage in recess
of HID headlamp bulb.
 Secure HID headlamp bulb with retaining clip.
 Secure housing cover with retaining clip.
 Reconnect battery. Required steps Reconnecting.

HID headlamp bulb, disposal

NOTE:  HID headlamp bulbs contain mercury.

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 Faulty HID headlamp bulbs (not covered by new vehicle warranty) may
need to be disposed of as hazardous waste. Always heed state/local
regulations concerning disposal of hazardous waste.

High Beam Headlamp M30 / M32 - bulb, replacing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Left headlamp

Fig. 332: Removing Cover In Engine Compartment (Left Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove left engine cover - 1 -.

Fig. 333: Disconnecting Electrical Connections From Retainer And Removing Retainer
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Disconnect electrical connectors - 1 - and - 2 - from retainer.

 Unclip retainer for connectors and pull off upwards - arrow -.

Additional preparation:

Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine:

 Remove air cleaner housing.

Right headlamp - vehicles with 3.0L 6-cylinder engine:

 Remove air cleaner housing.

Right headlamp - vehicles with 4.2L 8-cylinder petrol engine:

 Remove air cleaner housing.

Fig. 334: Releasing Retaining Clip And Detaching Housing Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Both sides, continued:

 Release retaining clip - arrow - and detach housing cover for high beam from headlamp housing.

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Fig. 335: Identifying Electrical Connection, Retaining Clip, And Bulb

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 3 - at high beam headlamp bulb.

 Release retaining clip - 2 - and remove bulb - 1 - from housing.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Fit new bulb in housing.

 Secure bulb with retaining clip.
 Secure housing cover with retaining clip.

Turn signal/parking lamp bulb, replacing

Removing

 Remove headlamp --> Headlamps, removing and installing.

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Fig. 336: Identifying Bulb Holder

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Turn bulb holder - arrow - counter-clockwise and pull it from housing.

 Pull bulb out of bulb holder.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing bulb holder, ensure proper seating. Water intrusion
will damage headlamp.

 Fit new bulb in housing.

 Install headlamp Installing.

Headlamp Beam Adjustment Motor V48 / V49, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Left headlamp

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Fig. 337: Removing Cover In Engine Compartment (Left Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove left engine cover - 1 -.

Fig. 338: Disconnecting Electrical Connections From Retainer And Removing Retainer
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections - 1 - and - 2 - from retainer.

 Unclip retainer for connectors and pull off upwards - arrow -.

Additional preparation:

Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine:

 Remove air cleaner housing.

Right headlamp - vehicles with 3.0L 6-cylinder engine

 Remove air cleaner housing.

Right headlamp - vehicles with 4.2L 8-cylinder engine

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 Remove air cleaner housing.

Fig. 339: Releasing Retaining Clip And Detaching Housing Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Both sides, continued:

 Release retaining clip - arrow - and detach housing cover for high beam from headlamp housing.

Fig. 340: Releasing Headlamp Range Control Motor

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release headlamp range control motor: at right-side headlamp by turning counter-clockwise - arrow - ; at
left-side headlamp by turning clockwise.
 Press ball head of actuator shaft downwards out of its mounting by tilting control motor.
 Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

 Start by inserting ball head of actuator shaft in mounting on reflector from below; to do so, pull reflector
to rear.

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 Secure housing cover with retaining clip.

 Following installation, check and adjust headlamps if necessary --> 00 - TECHNICAL DATA .

NOTE:  Headlamps must always be adjusted if the control motors are removed
and installed or replaced.

High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - through approx. 09.01, removing and installing

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.

Removing

 Remove headlamp --> Headlamps, removing and installing.

Fig. 341: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp
Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clip - arrow - and detach housing cover for low beam from headlamp housing.

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Fig. 342: Locating Connector And Retaining Clip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove connector - 1 - at HID headlamp bulb by turning counter-clockwise.

NOTE:  Leave retaining clip - arrows - for HID headlamp bulb in position.

Fig. 343: Identifying Control Module Screws

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove control module from headlamp housing.
 Connector at HID headlamp bulb can then be passed through headlamp housing.

Installing

Install in reverse order of removal, noting the following:

 Secure housing cover with retaining clip.

 Install headlamp Installing.

High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - from approx. 09.01, removing and installing

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CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.

Removing

 Remove headlamp --> Headlamps, removing and installing.

Fig. 344: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp
Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clip - arrow - and detach housing cover for low beam from headlamp housing.

Fig. 345: Identifying Retaining Clip, HID Headlamp Bulb, And Electrical Connection
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clip - 2 - and remove HID headlamp bulb - 3 - from housing.
 Disconnect electrical connection - 1 -.

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Fig. 346: Identifying Control Module Screws

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove control module from headlamp housing.
 Disconnect electrical connections.
 Remove adapter lead for HID headlamp bulb.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Insert HID headlamp bulb in housing.

NOTE:  Heed installation position: lug at top of bulb holder must engage in recess
of HID headlamp bulb.
 Secure HID headlamp bulb with retaining clip.
 Secure housing cover with retaining clip.
 Install headlamp Installing.

Headlamp securing lugs, servicing

NOTE:  If headlight securing lugs break due to application of excessive force, it

may still be possible to service headlight in a cost effective manner
(though headlight housing must not be damaged).

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 Different repair sets are available for left and right headlight.

Procedure

 Remove headlamp with broken lug --> Headlamps, removing and installing.

Fig. 347: Exploded View Of Headlamp Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove remains of broken lug - 3 - and - 4 - at headlamp housing.

 Position retaining tab - 2 - from repair kit at edge of headlamp housing and secure from rear with the two
screws - 1 -.

Tightening torque

Component Nm
Headlamp to lock carrier 6

HEADLAMPS WITH HIGH INTENSITY GAS DISCHARGE HID LAMPS - THROUGH 10.04

General information

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.
 The physical and mechanical properties of HID bulbs are very
sensitive. Internal pressure of HID glass bulb may exceed 100 bar (in
operation). Bulb temperature may exceed 700 degrees Celsius.
 Danger of explosion and burning.

 The control modules for HID lamps must never be operated

(headlamps turned on) without an HID lamp.

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 HID bulbs must only be operated (headlamps turned on) when

installed in the headlamp housing.
 Always wear safety glasses and gloves when removing and installing
HID bulb.
 Never look directly at an operating HID bulb. The UV emissions of an
HID bulb are approximately 2.5 times that of a comparable halogen
bulb..

Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of
the standard or optional headlamp or lighting system. Always read the owners manual and review applicable
system functions.

NOTE:  Additional information:

Owners Manual

Self Study Program - Course Number 991103 "2002 Audi A4 Technical Features"

Wiring Diagrams Component Locations

CAUTION: Before beginning repairs on electrical system

 Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

On Board Diagnostic (OBD), functions

Headlamp system functions are controlled by the Vehicle Electrical System Control Module J519 which has On
Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes
(DTC) will be stored in memory.

Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing
and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".

Headlamps with High Intensity Gas Discharge (HID) "Bi-Xenon" Lamps, assembly

NOTE:  After performing any repairs or service that could affect headlight aim,
check/adjust aim.

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Fig. 348: Headlamps With High Intensity Gas Discharge (HID) "Bi-Xenon" Lamps, Assembly
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Trim cover

2 - Headlamp housing

 Removing and installing --> Headlamps, removing and installing

3 - Turn signal/parking lamp bulb

 12 V, 28/7 W
 Orange
 Replacing --> Turn signal/parking lamp bulb, replacing

4 - Bulb holder

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 For turn signal

5 - Headlamp beam adjustment motor

 Left Headlamp Beam Adjustment Motor V48

 Right Headlamp Beam Adjustment Motor V49
 Removing and installing --> Headlamp Beam Adjustment Motor V48 / V49, removing and installing

6 - High intensity gas discharge (HID) low beam headlamp bulb

 35 W, D1S
 Replacing --> HID low beam headlamp bulb, replacing

7 - Screw - 1.5 Nm

8 - Adapter lead

 Removing and installing --> Adapter cable for HID headlamp bulb control module, removing and
installing

9 - High intensity gas discharge (HID) lamp control module

 Left High-intensity Gas Discharge (HID) Lamp Control Module J343

 Right High-intensity Gas Discharge (HID) Lamp Control Module J344
 Removing and installing --> High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344,
removing and installing

10 - Screw - 1.5 Nm

11 - Housing cover

12 - Cover cap with adjuster wheel

13 - Screw - 1.5 Nm

14 - Adjuster rod

15 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb

 H10 - 12 V, 42 W
 Replacing --> High Beam Headlamp bulb M30 / M32, replacing

16 - Vent element

 1x

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17 - Screw - 6 Nm

18 - Stop bolt

 For aligning headlamp housing with body contour

 Must make contact with lock carrier

Headlamps, removing and installing

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.

Removing

Left headlamp

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

Fig. 349: Removing Cover In Engine Compartment (Left Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove left engine cover - 1 -.

Right headlamp

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Fig. 350: Removing Cover In Engine Compartment (Right Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove right engine cover - 1 -.

Fig. 351: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
 Remove air duct - 2 -.

Both sides, continued:

 Use adhesive tape to mask area beneath headlamp to prevent damage to paintwork.

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Fig. 352: Locating Screws And Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 1 - and - 5 -.

 Loosen screws - 2 - and - 4 - (do not remove).
 Where applicable, remove cable tie.
 Disconnect electrical connection - 3 -.

 Remove headlamp from body towards front.

Installing

Install in reverse order of removal, noting the following:

Fig. 353: Checking Whether Vent Element Has Been Inserted On Underside Of Headlamp
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Check whether vent element has been inserted on underside of headlamp - detail -.
 Slide headlamp horizontally onto lower headlamp mounting as far as it will go.

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Fig. 354: Locating Screws And Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Position stop screw - 1 - so that it makes contact with lock carrier.

 Use stop screw to align headlamp with body contours (gap widths).

NOTE:  Pay attention to area around fender opening when aligning headlamp.
 Tighten screws - 2... 5 -.
 Reconnect battery. Required steps Reconnecting.
 Following installation, check and adjust headlamps if necessary --> 00 -
TECHNICAL DATA .

Tightening torque

Component Nm
Headlamp to lock carrier 6

Headlamps, adjusting

Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and
specifications --> 00 - TECHNICAL DATA .

HID low beam headlamp bulb, replacing

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.
 The physical and mechanical properties of HID bulbs are very
sensitive. Internal pressure of HID glass bulb may exceed 100 bar (in
operation). Bulb temperature may exceed 700 degrees Celsius.
 Danger of explosion and burning.

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 The control modules for HID lamps must never be operated

(headlamps turned on) without an HID lamp.
 HID bulbs must only be operated (headlamps turned on) when
installed in the headlamp housing.
 Always wear safety glasses and gloves when removing and installing
HID bulb.
 Never look directly at an operating HID bulb. The UV emissions of an
HID bulb are approximately 2.5 times that of a comparable halogen
bulb..

Removing

 Remove headlamp --> Headlamps, removing and installing.

Fig. 355: Removing Screws And Retaining Clip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 1 - and - 2 -.

 Release retaining clip - 3 - in direction of - arrow - and detach housing cover from headlamp housing.

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Fig. 356: Identifying Electrical Connection, Retaining Clip, And HID Headlamp Bulb
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 3 -.

 Release retaining clip - 1 - and remove HID headlamp bulb - 2 - from housing.

Faulty HID headlamp bulb disposal --> HID headlamp bulb, disposal

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Insert new HID headlamp bulb in housing.

NOTE:  Heed installation position: lug at top of bulb holder must engage in recess
of HID headlamp bulb.
 Secure HID headlamp bulb with retaining clip.
 Secure housing cover with screws and retaining clip.
 Install headlamp Installing.
 Reconnect battery. Required steps Reconnecting.

HID headlamp bulb, disposal

NOTE:  HID headlamp bulbs contain mercury.

 Faulty HID headlamp bulbs (not covered by new vehicle warranty) may

12:18:32 AM Page 66
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need to be disposed of as hazardous waste. Always heed state/local

regulations concerning disposal of hazardous waste.

High Beam Headlamp bulb M30 / M32, replacing

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.

Removing

 Remove headlamp --> Headlamps, removing and installing.

Fig. 357: Removing Screws And Retaining Clip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 1 - and - 2 -.

 Release retaining clip - 3 - in direction of - arrow - and detach housing cover from headlamp housing.

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Fig. 358: Turning Bulb Clockwise And Removing From Housing/Disconnecting Electrical Connection
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Turn bulb - 1 - clockwise - arrow - and remove from housing.

 Disconnect electrical connection - 2 -.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Fit new bulb in housing.

 Secure bulb by turning in counter-clockwise direction.
 Secure housing cover with screws and retaining clip.
 Install headlamp Installing.

 Reconnect battery. Required steps Reconnecting.

High/Low Beam Switch-Over Solenoid N347 / N348, removing and installing

Left High/Low Beam Switch-Over Solenoid N347 and Right High/Low Beam Switch-Over Solenoid N348 are
integrated with the headlamp housing and cannot be replaced separately in the event of malfunction.

 Replace headlamp --> Headlamps, removing and installing.

Turn signal/parking lamp bulb, replacing

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CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.

Removing

 Remove headlamp --> Headlamps, removing and installing.

Fig. 359: Identifying Bulb Holder

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Turn bulb holder - arrow - counter-clockwise and pull it from housing.

 Pull bulb out of bulb holder.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing bulb holder, ensure proper seating. Water intrusion
will damage headlamp.

 Fit new bulb in housing.

 Install headlamp Installing.

Headlamp Beam Adjustment Motor V48 / V49, removing and installing

CAUTION:  HIGH VOLTAGE!

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 Always disconnect negative ( - ) battery terminal prior to working on

parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.

Removing

 Remove headlamp --> Headlamps, removing and installing.

Fig. 360: Removing Screws And Retaining Clip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 1 - and - 2 -.

 Release retaining clip - 3 - in direction of - arrow - and detach housing cover from headlamp housing.

Fig. 361: Locating Screw And Cover Cap

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Remove screw - 2 -.
 Lift off cover cap - 1 - with adjuster wheel.

Fig. 362: Identifying Adjuster Rod, Electrical Connection, Control Motor, Swivel Ball Head, And
Mounting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove adjuster rod - 3 - upwards out of headlamp housing.

 Disconnect electrical connection - 4 -.
 Turn control motor - 5 - for left-side headlamp in a clockwise direction, for right-side headlamp in
counter-clockwise direction - arrow -.
 Swivel ball head - 2 - of actuator shaft downwards out of mounting - 1 - on reflector.

 Remove headlamp range control motor from headlamp housing.

Installing

Install in reverse order of removal, noting the following:

 Push ball head of actuator shaft into mounting on reflector and turn control motor to limit stop in
installation position.
 Insert adjuster rod into headlamp housing.
 Secure housing cover with screws and retaining clip.
 Install headlamp Installing.

 Reconnect battery. Required steps Reconnecting.

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 Following installation, check and adjust headlamps if necessary --> 00 - TECHNICAL DATA .

NOTE:  Headlamps must always be adjusted if the control motors are removed
and installed or replaced.

Tightening torque

Component Nm
Cover cap with adjuster wheel to headlamp housing 1.5

High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344, removing and installing

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.

Removing

 Remove headlamp --> Headlamps, removing and installing.

Fig. 363: Identifying Screws And Control Module

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove control module - 1 - from housing cover for headlamp housing.

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Fig. 364: Identifying Electrical Connections

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections - 1 - and - 2 -.

Installing

Install in reverse order of removal, noting the following:

 Check gasket between control module for HID headlamp bulb and headlamp housing.
 Install headlamp Installing.
 Reconnect battery. Required steps Reconnecting.

Tightening torque

Component - fastener Nm
Control module to headlamp - screw 1

Adapter cable for HID headlamp bulb control module, removing and installing

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.

Removing

 Remove headlamp --> Headlamps, removing and installing.

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Fig. 365: Removing Screws And Retaining Clip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 1 - and - 2 -.

 Release retaining clip - 3 - in direction of - arrow - and detach housing cover from headlamp housing.

Fig. 366: Identifying Screws And Control Module

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove control module - 1 - from housing cover for headlamp housing.

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Fig. 367: Identifying Electrical Connections

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 -.

NOTE:  Disregard - 2 -.

Fig. 368: Identifying Electrical Connection, Wiring, Adapter Cable, Retainer, And Housing Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 4 - at HID headlamp bulb.

 Remove wiring - 1 - and adapter cable - 3 - from retainer - 2 -.
 Guide adapter cable out of housing cover - 5 -.

Installing

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Install in reverse order of removal, noting the following:

 Insert adapter cable and electrical wiring in retainer.

 Check gasket between control module for gas discharge lamp and headlamp housing.
 Install headlamp Installing.
 Reconnect battery. Required steps Reconnecting.

Tightening torque

Component - fastener Nm
Control module to headlamp - screw 1

Headlamp securing lugs, servicing

NOTE:  If headlight securing lugs break due to application of excessive force, it

may still be possible to service headlight in a cost effective manner
(though headlight housing must not be damaged).
 Different repair sets are available for left and right headlight.

Procedure

 Remove headlamp with broken lug --> Headlamps, removing and installing.

Fig. 369: Exploded View Of Headlamp Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove remains of broken-off lug - 3 - and - 4 - at headlamp housing.

 Position retaining tab - 2 - from repair kit at edge of headlamp housing and secure from rear with the two
screws - 1 -.

Tightening torque

Component Nm

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Headlamp to lock carrier 6

HEADLAMPS WITH HIGH INTENSITY GAS DISCHARGE HID BI-XENON LAMPS - THROUGH
10.04

General information

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.
 The physical and mechanical properties of HID bulbs are very
sensitive. Internal pressure of HID glass bulb may exceed 100 bar (in
operation). Bulb temperature may exceed 700 degrees Celsius.
 Danger of explosion and burning.

 The control modules for HID lamps must never be operated

(headlamps turned on) without an HID lamp.
 HID bulbs must only be operated (headlamps turned on) when
installed in the headlamp housing.
 Always wear safety glasses and gloves when removing and installing
HID bulb.
 Never look directly at an operating HID bulb. The UV emissions of an
HID bulb are approximately 2.5 times that of a comparable halogen
bulb..

Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of
the standard or optional headlamp or lighting system. Always read the owners manual and review applicable
headlamp system functions.

NOTE:  Additional information:

Owners Manual

Self Study Program - Course Number 991503 "The 2005 Audi A4"

Wiring Diagrams Component Locations

CAUTION: Before beginning repairs on electrical system

 Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

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On Board Diagnostic (OBD), functions

Headlamp system functions are controlled by the Vehicle Electrical System Control Module J519 which has On
Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes
(DTC) will be stored in memory.

Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing
and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".

Headlamps with High Intensity Gas Discharge (HID) "Bi-Xenon" Lamps, assembly

NOTE:  After performing any repairs or service that could affect headlight aim,
check/adjust aim.
 Headlamp without adaptive light function (cornering lights) is illustrated.

Fig. 370: Headlamps With High Intensity Gas Discharge (HID) "Bi-Xenon" Lamps, Assembly

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Screw - 1.5 Nm

2 - High intensity gas discharge (HID) lamp control module

 Left High-intensity Gas Discharge (HID) Lamp Control Module J343

 Right High-intensity Gas Discharge (HID) Lamp Control Module J344
 Removing and installing --> High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344,
removing and installing

3 - Headlamp housing

4 - Screw - 4.5 Nm

5 - Housing cover

 For parking/daytime running lamps

6 - Daytime running lamp (DRL) bulb

 12 V, 21 W
 Replacing --> Daytime Running Lamp (DRL) bulb, replacing

7 - Bulb holder

 For daytime running lamp (DRL) bulb

8 - Bulb holder

 For parking lamps

9 - Left Parking Lamp M1 , Right Parking Lamp M3 - bulb

 12 V, 5 W
 Replacing --> Parking Lamp M1 / M3 - bulb, replacing

10 - Screw - 4.5 Nm

11 - Housing cover

 For low beam headlamps

12 - Screw - 1.5 Nm

13 - High intensity gas discharge (HID) lamp

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 35 W, D1S
 Replacing --> HID headlamp bulb, replacing

14 - Bulb holder

 For turn signal bulb

15 - Left Front Turn Signal Lamp M5 , Right Front Turn Signal Lamp M7 - bulb

 12 V, 21 W
 Orange
 Replacing --> Front Turn Signal Lamp M5 / M7 - bulb, replacing

16 - Trim cover

Headlamps, removing and installing

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.

Removing

 Remove front bumper cover --> 63 BUMPER .

 Disconnect battery. Audi A4 S4 --> Battery in engine compartment, disconnecting and reconnecting.
Audi RS4 --> Battery in luggage compartment, disconnecting and connecting.

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Fig. 371: Locating Screws

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screw - 3 -.
 Loosen screws - 1 - and - 2 - (do not remove).
 Remove headlamp from body towards front.
 Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

Fig. 372: Checking Adjusting Nut Of Adjuster For Freedom Of Movement

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Check adjusting nut - 1 - of adjuster for freedom of movement - arrows -.

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 Screw adjusting nut as far as it will go, but do not tighten.

Fig. 373: Locating Screws

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Insert headlamp and screw in screws - 1... 3 - two complete turns.

 Install front bumper cover --> 63 BUMPER .
 Align headlamp with body contours and front bumper cover (note gap widths).
 Tighten screws in sequence - 2 - , - 1 - and - 3 -.

NOTE:  When the screws are tightened the adjusting nut of the adjuster element
automatically rotates against the mounting point of the headlamp housing
and fixes it in place.
 Check gaps; if necessary, repeat procedure for installing headlamp.
 Reconnect battery. Required steps Audi A4 S4 Reconnecting. Required
steps Audi RS4 Connecting
 Following installation, check and adjust headlamps if necessary --> 00 -
TECHNICAL DATA .

Tightening torque

Component - fastener Nm
Headlamp to lock carrier - screw 4.5

Headlamps, adjusting

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Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and
specifications --> 00 - TECHNICAL DATA .

Headlamps, service preparation

The following equipment and engine-dependent procedures are required in order to replace certain headlamp
bulbs.

Upper washer fluid reservoir and power steering fluid reservoir, removing and installing

Procedure

Fig. 374: Identifying Nut, Bolts, Breather Hose, And Washer Fluid Reservoir
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nut - 1 - and bolts - 4 - and - 5 -.

 Remove breather hose - 2 - from top section of washer fluid reservoir - 3 -.
 Remove top section of washer fluid reservoir and move power steering reservoir - 6 - to side with
hydraulic hoses still attached.

Install in reverse order of removal, noting the following:

NOTE:  Clean remnants of locking fluid from bolts using wire brush. Then apply
locking fluid and fit bolts. Locking fluid.
 Clean remnants of locking fluid from inside thread using a thread tap.
Otherwise, bolts may break should they need to be removed again later.

Tightening torque

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Component Nm
Top section of reservoir to body 5.5
Top section of reservoir and power steering reservoir to body 18 1) 2)

1) Replace bolt.


2) Insert with locking compound; locking compound.

Preparation - vehicles with 1.8L 4-cylinder Turbo engine

Procedure

Fig. 375: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
 Remove air duct - 2 -.

Fig. 376: Disconnect Wires/Unplug Connectors

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections:

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1. at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80

2. at Mass Air Flow (MAF) Sensor G70
3. at Wastegate Bypass Regulator Valve N75

 Disconnect hoses - 4... 7 -.

 Disconnect hose to secondary air pump.
 Set aside wiring.
 Release fastener - 8 -.

 Remove air cleaner housing.

NOTE:  The vacuum line leading to combination valve for secondary air is clipped
onto the underside of the air intake hose.

Install in reverse order of removal.

Preparation - vehicles with 2.0L 4-cylinder Turbo FSI engine

Procedure

Fig. 377: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
 Remove air duct - 2 -.

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Fig. 378: Identifying Intake, Mass Air Flow (MAF) Sensor G70 Electrical Harness Connector & Air
Filter Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove air intake hose - 1 - between turbocharger and air cleaner housing.
 Disconnect electrical connection - 2 - at Mass Air Flow (MAF) Sensor G70.
 Pull off clip - 3 - and remove air cleaner housing together with Mass Air Flow (MAF) Sensor G70.

Install in reverse order of removal.

Preparation - vehicles with 3.0L 6-cylinder engine

Procedure

Fig. 379: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
 Remove air duct - 2 -.

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Fig. 380: Identifying Lines And Air Cleaner Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull off lines and disconnect electrical connections:

1. at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80

2. vacuum hose at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80
3. at Mass Air Flow (MAF) Sensor G70

 Pull off hose connections, set aside hoses and remove air cleaner housing - arrows -

NOTE:  Disregard - 4 - and - 5 -.

Install in reverse order of removal.

Preparation - vehicles with 3.2L 6-cylinder FSI engine

Procedure

Fig. 381: Identifying Bolts & Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

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 Remove air duct - 1 - and - 2 -.

Fig. 382: Locating Fastener

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fastener - arrow -.

 Remove air cleaner housing.

Install in reverse order of removal.

Preparation - vehicles with 4.2L 8-cylinder engine (Audi S4)

Procedure

Fig. 383: Removing Cover In Engine Compartment (Right Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove right engine cover - 1 -.

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Fig. 384: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air duct.
 Remove air duct - 2 -.

Fig. 385: Identifying Electrical Harness Connectors, Secondary Air Injection (AIR) Pump Hose, Air
Guide Hose & Mass Air Flow (MAF) Sensor
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 2 - at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1
N80.
 Disconnect electrical connection - 3 - at Mass Air Low (MAF) Sensor G70.
 Disconnect hose - 1 - to secondary air pump.
 Remove air intake hose - 4 - at Mass Air Low (MAF) Sensor G70.

 Set aside wiring harness at air cleaner housing.

 Remove clip - arrow - and remove air cleaner housing together with Mass Air Low (MAF) Sensor G70.

Install in reverse order of removal.

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Preparation - vehicles with 4.2L 8-cylinder FSI engine (Audi RS4)

Procedure

Fig. 386: Pulling Rear Engine Cover Off

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove rear engine cover in direction of - arrows -.

Fig. 387: Identifying Bolts & Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove air duct - 1 - and - 2 -.

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Fig. 388: Identifying Mass Air Flow (MAF) Sensor G70 Electrical Harness Connector, Secondary Air
Injection (Air) Pump Hose, Vacuum Lines & Air Guide Hose
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 4 - for Mass Air Flow (MAF) Sensor G70.
 Remove hose - 5 - to Secondary Air Injection (AIR) pump.
 Remove vacuum hoses - 1 -.
 Remove air guide hose - 3 - at Mass Air Flow (MAF) Sensor.

 Free up wiring harness at air filter housing.

 Remove screws - arrows - and remove upper part of air filter housing.
 Disengage electrical wiring harness bracket at body.
 Remove clip - arrow - and remove air filter housing with Mass Air Flow (MAF) sensor.

NOTE:  Disregard - 6 -.

Install in reverse order of removal.

HID headlamp bulb, replacing

CAUTION:  HIGH VOLTAGE!

 Always disconnect negative ( - ) battery terminal prior to working on
parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.
 The physical and mechanical properties of HID bulbs are very
sensitive. Internal pressure of HID glass bulb may exceed 100 bar (in
operation). Bulb temperature may exceed 700 degrees Celsius.

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 Danger of explosion and burning.

 The control modules for HID lamps must never be operated

(headlamps turned on) without an HID lamp.
 HID bulbs must only be operated (headlamps turned on) when
installed in the headlamp housing.
 Always wear safety glasses and gloves when removing and installing
HID bulb.
 Never look directly at an operating HID bulb. The UV emissions of an
HID bulb are approximately 2.5 times that of a comparable halogen
bulb..

Removing

 Disconnect battery. Audi A4 S4 --> Battery in engine compartment, disconnecting and reconnecting.
Audi RS4 --> Battery in luggage compartment, disconnecting and connecting.

Left headlamp

 Remove top section of washer fluid reservoir and power steering reservoir.

Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine:

 Preparation.

Right headlamp - vehicles with 2.0L 4-cylinder Turbo FSI engine:

 Preparation.

Right headlamp - vehicles with 3.0L 6-cylinder engine

 Preparation.

Right headlamp - vehicles with 3.2L 6-cylinder FSI engine

 Preparation.

Right headlamp - vehicles with 4.2L 8-cylinder engine (Audi S4)

 Preparation.

Right headlamp - vehicles with 4.2L 8-cylinder FSI engine (Audi RS4)

 Preparation.

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Both sides, continued:

Fig. 389: Removing Screws And Cover For Low Beam From Headlamp Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 1 - and - 2 -.

 Remove cover for low beam from headlamp housing - arrow -.

Fig. 390: Identifying Retainers, Electrical Connection, Retaining Clips, And HID Headlamp Bulb
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove electrical wire from retainers - arrow -.

 Disconnect electrical connection - 4 -.
 Release retaining clips - 1 - and - 3 - and remove HID headlamp bulb - 2 - from housing.

Faulty HID headlamp bulb disposal --> HID headlamp bulb, disposal

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the

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smallest amount of moisture and/or contaminants from fingers that

evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Insert new HID headlamp bulb in housing.

NOTE:  Note installation position: the electrical connection must always point
downwards.
 Secure HID headlamp bulb with retaining clips.
 Reconnect battery. Required steps Audi A4 S4 Reconnecting. Required
steps Audi RS4

Tightening torque

Component Nm
Housing cover for low beam to headlamp housing 1.5

HID headlamp bulb, disposal

NOTE:  HID headlamp bulbs contain mercury.

 Faulty HID headlamp bulbs (not covered by new vehicle warranty) may
need to be disposed of as hazardous waste. Always heed state/local
regulations concerning disposal of hazardous waste.

Daytime Running Lamp (DRL) bulb, replacing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Right headlamp

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Fig. 391: Removing Bolts & Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove air ducts - 1 - and - 2 -.

Fig. 392: Releasing Retaining Tab And Detaching Housing Cover For Side Lights From Headlamp
Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Both sides, continued:

 Release retaining tab - arrow - and detach housing cover for side lights from headlamp housing.

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Fig. 393: Turning Bulb Holder Counter-Clockwise And Removing From Headlamp Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Turn bulb holder - 1 - counter-clockwise - arrow - and remove from headlamp housing.
 Screw bulb out of bulb holder.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Fit new bulb in housing.

 Secure bulb holder by turning clockwise.
 Close housing cover.

Parking Lamp M1 / M3 - bulb, replacing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Right headlamp

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Fig. 394: Removing Bolts & Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove air ducts - 1 - and - 2 -.

Fig. 395: Releasing Retaining Tab And Detaching Housing Cover For Side Lights From Headlamp
Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Both sides, continued:

 Release retaining tab - arrow - and detach housing cover for side lights from headlamp housing.

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Fig. 396: Releasing Two Retainer Tabs And Pulling Bulb Holder Out Of Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release the two retainer tabs and pull bulb holder - 1 - out of housing - arrow -.
 Pull bulb for side lights out of bulb holder.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Insert new bulb in bulb holder.

 Close housing cover.

High/Low Beam Switch-Over Solenoid N347 / N348 and Dynamic Cornering Light Motor V318 / V319, removing and
installing

Left High/Low Beam Switch-Over Solenoid N347 , Right High/Low Beam Switch-Over Solenoid N348 , Left
Dynamic Cornering Light Motor V318 and Right Dynamic Cornering Light Motor V319 are integrated with the
headlamp housing and cannot be replaced separately in the event of a fault.

 Replace headlamp --> Headlamps, removing and installing.

Front Turn Signal Lamp M5 / M7 - bulb, replacing

Removing

CAUTION:

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 Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Left headlamp

 Remove washer fluid reservoir --> Washer fluid reservoir - Audi A4 S4, removing and installing.

Right headlamp

 Lift vehicle.
 Remove right front wheel.

Fig. 397: Loosening Left/Right Wheelhousing Liners In Front Area

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove forward portion of wheel housing liner.

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Fig. 398: Turning Bulb Holder Counter-Clockwise And Pulling From Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

All models:

 Turn bulb holder - 3 - counter-clockwise - arrow - and pull from housing.

 Screw bulb out of holder.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Fit new bulb in housing.

 Markings - 1 - and - 2 - must be opposite each other when inserting bulb holder into housing.

Left headlamp

 Install washer fluid reservoir --> Washer fluid reservoir - Audi A4 S4, removing and installing.

Right headlamp

 Install wheel housing liner --> 66 EXTERIOR EQUIPMENT .

High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344, removing and installing

CAUTION:  HIGH VOLTAGE!

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 Always disconnect negative ( - ) battery terminal prior to working on

parts of HID headlamp components marked with yellow "HIGH
VOLTAGE" warning symbols.

Removing

 Remove headlamp.

Fig. 399: Identifying Screws, And Control Module

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove control module - 1 - from headlamp housing.

Fig. 400: Disconnecting Adapter Cable For HID Headlamp Bulb At Control Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect adapter cable - 2 - for HID headlamp bulb at control module - 1 -.

Installing

Install in reverse order of removal, noting the following:

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 Check gasket between control module for HID headlamp bulb and headlamp housing.
 Install headlamp Installing.

Headlamp securing lugs, servicing

NOTE:  If headlight securing lugs break due to application of excessive force, it

may still be possible to service headlight in a cost effective manner
(though headlight housing must not be damaged).
 Different repair sets are available for left and right headlight.

Procedure

 Remove headlamp with broken lugs --> Headlamps, removing and installing.
 Remove remains of broken lugs from headlamp housing.

Fig. 401: Locating Lugs, And Screws For Headlamp Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Fit lugs - 2 - and - 3 - from repair kit on headlamp housing and secure with screws - 1 - and - 4 -.

Tightening torque

Component Nm
Headlamp to lock carrier 6

FOG LAMPS - THROUGH 10.04

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Fog lamp housing, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Audi A4:

Fig. 402: Releasing Catches Using Screwdriver And Removing Air Intake Grille On Left/Right On
Bottom Part Of Bumper
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining hooks - 1... 4 - using a screwdriver - arrow - and pull off air intake grille in bottom
section of bumper.

Audi S4:

Fig. 403: Identifying Screw, Air Intake Grille, And Retaining Clip
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Turn screw - 1 - 90 ° (1/4 turn).

 Remove air intake grille from fog lamp housing in direction of - arrow A -.
 Then push air intake grille in direction of - arrow B - and simultaneously disengage retaining clip - 2 -.
 Remove air intake grille.

All models:

Fig. 404: Identifying Screws For Fog Lamp Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Disengage fog lamp housing and remove.
 Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

 Engage fog lamp housing.

 Check and adjust fog lamps if necessary --> 00 - TECHNICAL DATA .

Tightening torque

Component - fastener Nm
Fog lamp housing to bumper - screw 5

Fog lamp bulb, replacing

Removing

 Remove fog lamp assembly --> Fog lamp housing, removing and installing.

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Fig. 405: Disconnecting Electrical Connection At Bulb And Turning Bulb Counter-Clockwise To Remove
From Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 - at bulb.

 Turn bulb counter-clockwise - arrow - and remove from housing.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Insert bulb and secure by turning in clockwise direction.

 Check and adjust fog lamps if necessary --> 00 - TECHNICAL DATA .

Fog lamps, adjusting

Fog lamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and
specifications --> 00 - TECHNICAL DATA .

FOG LAMPS - FROM 11.04

Fog lamp housing - Audi A4, removing and installing

Removing

 Turn light switch to position "0".

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CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Vehicles without charge air cooler:

Fig. 406: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners - 1 - and - 2 - and remove front noise insulation.

Vehicles with charge air cooler:

 Remove front bumper cover --> 63 BUMPER .

All models:

Fig. 407: Identifying Screws, Electrical Connection, And Fog Lamp Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Disconnect electrical connection - 2 -.
 Remove fog lamp housing - 1 -.

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Installing

Install in reverse order of removal, noting the following:

Vehicles with charge air cooler:

 Install front bumper cover --> 63 BUMPER .

All models:

 Check and adjust fog lamps if necessary --> 00 - TECHNICAL DATA .

Tightening torque

Component - fastener Nm
Fog lamp housing to bumper cover - screw 6

Fog lamp housing - Audi A4 with "S-line" equipment Audi S4, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Fig. 408: Removing Air Intake Grille From Fog Lamp Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove air intake grille from fog lamp housing in direction of - arrows -.

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Fig. 409: Locating Screws For Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Disconnect electrical connection.
 Remove housing from opening.

Installing

Install in reverse order of removal, noting the following:

 Check and adjust fog lamps if necessary --> 00 - TECHNICAL DATA .

Tightening torques

Component - fastener Nm
Fog lamp housing to bumper cover - screw 6

Fog lamp housing - Audi RS4, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Removing

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Fig. 410: Pulling Off Air Inlet Grille In Lower Section Of Bumper Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull off air inlet grille in lower section of bumper cover - arrows -.

Fig. 411: Identifying Screws For Fog Lamp Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Disengage housing and remove from opening.
 Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

 First engage fog lamp housing on inner side of bumper cover.

 Check and adjust fog lamps if necessary --> 00 - TECHNICAL DATA .

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Tightening torques

Component - fastener Nm
Fog lamp housing to bumper cover - screw 6

Fog lamp bulb - Audi A4, replacing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Vehicles with charge air cooler:

 Remove front bumper cover --> 63 BUMPER .

Vehicles without charge air cooler:

Fig. 412: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners - 1 - and - 2 - and remove front noise insulation.

All models:

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Fig. 413: Disconnecting Electrical Connection And Turning Bulb Counter Clockwise To Remove
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 2 -.

 Turn bulb - 1 - counter-clockwise - arrow - and remove from housing.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Insert bulb and secure by turning in clockwise direction.

Vehicles with charge air cooler:

 Install front bumper cover --> 63 BUMPER .

All models:

 Check and adjust fog lamps if necessary --> 00 - TECHNICAL DATA .

Fog lamp bulb - Audi A4 with "S-line" equipment Audi S4, replacing

Removing

 Remove fog lamp housing --> Fog lamp housing - Audi A4 with "S-line" equipment Audi S4,
removing and installing.

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Fig. 414: Disconnecting Electrical Connection At Bulb And Turning Bulb Counter-Clockwise To Remove
From Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 -.

 Rotate bulb counter-clockwise - arrow - and remove from housing.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Insert bulb and secure by turning in clockwise direction.

 Check and adjust fog lamps if necessary --> 00 - TECHNICAL DATA .

Fog lamp bulb - Audi RS4, replacing

Removing

 Remove housing --> Fog lamp housing - Audi RS4, removing and installing

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Fig. 415: Disconnecting Electrical Connection At Bulb And Turning Bulb Counter-Clockwise To Remove
From Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 - at bulb.

 Rotate bulb holder counterclockwise - arrow - and remove from housing.

Installing

Install in reverse order of removal, noting the following:

CAUTION:  Do not touch glass portion of bulb with bare hands. Even the
smallest amount of moisture and/or contaminants from fingers that
evaporates on the bulb during operation can cause the glass to cloud
over.
 When installing housing cover, ensure proper seating. Water
intrusion will damage headlamp.

 Insert bulb and secure by turning in clockwise direction.

 Check and adjust fog lamps if necessary --> 00 - TECHNICAL DATA .

Fog lamps, adjusting

Fog lamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and
specifications --> 00 - TECHNICAL DATA .

SIDE MOUNTED TURN SIGNALS

Side mounted turn signals, removing and installing

Removing

 Turn light switch to position "0".

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CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Fig. 416: Pushing Turn Signal Light/Housing Against Retainer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Press turn signal housing towards front of vehicle against retainer tab - arrow - and remove carefully
from fender opening.
 Disconnect electrical connection.

Installing

Install in reverse order of removal.

REAR LIGHTS - THROUGH 10.04

Rear lights - Sedan, assembly

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Fig. 417: Rear Lights - Sedan, Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Taillamp bulb

 12 V, 5 W

2 - Brake/taillamp bulb

 12 V, 21/5 W

3 - Clip nut

 2x

4 - Electrical connector

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5 - Retainer

 Replace if seal is damaged

6 - Nut - 12 Nm

7 - O-ring

 Replace if damaged

8 - Bolt - 6 Nm

9 - Turn signal lamp bulb

 12 V, 21 W
 Orange

10 - Backup lamp bulb

 12 V, 21 W

11 - Bulb holder

12 - Rear fog lamp bulb (where applicable)

 12 V, 21 W

13 - Housing

Rear light/bulb carrier - Sedan, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

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Fig. 418: Folding Pre-Punched Area Of Luggage Compartment And Removing Screw
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Fold pre-punched area - 1 - of luggage compartment lining forwards.

 Remove screw - 3 -.
 Swivel rear light outwards, and at the same time disengage retaining pins from body.
 Disconnect electrical connection at bulb carrier.

Fig. 419: Pressing Retaining Clips Together To Take Bulb Carrier Out Of Rear Light
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Press retaining clips together - arrows - and take bulb carrier out of rear light.
 Turn bulbs to remove them from their holders.

Installing

Install in reverse order of removal, noting the following:

NOTE:  Ensure seal between body and rear light housing seals completely.
 Fit rear light in position on body and press retaining pins into holes.

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Fig. 420: Folding Pre-Punched Area Of Luggage Compartment And Removing Screw
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Tighten screw - 3 -.

NOTE:  After loosening nut - 2 - , rear light can be aligned with body contours
(uniform gap widths).

Tightening torques

Component - fastener Nm
Rear light to body - nut 12
Rear light to body - screw 6

Rear lights - Avant, assembly

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Fig. 421: Rear Lights - Avant, Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bulb holder

2 - Clip nut

 2x

3 - Electrical connector

4 - Retainer

 Replace if seal is damaged

5 - Nut - 12 Nm

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6 - O-ring

 Replace if damaged

7 - Bolt - 6 Nm

8 - Rear fog lamp bulb (where applicable)

 12 V, 21 W

9 - Turn signal lamp bulb

 12 V, 21 W
 Orange

10 - Backup lamp bulb

 12 V, 21 W

11 - Brake/taillamp bulb

 12 V, 21/5 W

12 - Housing

Rear light/bulb carrier - Avant, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

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Fig. 422: Removing Plug From Luggage Compartment Lining

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove plug - arrow - from luggage compartment lining.

Fig. 423: Locating Screw

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screw - 1 -.
 Swivel rear light outwards, and at the same time disengage retaining pins from body.
 Disconnect electrical connection at bulb carrier.

Fig. 424: Pressing Apart Retaining Clips And Taking Bulb Carrier Out Of Rear Light
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Press apart retaining clips - arrows - and take bulb carrier out of rear light.
 Turn bulbs to remove them from their holders.

Installing

Install in reverse order of removal, noting the following:

NOTE:

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 Ensure seal between body and rear light housing seals completely.
 Fit rear light in position on body and press retaining pins into holes.

Fig. 425: Locating Screw

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Tighten screw - 1 -.

NOTE:  After loosening nut - 2 - , rear light can be aligned with body contours
(uniform gap widths).

Tightening torques

Component - fastener Nm
Rear light to body - nut 12
Rear light to body - screw 6

REAR LIGHTS - FROM 11.04

Rear lights in rear fender - Sedan, assembly

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Fig. 426: Rear Lights In Rear Fender - Sedan, Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Turn signal lamp bulb

 12 V, 21 W

2 - Brake/taillamp bulb

 12 V, 21 W

3 - Clip nut

 2x

4 - Electrical connector

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5 - Bolt - 3.5 Nm

 With hex socket (17 mm)

6 - Bulb holder

 Removing and installing --> Rear light/bulb carrier in rear fender - Sedan, removing and installing

7 - Taillamp bulb

 12 V, 21 W

8 - Backup lamp bulb

 12 V, 21 W

9 - Housing

 Removing and installing --> Rear light/bulb carrier in rear fender - Sedan, removing and installing

Rear light/bulb carrier in rear fender - Sedan, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Fig. 427: Identifying Pre-punched Area Of Luggage Compartment Lining, Fastener, And Rear Light
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Fold pre-punched area - 2 - of luggage compartment lining forwards.

 Remove fastener - 1 - (17 mm hex socket ).

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 Swivel rear light outwards - arrow - , and at the same time disengage retaining pins from body.
 Disconnect electrical connection at bulb carrier.

Fig. 428: Pressing Together Retaining Tabs And Removing Bulb Carrier From Rear Light
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Press together retaining tabs - arrows - and remove bulb carrier - 1 - from rear light.
 Turn bulbs to remove them from their holders.

Installing

Install in reverse order of removal, noting the following:

NOTE:  Ensure seal between body and rear light housing seals completely.
 Fit rear light in position on body and press retaining pins into holes.

Tightening torque

Component - fastener Nm
Rear light to body - screw 3.5

Rear lights in rear lid - Sedan, assembly

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Fig. 429: Rear Lights In Rear Lid - Sedan, Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Housing

 Removing and installing --> Rear light/bulb carrier in rear lid - Sedan, removing and installing

2 - Taillamp/rear fog lamp bulb

 12 V, 21 W

3 - Bulb holder

 For taillamp/rear fog lamp bulb

 Removing and installing --> Taillamp/rear fog lamp bulb, replacing

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4 - Electrical connector

5 - Nut - 3.5 Nm

6 - Retainer

 For securing housing to rear lid

Rear light/bulb carrier in rear lid - Sedan, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Fig. 430: Unclipping Plug From Luggage Compartment Trim Using A Small Screwdriver
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Unclip plug - 1 - from luggage compartment trim - arrow - using a small screwdriver.

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Fig. 431: Identifying Nut, Retainer, And Inner Rear Light

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nut - 3 - and remove retainer - 2 -.

 Press inner rear light - 1 - towards - arrow - (working from inside of rear lid) until light can be removed
from the outside.
 Disconnect electrical connection at bulb carrier.

Installing

Install in reverse order of removal, noting the following:

NOTE:  Ensure seal between body and rear light housing seals completely.
 Position inner rear light at outer edge of rear lid.
 Push on retainer at stud for inner rear light and tighten nut.

NOTE:  As the nut is tightened the retainer becomes wedged at the inner rear light
and the rear lid.
 Clip plug into luggage compartment lining.

Tightening torque

Component - fastener Nm
Inner rear light to body - nut 3.5

Taillamp/rear fog lamp bulb, replacing

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Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Fig. 432: Unclipping Plug From Luggage Compartment Trim Using A Small Screwdriver
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Unclip plug - 1 - from luggage compartment trim - arrow - using a small screwdriver.

Fig. 433: Releasing Retaining Tab To Remove Bulb Holder

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining tab - arrow - and remove bulb holder - 1 -.

 Twist and remove bulb from bulb holder.

Installing

Install in reverse order of removal.

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Rear lights in rear fender - Avant, assembly

Fig. 434: Rear Lights In Rear Fender - Avant, Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Turn signal lamp bulb

 12 V, 21 W

2 - Electrical connector

3 - Clip nut

 2x

4 - Bolt - 3.5 Nm

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 With hex socket (17 mm)

5 - Bulb holder

 Removing and installing --> Rear light/bulb carrier in rear fender - Avant, removing and installing

6 - Brake/taillamp bulb

 12 V, 21 W

7 - Backup lamp bulb

 12 V, 21 W

8 - Housing

 Removing and installing --> Rear light/bulb carrier in rear fender - Avant, removing and installing

Rear light/bulb carrier in rear fender - Avant, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Fig. 435: Unclipping Plug From Luggage Compartment Trim Using A Screwdriver
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Unclip plug - 1 - from luggage compartment trim - arrow - using a screwdriver.

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Fig. 436: Identifying Screw And Rear Light

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screw - 2 -.
 Swivel rear light - 1 - outwards - arrow - , and at the same time disengage retaining pins from body.
 Disconnect electrical connection at bulb carrier.

Fig. 437: Pressing Apart Retaining Tabs And Removing Bulb Carrier From Rear Light
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Press apart retaining tabs - arrows - and remove bulb carrier - 1 - from rear light.
 Turn bulbs to remove them from their holders.

Installing

Install in reverse order of removal, noting the following:

NOTE:  Ensure seal between body and rear light housing seals completely.
 Fit rear light in position on body and press retaining pins into holes.
 Tighten screw.

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Tightening torque

Component - fastener Nm
Rear light to body - nut 3.5

Rear lights in rear lid - Avant, assembly

Fig. 438: Rear Lights In Rear Lid - Avant, Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Housing

 Removing and installing --> Rear light/bulb carrier in rear lid - Avant, removing and installing

2 - Taillamp bulb

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 12 V, 21 W

3 - Electrical connector

4 - Nut - 3.5 Nm

5 - Retainer

 For securing housing to rear lid

6 - Bulb holder

 For tail light/rear Fog lamp bulb

 Removing and installing --> Taillamp/rear fog lamp bulb, removing and installing

7 - Taillamp/rear fog lamp bulb

 12 V, 21 W

8 - Nut - 3.5 Nm

9 - Retainer bracket

 For securing bulb holder and housing to rear lid

Rear light/bulb carrier in rear lid - Avant, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

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Fig. 439: Unclipping Plug From Luggage Compartment Trim

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Unclip plug - 1 - from luggage compartment trim - arrow - using a small screwdriver.

Fig. 440: Identifying Nuts, Bulb Holder, And Rear Light

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nut - 2 - and remove retainer bracket and bulb holder - 3 -.

 Remove nut - 4 - and remove inner rear light - 1 - from outside in direction of - arrow -.
 Pull the retainer - 5 - out of body opening.

Tightening torques

Component - fastener Nm
Retainer to housing - nut 3.5
Retainer bracket to housing - nut 3.5

Taillamp/rear fog lamp bulb, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

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Fig. 441: Unclipping Plug From Luggage Compartment Trim

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Unclip plug - 1 - from luggage compartment trim - arrow - using a small screwdriver.

Fig. 442: Identifying Nut, Bulb Holder, And Retaining Tabs

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nut - 1 - and detach retainer bracket.

 Remove bulb holder - 2 - from housing (press apart retaining tabs - arrows - ).
 Screw bulb out of bulb holder.

Installing

Install in reverse order of removal, noting the following:

 Insert new bulb in bulb holder.

Tightening torque

Component - fastener Nm
Retainer bracket to housing - nut 3.5

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HIGH-MOUNT BRAKE LAMP - THROUGH 10.04

High-mount brake lamp - Sedan, removing and installing

Removing

NOTE:  High-mount brake lamp is accessible from luggage compartment via panel
opening below rear shelf.
 Complete high-mount brake lamp must be replaced if LEDs are
inoperative.
 Do not press brake pedal.

Fig. 443: Identifying Electrical Connection, High-Mount Brake Lamp, And Retaining Clips
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 - at high-mount brake lamp - 2 -.

 Pry off retaining clips in direction of - arrows -.
 Pull high-mount brake lamp downwards out of opening.

Installing

Install in reverse order of removal.

High-mount brake lamp - Avant, removing and installing

NOTE:  Complete high-mount brake lamp must be replaced if LEDs are

inoperative.

Special tools, testers and auxiliary items required

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Fig. 444: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hook 3370

Removing

 Do not press brake pedal.

Fig. 445: Releasing Retaining Rail Of Spring Tabs Towards Right By Pressing Screwdriver Handle Left
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove upper rear lid trim --> 70 - INTERIOR TRIM .

 Insert screwdriver - 1 - into hole in rear lid through which wire is routed to high-mount brake lamp.
 Release retaining rail - 2 - of spring tabs towards right - arrow in detail view - by pressing screwdriver
handle firmly to left - arrow -.

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Fig. 446: Identifying High-Mount Brake Lamp And Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Starting on the right, use hook 3370 to pull high-mount brake lamp - 2 - out of rear lid opening - arrow -.
 Disconnect electrical connection - 1 -.
 Remove fastening elements for high-mount brake lamp (5x) out of rear lid.

Installing

Install in reverse order of removal, noting the following:

Fig. 447: Identifying Lug, Spring Clip, Catches, Housing Guides, And Retaining Rail
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Position spring clips on high-mount brake lamp housing such that lug - 2 - faces recess on spring clip - 3 -
.

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 Ensure spring clip catches - 4 - engage in guides - 5 - on housing.

 Position retaining rail - 1 - onto housing and lock in direction of - arrow -.

 The spring clips are locked in place by the retaining rail.

 Connect electrical connector and push high-mount brake lamp into rear lid opening until it engages
audibly.

HIGH-MOUNT BRAKE LAMP - FROM 11.04

High-mount brake lamp - Sedan, removing and installing

NOTE:  High-mount brake lamp is accessible from luggage compartment via panel
opening below rear shelf.
 Complete high-mount brake lamp must be replaced if LEDs are
inoperative.

Removing

 Do not press brake pedal.

Fig. 448: Identifying Electrical Connection, High-Mount Brake Lamp, And Retaining Clips
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 - at high-mount brake lamp - 2 -.

 Release retaining clips - 3 - in direction of - arrow -.
 Pull high-mount brake lamp downwards out of opening.

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Installing

Install in reverse order of removal.

High-mount brake lamp - Avant, removing and installing

NOTE:  Complete high-mount brake lamp must be replaced if LEDs are

inoperative.

Special tools, testers and auxiliary items required

Fig. 449: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hook 3370

Removing

 Do not press brake pedal.

 Remove upper rear lid trim --> 70 - INTERIOR TRIM .

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Fig. 450: Releasing Retaining Rail Of Spring Tabs Towards Right By Pressing Screwdriver Handle Left
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Insert screwdriver - 1 - into hole in rear lid through which wire is routed to high-mount brake lamp.
 Release retaining rail - 2 - of spring tabs towards right - arrow in detail view - by pressing screwdriver
handle firmly to left - arrow -.

Fig. 451: Identifying High-Mount Brake Lamp And Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Starting on the right, use hook 3370 to pull high-mount brake lamp - 2 - out of rear lid opening - arrow -.
 Disconnect electrical connection - 1 -.
 Remove fastening elements for high-mount brake lamp (4x) out of rear lid.

Installing

Install in reverse order of removal, noting the following:

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Fig. 452: Identifying Lug, Spring Clip, Catches, Housing Guides, And Retaining Rail
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Position spring clips on high-mount brake lamp housing such that lug - 2 - faces recess on spring clip - 3 -
.
 Ensure spring clip catches - 4 - engage in the guides - 5 - on the housing.
 Position retaining rail - 1 - onto housing and lock in direction of - arrow -.

 The spring clips are locked in place by the retaining rail.

 Connect electrical connector and push high-mount brake lamp into rear lid opening until it engages
audibly.

LICENSE PLATE LAMP

License plate lamp, removing and installing

Removing

 Turn light switch to position "0".

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

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Fig. 453: Identifying Bolt In Handle Recess

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screw - arrow - in handle trim.

 Lever bulb holder out of handle trim.
 Remove bulb (12 V, 5 W) from bulb holder.

Installing

Install in reverse order of removal.

STEERING COLUMN SWITCH MODULE

General information

The steering column switches, spiral spring and Steering Angle Sensor G85 are integrated into a single
assembly (module) along with the Steering Column Electronic Systems Control Module J527.

Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of
the steering column electronics. Always read the owners manual and review applicable system functions.

NOTE:  Additional information:

Owners Manual

Self Study Program - Course Number 991103 "2002 Audi A4 Technical Features"

Self Study Program - Course Number 991503 "The 2005 Audi A4"

Wiring Diagrams Component Locations

On Board Diagnostic (OBD), function

The Steering Column Electronic Systems Control Module J527 is controlled by an internal microprocessor with

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On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble
Codes (DTC) will be stored in memory.

Troubleshoot steering column electronics malfunctions by performing OBD program with VAS 5051 Vehicle
Diagnostic Testing and Information system or VAS 5052 Vehicle Testing and Service System.

Steering column switch module, assembly

Fig. 454: Steering Column Switch Module (SCSM), Assembly Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Spiral spring

CAUTION: Position of spiral spring must not be changed once removed.

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 Removing and installing --> Spiral spring, removing and installing

2 - Steering Angle Sensor G85

 Removing and installing --> Steering Angle Sensor G85 , removing and installing

3 - Socket head bolt

4 - Cruise Control Switch E45

 Removing and installing --> Cruise Control Switch E45 , removing and installing

5 - Socket head bolt

6 - Turn Signal Switch E2

 Removing and installing --> Turn Signal Switch E2 , removing and installing

7 - Retaining clip

8 - Steering Column Electronic Systems Control Module J527

 Removing and installing --> Steering Column Electronics Systems Control Module J527 , removing
and installing
 Multi-pin connector assignments --> Steering Column Electronics Systems Control Module J527 ,
front multi-pin connector assignments

9 - Clamping bolt - 3 Nm

10 - Windshield Wiper/Washer Switch E22

 Removing and installing --> Windshield Wiper/Washer Switch E22 , removing and installing

11 - Socket head bolt

Steering column switch module, removing and installing

Special tools, testers and auxiliary items required

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Fig. 455: Torx Screwdriver T8 T 40056

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Special screwdriver T8 T40056 or equivalent "Torx - 8"

Removing

NOTE:  Should any steering column switches require replacement, follow

applicable component "Replacement" procedure using VAS 5051/5051 in
operating mode "Guided Fault Finding".
 Move steering wheel down and to rear as far as possible; make use of the
full range of the steering column adjuster.

CAUTION: Special safety precautions apply to vehicles equipped with airbags. Heed
all WARNINGS pertaining to airbag servicing --> 69 - PASSENGER
PROTECTION - AIRBAGS, SEAT BELTS

 Remove airbag and steering wheel --> 69 - PASSENGER PROTECTION - AIRBAGS, SEAT
BELTS .

Fig. 456: Identifying Ground Down Torx Screwdriver T8 T40056 Shoulder

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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NOTE:  Due to manufacturing tolerances, it may not be possible to insert Special

Screwdriver T8 T40056 all the way into access hole in switch module. In
these cases, grind down shoulder of screwdriver in areas indicated -
arrows -.

Fig. 457: Identifying Screws, Hex Socket Head Bolt, Trim Cover, And Upper Steering Column Trim
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use Special Screwdriver T8 T40056 to remove screws - 4 - and - 5 -.

 Remove hex socket head bolt - 6 -.
 Release trim cover - 1 - on upper steering column trim - 2 - using a small screwdriver - arrows A and B -
.


 Separate upper trim - 2 - from lower trim - 3 - and remove upper trim.
 Remove release lever for steering column adjustment - 7 - and guide out lower trim.

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Fig. 458: Identifying Screw And Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screw - 2 -.

CAUTION: Before disconnecting electrical connections at module, discharge any

static electricity by briefly grasping hold of door striker plate or similar,
grounded article on vehicle.

 Disconnect electrical connections - 1 - and - 3 -.

 Disconnect electrical connection - 4 -.

Fig. 459: Disengage Connector Lock To Release Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disengage connector lock - 1 - in direction of - arrow - in order to release connector - 2 -.

 Carefully remove steering column switch module.

Installing

Install in reverse order of removal, noting the following:

 Ensure all fasteners and electrical connectors are properly connected and locked into place.

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 Insert upper steering column trim in hooks for bottom trim, press both sections together and tighten
screws.
 Install steering wheel and drivers airbag --> 69 - PASSENGER PROTECTION - AIRBAGS, SEAT
BELTS .

Tightening torques

Component - fastener Nm
Steering column switch module - bolt 3
Trim for steering column switch - screw 1

Spiral spring, removing and installing

Special tools, testers and auxiliary items required

Fig. 460: Torx Screwdriver T8 T 40056

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Special Screwdriver T8 T40056 or equivalent "Torx - 8"

Removing

CAUTION:  Ensure steering is in straight ahead and centered prior to removing

spiral spring.
 Position of spiral spring must not be changed once removed.

 Move steering wheel down and to rear as far as possible; make use of the full range of the steering
column adjuster.

CAUTION: Special safety precautions apply to vehicles equipped with airbags. Heed
all WARNINGS pertaining to airbag servicing --> 69 - PASSENGER
PROTECTION - AIRBAGS, SEAT BELTS

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 Remove airbag and steering wheel --> 69 - PASSENGER PROTECTION - AIRBAGS, SEAT
BELTS .

Fig. 461: Identifying Ground Down Torx Screwdriver T8 T40056 Shoulder

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:  Due to manufacturing tolerances, it may not be possible to insert Special

Screwdriver T8 T40056 all the way into access hole in switch module. In
these cases, grind down shoulder of screwdriver in areas indicated -
arrows -.

Fig. 462: Identifying Screws, Hex Socket Head Bolt, Trim Cover, And Upper Steering Column Trim
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use Special Screwdriver T8 T40056 to remove screws - 4 - and - 5 -.

 Remove hex socket head bolt - 6 -.

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 Release trim cover - 1 - on upper steering column trim - 2 - using a small screwdriver - arrows A and B -
.


 Separate upper trim - 2 - from lower trim - 3 - and remove upper trim.
 Remove release lever for steering column adjustment - 7 - and guide out lower trim.
 Disconnect upper electrical connection at spiral spring.

Fig. 463: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully release clip fasteners - arrows - and remove spiral spring - 1 - from steering column switch
module.

NOTE:  Steering column switch module shown removed for illustration purposes.

Installing

Install in reverse order of removal, noting the following:

 Ensure all fasteners and electrical connectors are properly connected and locked into place.
 Insert upper steering column trim into bottom trim, press both sections together and tighten screws.
 Install steering wheel and airbag --> 69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS .

Tightening torques

Component - fastener Nm
Steering column switch module - bolt 3
Trim for steering column switch - screw 1

Steering Angle Sensor G85 , removing and installing

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NOTE:  Should the Steering Angle Sensor G85 require replacement, follow
applicable component "Replacement" as well as "zero - calibrate"
procedure using VAS 5051/5051 in operating mode "Guided Fault Finding".

Removing

 Remove spiral spring --> Spiral spring, removing and installing.

Fig. 464: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control
Module J527
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove Steering Angle Sensor G85 - 1 - from Steering Column Electronic Systems Control Module J527
in direction of - arrow -.

Installing

Install in reverse order of removal, noting the following:

 Perform "zero - calibrate" procedure using VAS 505/5052 in operating mode "Guided Fault Finding".

Steering Column Electronics Systems Control Module J527 , removing and installing

Removing

NOTE:  Should the Steering Column Electronic Systems Control Module J527
require replacement, follow applicable component "Replacement"
procedure using VAS 5051/5051 in operating mode "Guided Fault Finding".
 Remove steering column switch module --> Steering column switch
module, removing and installing.

CAUTION:  Ensure steering is in straight ahead and centered prior to removing

spiral spring.

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 Position of spiral spring must not be changed once removed.

Fig. 465: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully release clip fasteners - arrows - and remove spiral spring - 1 - from steering column switch
module.

Fig. 466: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control
Module J527
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove Steering Angle Sensor G85 - 1 - from Steering Column Electronic Systems Control Module J527
in direction of - arrow -.

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Fig. 467: Removing Screws, And Steering Column Electronics Systems Control Module J527 From
Steering Column Switch Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Steering Column Electronics Systems Control Module J527 - 1 - from steering column switch
module.

Installing

Install in reverse order of removal, noting the following:

 Ensure all fasteners and electrical connectors are properly connected and locked into place.
 Install steering column switch module Installing.

Tightening torques

Component Nm
Steering column switch module to Steering Column Electronics Systems Control Module J527 0.6
Intermittent wiper switch E22 to Steering Column Electronics Systems Control Module J527 0.6
Cruise Control Switch E45 to Steering Column Electronic Systems Control Module J527 0.6

Steering Column Electronics Systems Control Module J527 , front multi-pin connector assignments

The Steering Column Electronics Systems Control Module J527 is part of the steering column switch module. It
receives signals e.g. from the steering column switches.

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Fig. 468: Steering Column Electronics Systems Control Module J527 , Front Multi-Pin Connector
Assignments
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Cruise control system multi-pin connector

1 - Ground (GND) ( - )

2 - Set

3 - Distance

4 - 12 V voltage supply

5 - Activation/touch function "Off"

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6 - Acceleration/deceleration

7 - Locked "Off"

B - Turn signal switch multi-pin connector

1 - Ground (GND) ( - )

2 - Radio telephone (special-purpose vehicles)

3 - Alarm (special-purpose vehicles)

4 - Vacant

5 - Headlamp flasher/light control

6 - Turn signal indicators

C - Multi-function steering wheel / Tiptronic / heated steering wheel multi-pin connector

7 Tiptronic ""

8 - Multi-function steering wheel "+" voltage supply

9 - Multi-function steering wheel data

10 - Tiptronic "+"

11 - Multi-function steering wheel dimmer

12 - Tiptronic earth

13 - Heated steering wheel "+"

14 - Heated steering wheel ""

D - Steering angle sensor multi-pin connector

1 - Light barrier 5

2 - Light barrier 3

3 - Light barrier 1

4 - 12 V voltage supply

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5 -5 V voltage supply

6 - Light barrier 6

7 - Light barrier 4

8 - Light barrier 2

9 - Steering angle sensor Ground (GND) ( - )

10 - Light barrier 7

E - Horn switch multi-pin connector

1 - Horn Ground (GND) ( - )

2 - Horn

F - Wiper switch multi-pin connector

1 - Ground (GND) ( - )

2 - Intermittent wipe potentiometer

3 - Multi-function Indicator (On-board computer)

4 - Vacant

5 - Wash

6 - Wipe

Steering Column Electronics Systems Control Module J527 , rear multi-pin connector assignments

Fig. 469: Steering Column Electronic Systems Control Module (Rear) Assembly Overview

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Multi-pin connector, 16-pin

1. Ground (GND) ( - )
2. Terminal 30 (B+)
3. CAN-Bus Powertrain (shielding)
4. Vacant
5. Cruise control locked Off
6. Alarm (special-purpose vehicles)
7. Radio telephone (special-purpose vehicles)
8. CAN-Bus Low (convenience)
9. CAN-Bus High (convenience)
10. CAN-Bus High - Powertrain (shielding
11. CAN- Bus Low - Powertrain (shielding
12. Ignition lock terminal 75
13. Ignition lock terminal 15
14. Ignition lock S contact
15. Ignition lock terminal 50
16. Ignition lock terminal P

Turn Signal Switch E2 , removing and installing

Removing

 Remove steering column switch module --> Steering column switch module, removing and installing.

CAUTION:  Ensure steering is in straight ahead and centered prior to removing

spiral spring.
 Position of spiral spring must not be changed once removed.

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Fig. 470: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully release clip fasteners - arrows - and remove spiral spring - 1 - from steering column switch
module.

Fig. 471: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control
Module J527
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove Steering Angle Sensor G85 - 1 - from Steering Column Electronic Systems Control Module J527
in direction of - arrow -.

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Fig. 472: Identifying Screws, Steering Column Electronics Systems Control Module, Windshield
Wiper/Washer Switch, And Retaining Clip
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove the Steering Column Electronics Systems Control Module J527 - 2 - and Windshield
Wiper/Washer Switch E22 - 3 - from steering column switch module.
 Remove Cruise Control Switch E45 - 1 - from steering column switch module.
 Remove screw - 5 - and remove retaining clip - 4 -.

Installing

Further Install in reverse order of removal, noting the following:

 Ensure all fasteners and electrical connectors are properly connected and locked into place.
 Install steering column switch module Installing.

Tightening torques

Component Nm
Steering column switch module to Steering Column Electronics Systems Control Module J527 0.6
Intermittent wiper switch E22 to Steering Column Electronics Systems Control Module J527 0.6
Cruise Control Switch E45 to Steering Column Electronic Systems Control Module J527 0.6

Cruise Control Switch E45 , removing and installing

Removing

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 Remove steering column switch module --> Steering column switch module, removing and installing.

CAUTION:  Ensure steering is in straight ahead and centered prior to removing

spiral spring.
 Position of spiral spring must not be changed once removed.

Fig. 473: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully release clip fasteners - arrows - and remove spiral spring - 1 - from steering column switch
module.

Fig. 474: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control
Module J527
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove Steering Angle Sensor G85 - 1 - from Steering Column Electronic Systems Control Module J527
in direction of - arrow -.

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Fig. 475: Identifying Screws, Steering Column Electronics Systems Control Module, And Cruise Control
Switch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Remove Steering Column Electronics Systems Control Module J527 - 2 - from steering column switch
module.
 Remove Cruise Control Switch E45 - 1 - from steering column switch module.

Installing

Further Install in reverse order of removal, noting the following:

 Ensure all fasteners and electrical connectors are properly connected and locked into place.
 Install steering column switch module Installing.

Tightening torques

Component Nm
Steering column switch module to Steering Column Electronics Systems Control Module J527 0.6
Intermittent wiper switch E22 to Steering Column Electronics Systems Control Module J527 0.6
Cruise Control Switch E45 to Steering Column Electronic Systems Control Module J527 0.6

Windshield Wiper/Washer Switch E22 , removing and installing

Removing

 Remove steering column switch module --> Steering column switch module, removing and installing.

CAUTION:  Ensure steering is in straight ahead and centered prior to removing

spiral spring.
 Position of spiral spring must not be changed once removed.

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Fig. 476: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully release clip fasteners - arrows - and remove spiral spring - 1 - from steering column switch
module.

Fig. 477: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control
Module J527
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove Steering Angle Sensor G85 - 1 - from Steering Column Electronic Systems Control Module J527
in direction of - arrow -.

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Fig. 478: Identifying Screws And Windshield Wiper/Washer Switch

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 1 - and - 2 -.

 Remove Windshield Wiper/Washer Switch E22 - 3 - from steering column switch module - arrow -.

Installing

Further Install in reverse order of removal, noting the following:

 Ensure all fasteners and electrical connectors are properly connected and locked into place.
 Install steering column switch module Installing.

Tightening torque

Component Nm
Windshield Wiper/Washer Switch E22 to Steering Column Electronics Systems Control Module
0.6
J527

IGNITION/STARTER SWITCH AND LOCK CYLINDER

Lock cylinder, removing and installing

NOTE:  The immobilizer reading coil is integrated with the lock cylinder and
cannot be serviced or replaced individually.
 Should the reading coil malfunction, replace complete lock cylinder. .
 Observe reading coil specifications when replacing lock cylinders -->
Reader coil, replacing.

Removing

 Remove steering column switch module --> Steering column switch module, removing and installing
 Disconnect electrical connection at reader coil.

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Vehicles with automatic transmission:

 Move selector lever to "P".

Fig. 479: Turn Ignition Key To "Ignition On" Position

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Turn ignition key to "Ignition ON" position - arrow -.

 Then lift interlock lever - 1 - slightly and pull locking cable - 2 - out of ignition lock housing.

All models:

NOTE:  The spare key is necessary for removing the lock cylinder, because the
following sequence can only be performed using an ignition key with flat
key grip, i.e. without illumination and without remote control.

Fig. 480: Aligning Recess In Trim

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Turn spare key to ignition "ON" position, thus aligning recess in trim - arrow - with hole in ignition lock.

NOTE:  The illustration shows the correct lock position without the ignition key.

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Fig. 481: Identifying Steel Wire In Hole, Lock Cylinder And Reader Coil Out Of Steering Lock Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Insert a steel wire or pin ( approx. 1.5 mm) in hole - 1 - as far as it will go, at the same time pulling lock
cylinder - 2 - with reader coil out of steering lock housing - 3 -.

CAUTION: Steering lock must not be operated without the lock cylinder, otherwise it
will lock completely. The entire steering lock must then be replaced.

NOTE:  When replacing lock cylinder, note immobilizer reader coil specifications --
> Reader coil, replacing.

Installing

Install in reverse order of removal, noting the following:

 Insert spare ignition key into lock cylinder and turn to ignition "on" position.

Fig. 482: Identifying Steel Wire In Hole, Lock Cylinder And Reader Coil Out Of Steering Lock Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Re-insert steel wire/pin - 1 - in hole on end face as far as it will go.

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 Insert lock cylinder - 2 - with reader coil in steering lock housing - 3 -.

 Then pull out steel wire and press in lock cylinder firmly until catch engages audibly.
 Connect electrical connector on immobilizer reader coil.

Vehicles with automatic transmission:

 Turn ignition key to "Ignition ON" position.

 Slide locking cable - 2 - into ignition lock housing until it engages audibly.

Ignition/starter switch, removing and installing

Removing

 Remove steering column switch module --> Steering column switch module, removing and installing.
 Disconnect electrical connection at immobilizer reader coil.

Fig. 483: Locating Screws , Ignition/Starter Switch And Steering Lock Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 - at ignition/starter switch.

 Remove sealing paint from both securing screws - arrows -.
 Loosen bolts - arrows - (do not remove) and pull ignition/starter switch out of steering lock housing - 2 -.

Installing

Install in reverse order of removal, noting the following:

NOTE:  Ensure that the ignition/starter switch and lock cylinder are in the same
position, e.g. "Ignition ON" , when installing.
 Apply sealing paint to bolts - arrows - at steering lock housing - 2 -.
 Install steering column switch module Installing.

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Ignition/starter switch, multi-pin connector assignments

Fig. 484: Connection Assignment At Ignition/Starter Switch

Courtesy of VOLKSWAGEN UNITED STATES, INC.

15 - Terminal 15

30 - Terminal 30 (B+)

50 - Terminal 50

50b - Terminal 50b

75 - Terminal 75

86s - Terminal 86s

P - Park position

PARKING AID SYSTEM

General information

At time of publication, the optional parking aid system (also know as "Acoustic park assist" or " Parktronic (R)
" ) is only available as a 4-channel system that monitors the area to the rear of the vehicle.

The system is activated automatically whenever the vehicle is shifted into reverse.

Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of
the parking aid system. Always read the owners manual and review applicable system functions and operation
limitations.

NOTE:  Additional information:

Owners Manual

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Wiring Diagrams Component Locations

On Board Diagnostic (OBD), functions

Parking aid system functions are controlled by the Parking Aid Control Module J446 which has On Board
Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes
(DTC) will be stored in memory.

Troubleshoot parking aid system malfunctions by performing OBD program using Vehicle Diagnosis, Testing
and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".

Parking aid system, component overview

Fig. 485: Parking Aid System, Component Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Front sensors not applicable to USA/Canada

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2 - Not applicable to USA/Canada

3 - Not applicable to USA/Canada

4 - Rear Parking Aid Warning Buzzer H15

Sedan:

 Under rear parcel shelf

 Removing and installing --> Rear Parking Aid Warning Buzzer H15 - Sedan, removing and
installing

Avant:

 In luggage compartment rear left under side trim

 Removing and installing --> Rear Parking Aid Warning Buzzer H15 - Avant, removing and
installing

5 - Rear Parking Aid Sensors

 In rear bumper
 Removing and installing --> Rear parking aid sensors, removing and installing

6 - Parking Aid Control Module J446

 in left rear luggage compartment under side trim

 Removing and installing --> Parking Aid Control Module J446 , removing and installing

Parking Aid Control Module J446 , removing and installing

Removing

 Location: At left rear or luggage compartment below side trim/taillamp.

 Remove left luggage compartment side trim --> 70 - INTERIOR TRIM .

Sedan:

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Fig. 486: Removing Screws And Base Mount

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows - and remove base mount - 1 -.

Fig. 487: Disconnecting Electrical Connections And Antenna Wiring At Rear Of Navigation Interface
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Where applicable, disconnect electrical connections and antenna wiring at rear of Navigation Interface
R94 - 1 -.

NOTE:  Disregard - 2 -.

Avant:

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Fig. 488: Removing Screws And Base Mount

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows - and remove base mount - 1 -.

All:

Fig. 489: Identifying Electrical Connections, Screws, And Parking Aid Control Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections - 2 - and - 3 -.

 Remove screws - arrows -.
 Remove Parking Aid Control Module J446 - 1 -.

NOTE:  Sedan installation is illustrated.

Installing

Install in reverse order of removal.

Tightening torque

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Component - fastener Nm
Parking Aid Control Module J446 to body - screw 1.8

Rear Parking Aid Warning Buzzer H15 - Sedan, removing and installing

 Location: At right rear under rear parcel shelf

Removing

 Remove rear parcel shelf --> 70 - INTERIOR TRIM .

 Disconnect electrical connection.
 Remove expander clip threaded pin using a TORX screwdriver.

Fig. 490: Removing Warning Buzzer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove warning buzzer - arrow - upward out of lower luggage compartment partition.

Installing

Install in reverse order of removal, noting the following:

 Press threaded pins into expander clips.

 Install rear parcel shelf --> 70 - INTERIOR TRIM .

Rear Parking Aid Warning Buzzer H15 - Avant, removing and installing

 Location: In left rear luggage compartment under side trim

Removing

 Remove left side trim --> 70 - INTERIOR TRIM .

 Disconnect electrical connection.
 Remove expander clip threaded pin using a TORX screwdriver.

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Fig. 491: Removing Warning Buzzer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove warning buzzer - arrow - upward.

Installing

Install in reverse order of removal, noting the following:

 Press threaded pins into expander clips.

 Install left side trim --> 70 - INTERIOR TRIM .

Rear parking aid sensors, removing and installing

Fig. 492: Locating Parking Aid Sensors In Rear Bumper Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Location: In rear bumper cover - arrows -.

Removing

 Remove rear bumper cover --> 63 BUMPER

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Fig. 493: Identifying Electrical Connection, Catches, And Sensor

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect applicable electrical connection - 1 - from sensor.

 Press both catches - arrows - to side and press sensor - 2 - inward from outside.

Installing

Install in reverse order of removal, noting the following:

 Install rear bumper cover --> 63 BUMPER .

AUTOMATIC HEADLAMP RANGE CONTROL

General information

The automatic headlight aim control system is installed on vehicles with High Intensity Gas Discharge (HID)
headlamps.

The system contains the following components:

 Level control system sensors at front and rear axles

 Headlight range control module
 Headlight beam adjusting motors integrated with headlight units

When driving, the system automatically adapts the headlight beam inclination dependent on vehicle suspension
movement and load. Headlight glare to oncoming traffic is minimized.

On Board Diagnostic (OBD), function

The headlight range control module is controlled by a microprocessor and has On Board Diagnostic (OBD)
capability. If malfunctions occur in any of the system components, corresponding DTCs are stored in the
Diagnostic Trouble Code (DTC) memory.

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Before performing any troubleshooting or inspection, always begin by checking for DTCs using the On Board
Diagnostic (OBD) program. DTCs stored in memory are retrieved/checked with VAS 5051/5052 tester in mode
"Guided Fault Finding".

Automatic headlamp range control, component overview

Fig. 494: Automatic Headlamp Range Control, Component Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Headlamp beam adjustment motors

 Left Headlamp Beam Adjustment Motor V48

 Right Headlamp Beam Adjustment Motor V49

2 - Headlamp Range Control Module J431

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 Location: behind glove box at instrument panel support

 Removing and installing --> Headlamp Range Control Module J431 , removing and installing

3 - Left Rear Level Control System Sensor G76

 Location: at left rear suspension ink

 Removing and installing --> 42 - REAR SUSPENSION

4 - Left Front Level Control System Sensor G78

 Location: at left front track control link

 Removing and installing --> 40 - FRONT SUSPENSION

Headlamp Range Control Module J431 , removing and installing

Removing

 Location: at instrument panel carrier behind glove box

 Remove glove box --> 68 - INTERIOR EQUIPMENT .

Fig. 495: Identifying Connector, Bolts, And Headlight Range Control Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - arrow -.

 Remove screws - 1 - and - 2 - and remove module.

Installing

Install in reverse order of removal.

Tightening torque

Component - fastener Nm

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Control module to body - screw 3

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96 LIGHTS, SWITCHES - INTERIOR, ANTI-THEFT

SWITCHES - INTERIOR

Light Switch E1 , removing and installing

Removing

Fig. 496: Pressing Light Switch And Turning It Clockwise

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Push in light switch rotary knob - arrow 1 - and simultaneously turn clockwise - arrow 2 -.
 Hold switch in this position.

Fig. 497: Pulling Off Light Switch From Switch Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull light switch out of switch housing - arrow 3 -.

 Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

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 Press switch into switch housing until catch engages.

Ambient Illumination Deactivation Switch E491 , removing and installing

Where equipped, the Ambient Illumination Deactivation Switch E491 controls the "coming home " and
"leaving home" lighting function.

Additional information Owners Manual

Removing

 Remove light switch --> Light Switch E1 , removing and installing.

Fig. 498: Pressing Headlamp Range Control Adjuster Out Of Switch Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Reach through opening for light switch and press the switch unit out of the switch housing in direction of
- arrow -.
 Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

 Install light switch --> Light Switch E1 , removing and installing.

Daytime running lamps (DRL) switch, removing and installing

Where equipped, the daytime running lamps switch controls DRL lighting function where desired (on US
vehicles only).

Removing

 Remove light switch --> Light Switch E1 , removing and installing.

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Fig. 499: Pressing Headlamp Range Control Adjuster Out Of Switch Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Reach through opening for light switch and press the switch unit out of the switch housing in direction of
- arrow -.
 Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

 Install light switch --> Light Switch E1 , removing and installing.

Emergency Flasher Button E229 , removing and installing

Special tools, testers and auxiliary items required

Fig. 500: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hook 3370

Removing

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 Open glove compartment.

Fig. 501: Removing Trim Using Hook For Front End 3370
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully pull off trim panel - 1 - using hook 3370 as illustrated.

Fig. 502: Levering Out Emergency Flasher Button E229 From Switch Mounting Using Flat Screwdriver
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully lever out Emergency Flasher Button E229 - 1 - from switch mounting - arrows - using a flat
screwdriver.
 Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

 Push switch into mounting in instrument panel and ensure it is properly engaged.

Switches in center console, removing and installing

Special tools, testers and auxiliary items required

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Fig. 503: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hook 3370

Removing

 Open glove compartment.

Fig. 504: Removing Trim Using Hook For Front End 3370
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully pull off trim panel - 1 - to rear using hook 3370.

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Fig. 505: Prying Switch Out Of Mounting Using Flat Screwdriver

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use flat screwdriver to carefully pry appropriate switch out of mounting - arrows -.
 Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

 Push switch into mounting in instrument panel and ensure it is properly engaged.

Front heated seat regulating switches, removing and installing

Front seat heating switches are integrated into A/C Control Head E87 and cannot be replaced separately.

Rear heated seat regulating switches, removing and installing

Procedure for Left Rear Heated Seat Regulating Switch E128 and Right Rear Heated Seat Regulating Switch
E129 is the same.

Removing

 Remove rear ashtray.

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Fig. 506: Switch Mount Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Press retaining hooks - arrow A - on right and left outwards and swivel switch mounting to rear - arrow
B -.
 Disengage switch mounting at rear center console.
 Disconnect electrical connections.
 Unclip switches - 1 - and - 2 - from switch mounting.

Installing

Install in reverse order of removal.

Start System Button E378 - Audi RS4, removing and installing

Removing

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

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Fig. 507: Identifying Cigarette Lighter Cover And Start System Button E378
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Open cigarette lighter cover - 2 -.

 Lift Start System Button E378 - 1 - up - arrow - and remove from installation frame as illustrated.
 Disconnect electrical connection.

Installing

Install in reverse order of removal.

Glove Compartment Lamp Switch E26 , removing and installing

Special tools, testers and auxiliary items required

Fig. 508: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Hook 3370

Removing

 Open glove compartment.

Fig. 509: Removing Right Instrument Panel Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull off cover on right of instrument panel - arrow - using hook 3370.

Fig. 510: Identifying Connector, Joint Pin, And Switch

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 2 -.

 Pull out hinge pin - 1 -.
 Release switch - 3 - in clockwise direction - arrow - and detach.

NOTE:  Switch illustrated with glove compartment removed..

Installing

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Install in reverse order of removal.

Mirror selector/adjustment switch, removing and installing

Mirror Adjustment Switch E43 , Mirror Selector Switch E48 , and Mirror (with fold-away function) Switch
E168 (where applicable) are integrated into a single module.

Removing

 Remove front door trim --> 70 - INTERIOR TRIM .

Fig. 511: Identifying Electrical Connection, Mirror Adjustment Switch, And Fasteners
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 1 - at mirror adjustment switch - 2 -.

 Use small screwdriver to carefully release fasteners - arrows -.
 Pull mirror adjustment switch downwards out of door trim.

Installing

Install in reverse order of removal, noting the following:

NOTE:  When installing, ensure symbol trim is inserted before the mirror
adjustment switch.
 Press mirror adjustment switch into switch mounting until retaining hooks
engage.
 Install front door trim --> 70 - INTERIOR TRIM .

Drivers power window switch panel - 2 switches, removing and installing

Removing

 Remove front door trim --> 70 - INTERIOR TRIM .

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Fig. 512: Identifying Fasteners, Electrical Connection, And Window Switch

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use small screwdriver to carefully release fasteners - arrows -.

 Pull window switch downwards out of door trim.
 Disconnect electrical connection - 2 - at window switch - 1 -.

Installing

Install in reverse order of removal, noting the following:

 Press window switch into switch mounting until retaining hooks engage.
 Install front door trim --> 70 - INTERIOR TRIM .

Drivers power window switch panel - four switches, removing and installing

Removing

 Remove front door trim --> 70 - INTERIOR TRIM .

Fig. 513: Identifying Retaining Element, Retaining Hooks, Window Switches, And Electrical Connection
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Release retaining hooks on armrest side by pressing retaining element - arrows -.

 Use small screwdriver to carefully release retaining hooks - 1 - on trim side.
 Pull window switches - 2 - downwards out of door trim.
 Disconnect electrical connection - 3 - at window switch.

Installing

Install in reverse order of removal, noting the following:

 Press window switch into switch mounting until it engages.

 Install front door trim --> 70 - INTERIOR TRIM .

Front passengers power window switch panel, removing and installing

Removing

 Remove front door trim --> 70 - INTERIOR TRIM .

Fig. 514: Identifying Fasteners, Electrical Connection, And Window Switch

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use small screwdriver to carefully release fasteners - arrows -.

 Pull window switch downwards out of door trim.
 Disconnect electrical connection - 1 - at window switch - 2 -.

Installing

Install in reverse order of removal, noting the following:

 Press window switch into switch mounting until retaining hooks engage.
 Install front door trim --> 70 - INTERIOR TRIM .

Rear door power window switches, removing and installing

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Removing

 Remove rear door trim: --> 70 - INTERIOR TRIM .

Fig. 515: Locating Screws

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 1... 3 -.

 Remove armrest and disconnect electrical connection.

Fig. 516: Pulling Switch Mounting From Armrest

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull switch mounting - 1 - from armrest - 2 - - arrow -.

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Fig. 517: Using Small Screwdriver To Carefully Release Fasteners

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use small screwdriver to carefully release fasteners - arrows -.

 Pull out window switch downwards.

Installing

Install in reverse order of removal, noting the following:

 Press window switch into switch mounting until retaining hooks engage.
 Install rear door trim --> 70 - INTERIOR TRIM .

Sunroof Switch E8 , removing and installing

Removing

 Remove front interior/reading lamp --> Front interior lamp module, removing and installing.

Fig. 518: Identifying Electrical Connection, Screws, And Sunroof Switch

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 2 -.

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 Remove screws - arrows -.

 Take sunroof switch E8 - 1 - out of interior light/reading light.

Installing

Install in reverse order of removal, noting the following:

 Install front interior/reading lamp --> Front interior lamp module, removing and installing.

Tightening torque

Component Nm
Sunroof Switch E8 to interior light/reading light 1.5

Door contact switches, removing and installing

Door contact switches are integrated with the individual door locks and cannot be serviced or replaced
separately.

 Replacing front door lock: --> 57 FRONT DOORS/DOOR COMPONENTS/CENTRAL LOCKING

SYSTEM .
 Replacing rear door lock: --> 58 REAR DOORS/DOOR COMPONENTS .

Drivers Interior Locking Switch E150 , removing and installing

Removing

 Remove front door trim --> 70 - INTERIOR TRIM .

 Disconnect electrical connection - 2 -.

Fig. 519: Identifying Connector, Central Locking Switch, And Driver Side Door Trim
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Press switch - 1 - out of drivers door trim towards inside of vehicle - arrow -.

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Installing

Install in reverse order of removal, noting the following:

 Install front door trim --> 70 - INTERIOR TRIM .

Rear/Center Central Locking Switch E286 , removing and installing

Removing

 Remove rear ashtray.

Fig. 520: Pressing Retaining Hooks And Swiveling Switch Mounting To Rear
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Press retaining hooks - arrow A - on left and right outwards and swivel switch mounting to rear - arrow
B -.
 Disengage switch mounting at center console.
 Disconnect electrical connection.
 Unclip switch - 1 - from switch mounting.

Installing

Install in reverse order of removal.

Remote Fuel Tank Flap Switch E204 and Rear Lid Remote Control Lock Switch E233 , removing and installing

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Fig. 521: Locating Switch For Interior Monitoring And Towing Protection Or Trunk Release Switch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Location: drivers door trim in storage compartment - detail -

Removing

 Remove drivers door trim --> 70 - INTERIOR TRIM .

 Disconnect electrical connections.

Fig. 522: Identifying Catches, Interior Monitoring And Towing Protection, And Trunk Release Switch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully release retaining hooks - arrows -.

 Press switches as applicable - 1 - and - 2 - towards rear out of trim.

Installing

Install in reverse order of removal, noting the following:

 Install drivers door trim --> 70 - INTERIOR TRIM .

Drivers Seat Memory Program Control E97 , removing and installing

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Special tools, testers and auxiliary items required

Fig. 523: Identifying Trim Removal Wedge 3409

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Removal wedge 3409

Removing

Fig. 524: Removing Switch Using Removal Wedge 3409

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove switch - 1 - using removal wedge 3409 as illustrated.

 Disconnect electrical connection.

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Fig. 525: Identifying Fasteners, Switch, And Mounting

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use small screwdriver to carefully release fasteners - arrows -.

 Remove switch - 1 - from mounting - 2 -.

Installing

Install in reverse order of removal, noting the following:

 Press switch into switch mounting until fasteners engage.

Trunk Lock/Alarm/Central Locking Switch F124 - Sedan through 10.04, removing and installing

Removing

 Remove rear lid lock --> 55 HOOD, LIDS .

Fig. 526: Identifying Catch, Retaining Bolts, And Contact Switch

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use flat screwdriver to pry plastic tab - 3 - from retaining pins - 1 -.

 Fold plastic tab completely to rear.

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 First pull contact switch - 2 - to one side and then upwards out of lock for rear lid.

Installing

Install in reverse order of removal, noting the following:

NOTE:  Ensure washers are properly positioned between plastic tab and lock for
rear lid.
 Install rear lid lock --> 55 HOOD, LIDS .

Trunk Lock/Alarm/Central Locking Switch F124 - Avant through 10.04, removing and installing

The rear lid contact switch is integrated with the rear lid lock and cannot be serviced or replaced separately.

 Replace rear lid lock --> 55 HOOD, LIDS .

Trunk Lock/Alarm/Central Locking Switch F124 - from 11.04, removing and installing

Fig. 527: Identifying Rear Lid Contact And Rear Lid Lock
Courtesy of VOLKSWAGEN UNITED STATES, INC.

The rear lid contact switch is integrated with the rear lid lock - arrow - and cannot be serviced or replaced
separately.

 Replace rear lid lock --> 55 HOOD, LIDS .

12 V Socket U5 - in luggage compartment through 10.04, removing and installing

Special tools, testers and auxiliary items required

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Fig. 528: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hook 3370

Removing

Fig. 529: Rear Power Outlet Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully pull 12 V socket - 1 - from luggage compartment trim using hook 3370.

NOTE:  Pay attention to retaining hooks - 2 - and - 4 - when pulling out socket.
 Disconnect electrical connection - 3 -.

Installing

Install in reverse order of removal.

12 V Socket U5 - in luggage compartment from 11.04, removing and installing

Removing

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 Audi A4 S4: Release lower right part of luggage compartment side trim: --> 70 - INTERIOR TRIM .
 Audi RS4: Release lower right part of luggage compartment rear trim: --> 70 - INTERIOR TRIM .
 Disconnect electrical connection at socket.

Fig. 530: Identifying Nut And 12 V Socket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nut - 1 -.
 Remove 12 V socket - 2 - from trim.

Installing

Install in reverse order of removal, noting the following:

 Install luggage compartment trim --> 70 - INTERIOR TRIM .

ANTI-THEFT IMMOBILIZER

General information

All A4 from model year 2002 are equipped with Immobilizer Generation III.

Generation III has the same functionality as the previous version. However, in addition to the normal data
exchange between the immobilizer control module and ignition key, Gen. III includes data exchange between
the immobilizer control module and Engine Control Module (ECM).

The immobilizer control module is integrated into the instrument cluster, i.e. it is replaced together with
instrument cluster --> Instrument cluster, removing and installing.

Data exchange between the Immobilizer control module and ECM takes place over the vehicle CAN-Bus
network.

Function

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Immobilizer III consists of:

 an adapted control module for anti-theft immobilizer (integrated in instrument cluster)

 a warning light in instrument cluster
 a reading coil at ignition lock
 an adapted Engine Control Module (ECM)

 and adapted ignition keys with electronics (transponder)

The anti-theft immobilizer is a system for enabling/locking the Engine Control Module (ECM) via the CAN
wire.

The transponder code consists of a fixed code and a variable code. This is different for every start procedure and
therefore acts as a copy protection for the transponder.

Every immobilizer contains a different computational rule for the variable code that remains the same for its
entire service life. During adaptation of the vehicle key, the immobilizer writes this computational rule into the
transponder and simultaneously learns the fixed code of the current key.

The fixed code identifies each individual key so that a key that is lost can be blocked from usage. Each time the
ignition is switched on, the induction coil for immobilizer reads the transponders fixed code and then the
variable code and determines whether this key is authorized for vehicle start.

The warning lamp lights up briefly (max. 3 seconds) and then goes out when an authorized vehicle key is used.

When an unauthorized vehicle key is used or when a system malfunction occurs, the warning lamp blinks
constantly during ignition "on".

On Board Diagnostic (OBD), function

The electronic anti-theft immobilizer has extensive On Board Diagnostic (OBD) capabilities. If malfunctions
occur in any of the system components, corresponding Diagnostic Trouble Codes (DTC) are stored in the DTC
memory of the anti-theft immobilizer.

Before performing any troubleshooting or inspection, always begin by checking for DTCs using the On Board
Diagnostic (OBD) program. DTCs stored in memory are retrieved/checked with VAS 5051 or VAS 5052 in
mode "Guided Fault Finding".

Malfunctioning transponder and/or lost keys

 The transponder is integrated into the vehicle key and cannot be replaced separately.
 The complete vehicle key must be replaced if the transponder malfunctions.

 Order replacement key with integrated transponder on the basis of the lock number and/or VIN.
 Adapt all vehicle keys using VAS 5051/5052 in mode "Guided Fault Finding".

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Reader coil, replacing

 The reader coil is integrated into the lock cylinder and cannot be serviced or replaced separately.
 The complete lock cylinder must be replaced if the reader coil malfunctions --> Lock cylinder, removing
and installing

 Order replacement lock cylinder on the basis of the lock number and/or VIN.

Lock set or instrument cluster, replacing.

Follow replacement procedures as specified using VAS 5051/5052 in mode "Guided Fault Finding".

ALARM HORN H12

Alarm Horn H12 , removing and installing

Removing

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

 Remove right interior trim --> 70 - INTERIOR TRIM .

Fig. 531: Identifying Nut, Electrical Connection, Horn, Bolt, And Horn Bracket
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nut - 1 -.
 Disconnect electrical connection - 2 -.
 Remove horn - 3 -.
 If necessary, remove horn bracket - 5 - by removing bolt - 4 -.

Installing

12:19:47 AM Page 24
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ELECTRICAL Electrical Equipment

Install in reverse order of removal, noting the following:

 Install trim --> 70 - INTERIOR TRIM .

Tightening torque

Component - fastener Nm
Alarm Horn H12 to bracket - nut 5
Bracket to body - bolt 9

LIGHTS - INTERIOR

Make-up Mirror Illumination L31 , removing and installing

Removing

Fig. 532: Prying Out Light At Recess Using Flat-Head Screwdriver

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully pry out light at recess - arrow - using a flat-head screwdriver.

 Disconnect electrical connection.

Fig. 533: Bulb Holder And Cover

12:19:47 AM Page 25
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ELECTRICAL Electrical Equipment

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bulb cover - arrow -.

 Remove bulb (12 V, 5W) from socket on reverse side of make-up mirror light.

Installing

Install in reverse order of removal.

Front interior lamp module, removing and installing

Special tools, testers and auxiliary items required

Fig. 534: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hook 3370

Removing

Fig. 535: Removing Interior Lamp Module Trim Using Hook 3370
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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ELECTRICAL Electrical Equipment

 Carefully remove interior lamp module trim using hook 3370 as illustrated - arrow -.

Fig. 536: Disconnection Microphone Electrical Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Where applicable, disconnect microphone electrical connection - 1 -.

Fig. 537: Locating Screws

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

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 Swivel down module and remove from opening in headliner.

 Disconnect electrical connections.

Installing

Install in reverse order of removal, noting the following:

 Engage interior lamp module and tighten screws to 3 Nm.

Ambient lighting LEDs, removing and installing

Removing

 Remove front interior lamp module --> Front interior lamp module, removing and installing.

Fig. 538: Identifying Electrical Connections, Retaining Clips, And LED

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections - 1... 3 -.

 Release retaining clips - arrows - and remove LED - 4 -.

Installing

Install in reverse order of removal, noting the following:

 Install front interior lamp module --> Front interior lamp module, removing and installing.

Front Interior Light W1 - bulbs, replacing

12:19:47 AM Page 28
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ELECTRICAL Electrical Equipment

Special tools, testers and auxiliary items required

Fig. 539: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hook 3370

Removing

Fig. 540: Removing Interior Lamp Lens Using Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully remove interior lamp lens using hook 3370 as illustrated.

12:19:47 AM Page 29
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ELECTRICAL Electrical Equipment

Fig. 541: Removing Bulb From Holder

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bulb as applicable - 1 - or - 2 - (12 V, 10 W) from holder.

Installing

Install in reverse order of removal, noting the following:

 Press on lens until it engages.

Front Passengers Map/Reading Light W13 , Drivers Map/Reading Light W19 - bulbs, replacing

Special tools, testers and auxiliary items required

Fig. 542: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hook 3370

Removing

12:19:47 AM Page 30
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ELECTRICAL Electrical Equipment

Fig. 543: Removing Interior Lamp Module Trim Using Hook 3370
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully remove interior lamp module trim using hook 3370 as illustrated.

Fig. 544: Remove Bulb From Holder

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bulb as applicable - 1 - or - 2 - (12 V, 5 W) from bulb holder.

Installing

Install in reverse order of removal, noting the following:

 Press on trim until it engages.

Front Passengers Airbag Disabled Indicator Lamp K145 - from 11.04, removing and installing

Special tools, testers and auxiliary items required

12:19:47 AM Page 31
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ELECTRICAL Electrical Equipment

Fig. 545: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hook 3370

Removing

 Open glove compartment.

Fig. 546: Removing Trim Using Hook For Front End 3370
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully remove trim panel - 1 - using hook 3370 as illustrated.

12:19:47 AM Page 32
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ELECTRICAL Electrical Equipment

Fig. 547: Prying Out Indicator Lamp From Switch Mounting

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully pry out lever out indicator lamp - 1 - from switch mounting - arrows - using a flat screwdriver.
 Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

 Push lamp assembly into mounting in instrument panel and ensure it is properly engaged.

Rear interior lamp module, removing and installing

Special tools, testers and auxiliary items required

Fig. 548: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hook 3370

Removing

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Fig. 549: Removing Rear Interior Lamp Module From Headliner Opening Using Hook 3370
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully remove rear interior lamp module from headliner opening using hook 3370 as illustrated.
 Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

 Insert interior lamp module in opening in headliner and clip into place.

Left Rear Reading Light W11 , Right Rear Reading Light W12 - bulbs, replacing

Removing

 Remove rear interior lamp module --> Rear interior lamp module, removing and installing.

Fig. 550: Interior/Reading Light Bulbs

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Screw applicable bulb 12 V, 5 W - arrow - from holder.

Installing

12:19:47 AM Page 34
 2005 Audi A4 Quattro
ELECTRICAL Electrical Equipment

Install in reverse order of removal.

Glove Compartment Light W6 , removing and installing

Removing

 Turn light switch to position "0".

Fig. 551: Identifying Retaining Tab, Glove Box Light, And Electrical Connection
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Using a flat-head screwdriver, press in retaining tab - 1 - and pry out glove box light - 2 -.
 Disconnect electrical connection - 3 -.
 Remove bulb (12 V, 5 W) from bulb holder.

Installing

Install in reverse order of removal, noting the following:

 Insert glove box light in opening and engage on opposite side.

Front ashtray light, removing and installing

Removing

 Pull radio approx 10 mm out of mounting slot --> 91 - COMMUNICATION .

 Remove A/C Control Head E87 --> 87 AIR CONDITIONING .
 Open front ashtray.

12:19:47 AM Page 35
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Fig. 552: Identifying Ashtray Insert And Gear Lever Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove front ashtray insert - 2 -.

 Remove cover - 1 - for gear lever or selector lever on both sides - arrows -.

Fig. 553: Locating Screws For Ashtray

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - arrows -.

 Lift out front ashtray upwards.
 Disconnect electrical connection.

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Fig. 554: Releasing Retaining Clips And Swivel Light For Front Ashtray Out Of Retainer
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clips - 2 - and swivel light - 1 - for front ashtray out of retainer - arrow -.

Installing

Install in reverse order of removal, noting the following:

 Install A/C Control Head E87 --> 87 AIR CONDITIONING .

Tightening torque

Component Nm
Front ashtray to center console 5

Rear ashtray light, removing and installing

If rear ashtray light malfunctions, replace complete switch mounting panel:

 Rear seat heating switch mount --> Rear heated seat regulating switches, removing and installing
 Rear central locking switch mount --> Rear/Center Central Locking Switch E286 , removing and
installing

Drivers Door Opener Illumination L108 , Front Passengers Door Opener Illumination L109 , Left Rear Door Opener
Illumination L110 , Right Rear Door Opener Illumination L111 , removing and installing

Removing

 Remove applicable door trim --> 70 - INTERIOR TRIM .

12:19:47 AM Page 37
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Fig. 555: Identifying Bulb For Socket At Door Trim And Connector For Socket
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull bulb holder with bulb - 1 - out of door opener.

 Remove bulb.

Installing

Install in reverse order of removal, noting the following:

 Insert bulb for door opener light in opening and engage.

 Install door trim --> 70 - INTERIOR TRIM .

Door entry warning lights, removing and installing

Procedure for all door entry and warning lights

 Drivers Door Warning Light W30

 Left Front Entry Light W31
 Right Front Entry Light W32
 Left Rear Entry Light W33

 Right Rear Entry Light W34

 Front Passengers Door Warning Light W36
 Left Rear Door Warning Light W37
 Right Rear Door Warning Light W38

is the same.

Removing

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Fig. 556: Identifying Door Safety/Entry Light And Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use a flat-head screwdriver to press in retaining tab - 1 - and pry out door light - 2 -.
 Disconnect electrical connection - 3 -.

Fig. 557: Prying Off Cover On Door Safety Light

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Where applicable, carefully pry off cover at door light - arrow -.

 Remove bulb (12 V, 5 W) from bulb holder.

Installing

Install in reverse order of removal, noting the following:

 If applicable, attach cover at door light.

12:19:47 AM Page 39
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 Insert door light in opening and engage on opposite side.

Left Footwell Light W9 , Right Footwell Light W10 , removing and installing

Removing

Fig. 558: Identifying Retaining Tab, Footwell Light, And Electrical Connection
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use a flat screwdriver to press in retaining tab - 1 - and pry out footwell light - 2 -.
 Disconnect electrical connection - 3 -.
 Remove bulb (12 V, 5 W) from holder.

Installing

Install in reverse order of removal, noting the following:

 Insert footwell light in opening and engage on opposite side.

Left Rear Footwell Light W45 , Right Rear Footwell Light W46 , removing and installing

Removing

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ELECTRICAL Electrical Equipment

Fig. 559: Slide Footwell And Disengage

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Slide footwell light in direction of - arrow - and disengage.

Fig. 560: Prying Off Cap

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pry off cap - arrows -.

 Remove bulb (12 V, 5 W) from holder.

Installing

Install in reverse order of removal.

Left Luggage Compartment Light W18 , Right Luggage Compartment Light W35 - Sedan, removing and installing

Removing

12:19:47 AM Page 41
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ELECTRICAL Electrical Equipment

Fig. 561: Identifying Retaining Tab, Luggage Compartment Light, And Electrical Connection
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use a flat screwdriver to press in retaining tab - 1 - and pry out luggage compartment light - 2 -.
 Disconnect electrical connection - 3 -.
 Remove bulb (12 V, 5 W) from holder.

Installing

Install in reverse order of removal.

Luggage Compartment Light W3 - Avant, removing and installing

Special tools, testers and auxiliary items required

Fig. 562: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

12:19:47 AM Page 42
 2005 Audi A4 Quattro
ELECTRICAL Electrical Equipment

 Hook 3370

Removing

Fig. 563: Removing Luggage Compartment Light From Headliner Opening Using Hook 3370
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully remove luggage compartment light from headliner opening using hook 3370 as illustrated -
arrow -.
 Disconnect electrical connection.

Installing

Install in reverse order of removal.

Luggage Compartment Light W3 - bulb, Avant, replacing

Removing

Fig. 564: Prying Off Lens With Screwdriver

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Insert small screwdriver at recess in lens and carefully pry off lens - arrow -.

12:19:47 AM Page 43
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 Remove bulb (12 V, 6 W) from holder.

Installing

Install in reverse order of removal, noting the following:

 Press on lens until it engages.

Rear Lid Courtesy Lamp W51 - Avant, removing and installing

Special tools, testers and auxiliary items required

Fig. 565: Identifying Special Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Hook 3370

Removing

Fig. 566: Pulling Rear Lid Light Using Hook 3370

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Carefully pull rear lid light in direction of - arrow - using hook 3370 as illustrated.

12:19:47 AM Page 44
 2005 Audi A4 Quattro
ELECTRICAL Electrical Equipment

 Disconnect electrical connection.

Fig. 567: Pulling Reflector Out Of Rear Lid Light

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Where applicable, pull reflector - 1 - out of rear lid light - 2 -.

 Remove bulb (12 V, 6 W) from holder.

Installing

Install in reverse order of removal, noting the following:

 Insert rear lid light in opening and engage on opposite side.

HORN

Signal Horn/Dual Tone Horn H1 - through 10.04, removing and installing

Removing

 Remove applicable headlamp:

 Halogen headlamp through 10.04 --> Headlamps, removing and installing

 HID headlamp through 10.04 --> Headlamps, removing and installing
 HID "Bi-Xenon" headlamp through 10.04 --> Headlamps, removing and installing

12:19:47 AM Page 45
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Fig. 568: Identifying Connector, Nut, And Horn

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connection - 2 -.

 Remove nut - 1 - and detach horn from retainer.

NOTE:  Illustration shows bumper removed for clarity.

Installing

Install in reverse order of removal, noting the following:

 Install headlamp.

 Halogen headlamp through 10.04 --> Headlamps, removing and installing

 HID headlamp through 10.04 --> Headlamps, removing and installing
 HID "Bi-Xenon" headlamp through 10.04 --> Headlamps, removing and installing

Tightening torque

Component - fastener Nm
Horn to bracket - nut 5

Signal Horn/Dual Tone Horn H1 - from 11.04, removing and installing

Removing

Vehicles without charge air cooler or additional radiator:

12:19:47 AM Page 46
 2005 Audi A4 Quattro
ELECTRICAL Electrical Equipment

Fig. 569: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release fasteners - 1 - and - 2 - and remove front noise insulation.

Vehicles with charge air cooler or additional radiator:

 Remove front bumper cover --> 63 BUMPER .

Fig. 570: Disconnecting Left/Right Electrical Connectors Of Horns

Courtesy of VOLKSWAGEN UNITED STATES, INC.

All models:

 Disconnect electrical connection - 3 -.

 Remove nut - 1 - and detach horn - 2 - from retainer.

NOTE:  Illustration shows bumper removed for clarity.

Installing

Install in reverse order of removal, noting the following:

12:19:47 AM Page 47
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Vehicles with charge air cooler or additional radiator:

 Install front bumper cover --> 63 BUMPER .

Tightening torque

Component - fastener Nm
Horn to bracket - nut 5

HEATED STEERING WHEEL

Heated steering wheel, servicing

 Remove airbag module and steering wheel --> 69 - PASSENGER PROTECTION - AIRBAGS, SEAT
BELTS .
 Check wiring connections Wiring Diagrams.

NOTE:  Steering wheel must be replaced if heated steering wheel malfunctions.

GARAGE DOOR OPENER - HOMELINK (R)

Garage Door Opener Control Head E284 , removing and installing

Removing

Fig. 571: Prying Control Head Out Of Windshield Frame

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use small screwdriver to pry control head out of sun visor at locations indicated - arrows -.
 Disconnect electrical connection.

Installing

Install in reverse order of removal.

12:19:47 AM Page 48
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Garage Door Opener Control Module J530 - through 10.04, removing and installing

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Removing

 Remove front bumper cover --> 63 BUMPER .

Fig. 572: Identifying Bolt And Module For Removal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove bolt - 2 - and disengage retainer.

 Remove module - 1 - from bumper cover.
 Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

 Install front bumper cover --> 63 BUMPER .

Garage Door Opener Control Module J530 - from 11.04, removing and installing

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Removing

 Remove front bumper cover --> 63 BUMPER .

Vehicles with headlamp washers

12:19:47 AM Page 49
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Fig. 573: Identifying Hose, Spray Jet, And Screws

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release clamp and remove hose - 1 -.

 Turn hose connector - 2 - on headlight washer system upward.

Continued for all

Fig. 574: Identifying Retaining Clips, Retainer, Module, And Electrical Connection
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clips - 4 - and fold back retainer - 3 -.

 Remove module - 2 - from bumper cover.
 Disconnect electrical connection - 1 -.

Installing

Install in reverse order of removal, noting the following:

 Install front bumper cover --> 63 BUMPER .

12:19:47 AM Page 50
 2005 Audi A4 Quattro
2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

2005-06 ELECTRICAL

Fuses & Circuit Breakers - A4, S4, Cabriolet

IDENTIFICATION

WARNING: Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steering column, instrument panel or
related components, see SAFETY REQUIREMENTS FOR AIRBAGS in
BODY INTERIOR article.

ENGINE CODE

Engines are identified by a 3-letter code stamped on the engine. For engine code locations, see Fig. 1 - Fig. 4.
Engine codes are also located on the vehicle data plate.

Fig. 1: Locating Engine Code (1.8L & 2.0L - AMB Shown)

1:15:30 AM
1:15:34 Page 1
 2005 Audi A4 Quattro
2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

Courtesy of AUDI OF AMERICA, INC.

Fig. 2: Locating Engine Code (3.0L)

Courtesy of AUDI OF AMERICA, INC.

1:15:30 AM Page 2
 2005 Audi A4 Quattro
2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

Fig. 3: Identifying "Engine Code" And "Serial Number" (3.2L)

Courtesy of AUDI OF AMERICA, INC.

Fig. 4: Locating "Engine Code" And "Serial Number" (4.2L V8)

Courtesy of AUDI OF AMERICA, INC.

COMPONENT LOCATION

Relay/Fuse Panels & Connector Stations

1:15:30 AM Page 3
 2005 Audi A4 Quattro
2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

Fig. 5: Location Of Main Fuse, Connector Stations, Relay/Fuse Carriers & Fuse Panel - Overview
Courtesy of AUDI OF AMERICA, INC.

Location No. Description Refer to

1 Main Fuse Fig. 7
2 Connector station - Right A-pillar Fig. 13
3 Connector station - RF seat wiring Fig. 17
4 Relay panel (3-position) Fig. 9

1:15:30 AM Page 4
 2005 Audi A4 Quattro
2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

5 Relay panel (9-position) at Vehicle Electrical Fig. 12

System Control Module
6 Relay panel (4-position) with threaded connection Fig. 11
7 Connector station - LF seat wiring Fig. 17
8 Fuse panel Fig. 8
9 Connector station - Left A-pillar Fig. 15
10 Connector station E-Box Fig. 18
11 Relay panel (Carrier) E-Box Fig. 10
: For component locations refer to overview illustration, see Fig. 5

COMPONENT IDENTIFICATION
FUSES

WARNING: Never replace a fuse with one that has a higher amperage rating. A fuse
with a too high amperage could damage the electrical part and cause a
fire.

For access to fuse box, refer to Fig. 6.

Fig. 6: Identifying Fuses Box Panel Cover

Courtesy of AUDI OF AMERICA, INC.

Main Fuse (Engine Compartment)

The main fuse is located on the battery positive post, the fuse is numbered "S88" and has an amperage rating of

1:15:30 AM Page 5
 2005 Audi A4 Quattro
2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

150 amps. The battery is located in the plenum chamber on right side of engine compartment.

Fig. 7: Locating Main Fuse

Courtesy of AUDI OF AMERICA, INC.

MAIN FUSE IDENTIFICATION (ENGINE COMPARTMENT - RIGHT SIDE)

Designation Amp Rating
S88 - Strip fuse 150A

Fuse Index Information (Passenger Compartment)

1:15:30 AM Page 6
 2005 Audi A4 Quattro
2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

Fig. 8: Identifying Fuse Box Instrument Panel - Left Side

Courtesy of AUDI OF AMERICA, INC.

IDENTIFYING FUSES (INSTRUMENT PANEL - LEFT SIDE)

Fuse Function/Component Amp Rating
No. (A)
E87 - A/C Control Head
1 10A
J255 - Climatronic Control Module
W9 - Left Footwell Light
2 5A
W10 - Right Footwell Light
Z20 - Left Washer Nozzle Heater
3 5A
Z21 - Right Washer Nozzle Heater
J293 - Coolant Fan Control (FC) Control Module
4 5A
J671 - Coolant Fan Control (FC) Control Module 2
E272 - Function Selector Switch II
F189 - Tiptronic Switch
G266 - Oil Level Thermal Sensor
5 J401 - Navigation System with CD Drive Control Module 10A
J446 - Parking Aid Control Module
J526 - Telephone Control Module
R36 - Telephone Transceiver
G65 - High Pressure Sensor
6 5A
G238 - Sensor for air quality
E132 - Anti-Slip Control Switch
F36 - Clutch Pedal Switch
7 10A
G85 - Steering Angle Sensor
J104 - ABS Control Module

1:15:31 AM Page 7
 2005 Audi A4 Quattro
2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

J526 - Telephone/Telematics Control Module

8 R36 - Telephone Transceiver 5A
R86 - Telephone Amplifier
9 J569 - Brake Booster Relay 15A
E102 - Headlamp Adjuster
J431 - Headlamp Range Control Module
10 5A
V48 - Left Headlamp Beam Adjusting Motor
V49 - Right Headlamp Beam Adjusting Motor
11 Not used -
12 T16 - 16 pin connector, black, diagnostic connector 10A
13 J527 - Steering Column Electronic Systems Control Module 10A
F - Brake Light Switch
M9 - Left Brake Lamp
14 10A
M10 - Right Brake Lamp
M25 - High-mount Brake Light
J285 - Instrument Cluster Control Module
15 10A
J401 - Navigation System with CD Drive Control Module
E284 - Garage Door Opener Control Head
16 5A
J530 - Garage Door Opener Control Module
J446 - Parking Aid Control Module
17 10A
J502 - Tire Pressure Monitoring Control Module
18 Not used -
19 E23 - Fog Lamp Switch 10A
J344 - Right High-intensity Gas Discharge Lamp Control Module
M31 - Right Low Beam Headlamp
20 15A
M32 - Right High Beam Headlamp
V49 - Right Headlamp Beam Adjusting Motor
J343 - Left High-intensity Gas Discharge Lamp Control Module
M29 - Left Low Beam Headlamp
21 15A
M29 - Left High Beam Headlamp
V48 - Left Headlamp Beam Adjusting Motor
J386 - Drivers Door Control Module
J387 - Front Passenger's Door Control Module
22 15A
V14 - Left Window Motor
V15 - Right Window Motor
23 Not used -
24 J393 - Comfort System Central Control Module 20A
25 J126 - Fresh Air Blower Control Module 30A
J9 - Rear Window Defogger Relay
26 30A
E87 - A/C Control Head
27 J345 - Towing Recognition Control Module 30A
28 G6 - Transfer Fuel Pump (FP)
20A
J538 - Fuel Pump (FP) Control Module
N - Ignition Coil

1:15:31 AM Page 8
 2005 Audi A4 Quattro
2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

N70 - Ignition Coil 1 with Power Output Stage

N127 - Ignition Coil 2 with Power Output Stage
N128 - Ignition Coil 2
N158 - Ignition Coil 3
N291 - Ignition Coil 3 with Power Output Stage
29 20A
N292 - Ignition Coil 4 with Power Output Stage
N323 - Ignition Coil 5 with Power Output Stage
N324 - Ignition Coil 6 with Power Output Stage
N325 - Ignition Coil 7 with Power Output Stage
N326 - Ignition Coil 8 with Power Output Stage
30 J245 - Convertible Top Control Module 30A
F4 - Back-Up Light Switch
F125 - Multi-Function Transmission Range (TR) Switch
G70 - Mass Air Flow (MAF) Sensor
J60 - Starting Interlock Relay
31 J217 - Transmission Control Module (1CM) 15A
M16 - Left Back-Up Lamp
M17 - Right Back-Up Lamp
T16 - 16 Position Connector, Black Data Link Connector (DLC)
Y7 - Automatic Day/Night Interior Mirror
N30 - Cylinder 1 Fuel Injector
N31 - Cylinder 2 Fuel Injector
N32 - Cylinder 3 Fuel Injector
N33 - Cylinder 4 Fuel Injector
32 20A
N83 - Cylinder 5 Fuel Injector
N84 - Cylinder 6 Fuel Injector
N85 - Cylinder 7 Fuel Injector
N86 - Cylinder 8 Fuel Injector
U1 - Cigarette lighter 15A
33
U1 - Cigarette Lighter (from 2006 m.y.) 20A
G70 - Mass Air Flow (MAF) Sensor
J155 - Turbocharger (IC) Coolant Pump Control Module
N80 - Evaporative Emission (EVAP) Canister Purge Regulator
N112 - Secondary Air Injection (AIR) Solenoid Valve
N144 - Left Mount Solenoid Valve
34 15A
N145 - Right Electro-Hydraulic Engine Mount Solenoid Valve
N156 - Intake Manifold Change-Over Valve
Z19 - Oxygen Sensor (O2S) Heater
Z29 - Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic
Converter (TWC))
U - Socket 30A
35
U1 - Socket (from 2006 m.y.) 20A
36 J519 - Vehicle Electrical System Control Module 30A
J519 - Vehicle Electrical System Control Module
37 30A
V11 - Headlamp Washer Pump
G303 - Radar Interior Monitoring Control Module 1

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2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

G305 - Radar Interior Monitoring Control Module 2

38 H12 - Alarm Horn 15A
J393 - Comfort System Central Control Module
J401 - Navigation System with CD Drive Control Module
J402 - Operating Electronics, Navigation Control Module
J415 - Tuner for navigation/ TV
39 R - Radio 20A
R12 - Amplifier
R94 - Navigation Interface
T8 - 8 Pin Connector, black, radio connector III
H2 - High Tone Horn
40 H7 - Low Tone Horn 25A
J4 - Horn Relay
41 Not used 30A
42 J104 - ABS Control Module 25A
J220 - Motronic Engine Control Module (ECM)
N75 - Wastegate Bypass Regulator Valve
43 15A
N205 - Valve 1 for camshaft adjustment
N208 - Valve 2 for camshaft adjustment
J215 - Climatronic Control Module
30A
J216 - Right Rear Heated Seat Control Module
44
J215 - Left Rear Heated Seat Control Module (from 2006 m.y.)
35A
J216 - Right Rear Heated Seat Control Module (from 2006 m.y)
Some of the equipment items listed are optional or only available on certain model configurations.

AUTOMATIC CIRCUIT BREAKERS:

The electric power windows and the electric seat adjusters are protected with Circuit breakers which reset
automatically after the circuit overload has been corrected.

NOTE: Whenever replacing a fuse, always consult the sticker on the inside of the fuse
panel cover. It contains the most up-to-date information regarding the fuse
arrangement.

RELAYS

Relay Panel (3 Position) Dash Panel Driver's Side

For relay number, position number and circuits protected, see IDENTIFYING RELAYS (3 POSITION)
DASH PANEL DRIVER'S SIDE) table. For fuse number, position number, amperage rating and circuits
protected, see IDENTIFYING RELAYS (3 POSITION) DASH PANEL DRIVER'S SIDE table.

NOTE: The relay panel (3 position) carrier is located on the driver's side dash panel
area on the right side. For fuse and relay positions within the panel, see Fig. 9.

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2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

Fig. 9: Identifying Relay Carrier (3-Position)

Courtesy of AUDI OF AMERICA, INC.

IDENTIFYING RELAYS (3 POSITION) DASH PANEL DRIVER'S SIDE)

Position Socket Color Circuit Protected
2 Black J359 - Preheating Coolant , Low Heat Output Relay
3 Brown J360 - Preheating Coolant , High Heat Output Relay
Note: The remaining items in the relay carrier are not used.

IDENTIFYING RELAYS (3 POSITION) DASH PANEL DRIVER'S SIDE

Position Socket Color Circuit Protected Amp Rating
B Black S328 - Auxiliary Heater Fuse 2 60A
C Green S126 - Auxiliary Heater Fuse 40A
Note: The remaining items in the relay carrier are not used.

Relay Carrier In Electronics Box, Plenum Chamber

For fuse and relay positions within the panel, see Fig. 10.

For relay number, position number and circuits protected, see the appropriate IDENTIFYING RELAYS table.

For fuse number, position number, amperage rating and circuits protected, see the appropriate IDENTIFYING
FUSES table.

NOTE: The relay panel (4 position) carrier is located in electronics box, plenum
chamber, in the left rear corner of the engine compartment.

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Fig. 10: Relay Panel (4 Position) In E-Box

Courtesy of AUDI OF AMERICA, INC.

Relay Carrier E-Box (Gasoline Engine)

For identification of the relay panel 4 position carrier and it's layout, refer to Fig. 10.

IDENTIFYING RELAYS (RELAY CARRIER IN E-BOX - GASOLINE ENGINE)

Position No. Socket Color Circuit Protected
1 Black J60 - Starter Interlock Alarm System Relay

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1.1 Red J151 - Coolant Circulation Pump Relay

2 Brown J299 - Secondary Air Injection (AIR) Pump Relay
3 Black J271 - Motronic (ECM) Power Supply Relay
3 Red J155 - Turbocharger (TC) Coolant Pump Relay
J226 - Park/Nuetral Position (PNP) Relay
4 Blue
J434 - Starter Lock/Clutch Pedal Switch Relay
Note: The remaining items in the relay carrier are not used.

IDENTIFYING RELAYS (RELAY CARRIER IN E-BOX - GASOLINE ENGINE)

Position No. Socket Color Amp Rating Circuit Protected
A Black 15A S282 - Engine Electronics Fuse
B Black 40A S130- Secondary Air Injection (AIR) Pump
fuse
C Grey 15A S286 - Automatic Transmission After-Run
Fuse
Note: The remaining items in the relay carrier are not used.

Relay Carrier E-Box (Diesel Engine*)

For identification of the relay panel 4 position carrier and it's layout, refer to Fig. 10.

IDENTIFYING RELAYS (RELAY CARRIER IN E-BOX - DIESEL ENGINE)

Position No. Socket Color Circuit Protected
1 Black J60 - Starter Interlock Alarm System Relay
1.2 Blue J17 - Fuel Pump (FP) Relay
2 Black J52 - Glow Plug Relay
3 Brown J317 - Power Supply (Terminal 30, B+) Relay
J226 - Park/Nuetral Position (PNP) Relay
4 Black
J434 - Starter Lock/Clutch Pedal Switch Relay
: The remaining items in the relay carrier are not used.
*: Diesel engine - not for USA/CDN.

IDENTIFYING RELAYS (RELAY CARRIER IN E-BOX - DIESEL ENGINE)

Position No. Socket Color Amp Rating Circuit Protected
A Black 15A S102 - Engine Control Module (ECM)
Fuse
B Black 60A S39 - Engine Glow Plug Fuse Strip
C Grey 15A S286 - Automatic Transmission After-Run
Fuse
D Red 60A S189 - Fuse 2 For Glow Plugs
E - - V274 - Control Module Cooling Fan
F Red 60A S189 - Fuse 2 For Glow Plugs

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2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

: Items D, E and F are in electronic box, plenum chamber.

: The remaining items in the relay carrier are not used.
*: Diesel engine - not for USA/CDN.

Relay Panel (4-Position) With Threaded Connection

For fuse and relay positions within carrier, see Fig. 11. For relay number, position number and circuits
protected, see RELAY IDENTIFICATION (RELAY PANEL (4-POSITION) WITH THREADED
CONNECTION) table. For fuse number, position number, amperage rating and circuits protected, see FUSE
IDENTIFICATION (RELAY PANEL (4-POSITION) WITH THREADED CONNECTION) table.

NOTE: The relay panel (4-position) carrier is located under driver's side of instrument
panel.

Fig. 11: Identifying Relay Panel (4-Position) With Threaded Connection

Courtesy of AUDI OF AMERICA, INC.

RELAY IDENTIFICATION (RELAY PANEL (4-POSITION) WITH THREADED CONNECTION)

Position No. Socket Color Circuit Protected
3 White J662 - NG Engine Throttle Relay 1 (Driving
school)
4 Blue J663 - NG Engine Throttle Relay 2 (Driving
school)

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2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

Note: The remaining items in the relay carrier are not used.

FUSE IDENTIFICATION (RELAY PANEL (4-POSITION) WITH THREADED CONNECTION)

Position No. Socket Color Amp Rating Circuit Protected
B - - Optional Equipment, Repeller system
E Black 40A S214 - Radiator After run Fuse
40A S42 - Coolant Fan Fuse
G Black
60A S42 - Coolant Fan Fuse
H Brown 40A S123 - ABS Control Module Fuse 1
Note: The remaining items in the relay carrier are not used.

Relay Panel (9-Position) At Vehicle Electrical System Control Module

For fuse and relay position within carrier, see Fig. 12. For relay number, position number and circuits protected,
see RELAY IDENTIFICATION (RELAY PANEL (9-POSITION)) table. For fuse number, position
number, amperage rating and circuits protected, see FUSE IDENTIFICATION (RELAY PANEL (9-
POSITION)) table.

NOTE: The relay panel (9-position) is located behind instrument panel, driver's side,
behind 3-position relay panel.

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Fig. 12: Identifying Relay Panel (9-Position) At Vehicle Electrical System Control Module
Courtesy of AUDI OF AMERICA, INC.

RELAY IDENTIFICATION (RELAY PANEL (9-POSITION))

Position No. Socket No. Circuit Protected
1 Green J17 - Fuel Pump (FP) Relay
2 Red J236 - Servotronic Control Module
3 Blue J4 - Horn Relay
4 Brown J569 - Brake Booster Relay
5 Purple J9 - Rear Window Defogger Relay
6 Black J59 - Load Reduction Relay
Note: The remaining items in the relay carrier are not used.

FUSE IDENTIFICATION (RELAY PANEL (9-POSITION))

Position No. Socket Color Amp Rating Circuit Protected
B Brown 40A S67 - Convertible Top Operation Fuse
D Brown 30A S280 - Power Windows Fuse 2
E Red 30A S45 - Driver's Power Seat Adjustment Circuit
Breaker 2
F Black 30A S37 - Power Windows Fuse
G Green 30A S77 - Trailer (terminal 30, B+) Fuse
Note: The remaining items in the relay carrier are not used.

CONNECTOR STATION
CONNECTOR STATION - RIGHT A PILLAR

The connector station is located at the right side footwell below the A-pillar trim. For pin and fuse position in
connector station, see illustrations below.

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Fig. 13: Locating Connector Station (Right A Pillar)

Courtesy of AUDI OF AMERICA, INC.

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Fig. 14: Identifying Connector Station Fuses (Right A Pillar)

Courtesy of AUDI OF AMERICA, INC.

FUSE IDENTIFICATION (CONNECTOR STATION - RIGHT)

Fuse Position Socket Color Amp Rating Circuit Protected
Black 30A S46 - Power Seat
E
Black 10A S46 - Power Seat, Lumbar Adjustment.
Note: The remaining items in the connector point are not used.

PIN IDENTIFICATION (CONNECTOR STATION - RIGHT)

Position No. Designation Component
13 T6p, 6 pin connector, Lilac Satellite radio
14 T6q, 6 pin connector, Lilac Satellite radio
15 T17c, 17 pin connector, Red Headlamp
Note: The remaining items in the connector point are not used.

CONNECTOR STATION - LEFT A PILLAR

The connector station is located at the left side footwell below the A-pillar trim. For pin and fuse position in
connector station, see illustrations below.

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Fig. 15: Locating Connector Station (Left A Pillar)

Courtesy of AUDI OF AMERICA, INC.

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Fig. 16: Identifying Connector Station Fuses (Left A Pillar)

Courtesy of AUDI OF AMERICA, INC.

PIN & FUSE IDENTIFICATION (CONNECTOR STATION - LEFT)

Position No. Designation Component
7 T6b - 6 pin connector, Black Servotronic
8 T10i - 10 pin connector, Blue Parking aid (where applicable)
12 T10k - 10 pin connector, White Auxiliary heater
13 T10c - 10 pin connector, Violet Wiper motor
14 T10d -10 pin connector, Grey Fan/compressor
15 T17b - 17 pin connector, Green Left headlight (connector 3)
16 T17a - 17 pin connector, Red Left headlight (connector 2)
17 T17 - 17 pin connector, Black Left headlight (connector 1)
B T1a - 1 pin connector, Black Headlight washer system
Note: The remaining items in the connector point are not used.

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CONNECTOR STATION - LF/RF SEAT WIRING

The connector stations are located under the passenger seat and under the driver seat. For pin position in
connector station, see illustration below.

Fig. 17: Connector Station - LF/RF Seat Wiring

Courtesy of AUDI OF AMERICA, INC.

PIN IDENTIFICATION (CONNECTOR STATION - RIGHT SEAT WIRING)

Position No. Designation Component
1 T3d - 3 pin connector, Yellow Side airbag
2 T10p - 10 pin connector, Red Supply
3 T6e - 6 pin connector, Green Seat heating
4 T8c - 8 pin connector Black Seat belt buckle

PIN IDENTIFICATION (CONNECTOR STATION - LEFT SEAT WIRING)

Position No. Designation Component
1 T3c - 3 pin connector, Yellow Side airbag
2 T10o - 10 pin connector, Red Supply
3 T6d - 6 pin connector, Green Seat heating
4 T8b - 8 pin connector Black Seat belt buckle

CONNECTOR STATION E-BOX

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The connector station is located In the electronic box in plenum chamber on left side of engine compartment.
For pin position in connector station, see illustration below.

Fig. 18: Identifying Connector Station E-Box

Courtesy of AUDI OF AMERICA, INC.

PIN IDENTIFICATION (CONNECTOR STATION - E-BOX)

Position No. Designation Component
1 T10 - 10 pin connector, Black Engine/Transmission (connector 2)
2 T10a - 10 pin connector, Brown Engine/Transmission (connector 3)
3 T17d - 17 pin connector, Red Engine/Transmission (connector 1)
6 T17e - 17 pin connector, White Engine/Transmission (connector 4)
Note: The remaining items in the connector point are not used.

FUSES - CIRCUIT PROTECTION

WARNING: Never replace a fuse with one that has a higher amperage rating. A fuse
with a too high amperage could damage the electrical part and cause a
fire.

For access to fuse box, refer to Fig. 19.

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Fig. 19: Identifying Fuses Box Panel Cover

Courtesy of AUDI OF AMERICA, INC.

REPLACING A FUSE

A problem in the electrical system may be caused by a blown fuse.

 Switch off the ignition and the electrical component affected.

 Carefully pry the face cover off the instrument panel using the ignition key or a screwdriver. See Fig. 19.
 Check the fuse index to find out which fuse belongs to the component which has failed. See FUSES.
 Remove the blown fuse with the plastic clip provided. The clip is located on the holder in the fuse box.
 Replace a blown fuse (recognizable by the melted metal strip inside) with a fuse of the same amperage.
 Firmly snap the cover back onto the instrument panel face.

The various electrical circuits are protected by fuses. The fuses are clustered in a centralized unit. The unit is
located behind the face panel at the end of the instrument panel.

Two spare fuses end a sticker identifying the fuses are located on the inside of the fuse box cover.

You are well advised to keep a supply of spare fuses in your vehicle. Fuses with the proper ampere ratings are
available at your Audi dealer.

NOTE:  On no account should fuses be repaired (e.g. with tin foil or wire) as this
may cause serious damage elsewhere in the electrical circuit or cause fire.
 If a fuse blows repeatedly, do not keep replacing it. Track and fix shorted
or overloaded circuit.

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2005-06 ELECTRICAL Fuses & Circuit Breakers - A4, S4, Cabriolet

FUSE - COLOR CODES

Identifying fuse color and ampere rating, refer to table below.

WARNING: Never replace a fuse with one that has a higher amperage rating. A fuse
with a too high amperage could damage the electrical part and cause a
fire.

IDENTIFYING FUSE BY COLOR

Current Rating Amperes Color
1A Black
3A Violet
5A Light Brown
7.5A Brown
10A Red
15A Blue
20A Yellow
25A White or Natural
30A Green
35A Green-Blue
40A Orange
50A Red

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2005-08 ELECTRICAL

Fuses & Circuit Breakers - A4 & S4, Except Cabriolet

IDENTIFICATION

WARNING: Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steering column, instrument panel or
related components, refer to appropriate AIRBAG SAFETY PRECAUTIONS
or SAFETY REQUIREMENTS FOR AIRBAGS in BODY INTERIOR article.

ENGINE CODE

Engines are identified by a 3-letter code stamped on the engine. For engine code locations, see Fig. 1-Fig. 2 .
Engine codes are also located on the vehicle data plate.

Fig. 1: Locating Engine Code (1.8L & 2.0L - AMB Shown)

1:16:19 AM
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Courtesy of AUDI OF AMERICA, INC.

Fig. 2: Locating Engine Code (3.0L)

Courtesy of AUDI OF AMERICA, INC.

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 2005 Audi A4 Quattro
2005-08 ELECTRICAL Fuses & Circuit Breakers - A4 & S4, Except Cabriolet

Fig. 3: Identifying "Engine Code" And "Serial Number" (3.2L)

Courtesy of AUDI OF AMERICA, INC.

COMPONENT LOCATION

Relay/Fuse Panels & Connector Stations

Fig. 4: Identifying Location Of Relay/Fuse Panels & Connector Stations

Courtesy of AUDI OF AMERICA, INC.

Location No. Description Refer to

1 Main fuse Fig. 5

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2005-08 ELECTRICAL Fuses & Circuit Breakers - A4 & S4, Except Cabriolet

2 Connector station - Right A-pillar Fig. 11

3 Connector station - RF seat wiring Fig. 15
4 Relay panel (9-position) at Vehicle Electrical Fig. 10
System Control Module -J519-
5 Relay panel (4-position) with threaded connection Fig. 9
6 Connector station - LF seat wiring Fig. 15
7 Fuse panel Fig. 6
8 Connector station - Left A-pillar Fig. 13
9 Connector station with threaded connection Fig. 16
10 Relay panel (4-position) Fig. 7

COMPONENT IDENTIFICATION
FUSES

Main Fuse (Engine Compartment)

The main fuse is located on the battery positive post, the fuse is numbered "S88" and has an amperage rating of
150 amps. The battery is located in the plenum chamber on right side of engine compartment.

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Fig. 5: Locating Main Fuse

Courtesy of AUDI OF AMERICA, INC.

MAIN FUSE IDENTIFICATION (ENGINE COMPARTMENT - RIGHT SIDE)

Designation Amp Rating
S88 - Strip fuse 150A

Fuse Index Information (Passenger Compartment)

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Fig. 6: Identifying Fuse Box Instrument Panel - Left Side

Courtesy of AUDI OF AMERICA, INC.

IDENTIFYING FUSES (INSTRUMENT PANEL - LEFT SIDE)

Fuse Function/Component Amp Rating
No. (A)
1 J255 - Climatronic Control Module 10A
W9 - Left Footwell Light
2 5A
W10 - Right Footwell Light
Z20 - Left Washer Nozzle Heater
Z21 - Right Washer Nozzle Heater
3 5A
W45 - Left Rear Footwell Light
W46 - Right Rear Footwell Light
J293 - Coolant Fan Control (FC) Control Module
4 5A
J671 - Coolant Fan Control (FC) Control Module 2
E149 - Rear Window Shade Switch
E272 - Function Selector Switch II
F189 - Tiptronic Switch
5 G266 - Oil Level Thermal Sensor 10A
J262 - Rear Window Shade Control Module
J401 - Navigation System with CD Drive Control Module
J446 - Parking Aid Control Module
G65 - High Pressure Sensor
6 5A
G238 - Sensor for air quality

E132 - Anti-Slip Control Switch

7 10A
F36 - Clutch Pedal Switch
F47 - Brake Pedal Switch

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J104 - ABS Control Module

R36 - Telephone Transceiver
8 5A
R86 - Telephone Amplifier
9 J569 - Brake Booster Relay 15A
E102 - Headlamp Adjuster
J431 - Headlamp Range Control Module
J745 - Headlamp Range/Cornering Lamp Control Module
10 5A
V48 - Left Headlamp Beam Adjusting Motor
V49 - Right Headlamp Beam Adjusting Motor
V319 - Right Dynamic Cornering Light Motor
J234 - Airbag Control Module
11 5A
K145 - Warning Lamp for airbag off, passenger side
12 T16 - 16 pin connector, black, diagnostic connector 10A
13 J527 - Steering Column Electronic Systems Control Module 10A
14 F - Brake Light Switch 10A
J285 - Instrument Cluster Control Module
15 10A
J401 - Navigation System with CD Drive Control Module
E284 - Garage Door Opener Control Head
16 5A
J530 - Garage Door Opener Control Module
G397 - Rain/Light Recognition Sensor
17 J446 - Parking Aid Control Module 10A
J502 - Tire Pressure Monitoring Control Module
18 V318 - Left Dynamic Cornering Light Motor 5A
L22 - Left Front Fog Lamp
19 10A
L23 - Right Front Fog Lamp
20 Not used -
21 Not used -
J386 - Drivers Door Control Module
22 15A
J387 - Front Passenger's Door Control Module
J388 - Left Rear Door Control Module
23 15A
J389 - Right Rear Door Control Module
24 J393 - Comfort System Central Control Module 20A
25 J126 - Fresh Air Blower Control Module 30A
26 J9 - Rear Window Defogger Relay 30A
27 J345 - Towing Recognition Control Module 30A
G6 - Transfer Fuel Pump (FP)
28 20A
J538 - Fuel Pump (FP) Control Module
29 Not used -
30 J245 - Power Sunroof Control Module 20A

F4 - Back-Up Light Switch

31 G70 - Mass Air Flow (MAF) Sensor 15A
G399 - Light Recognition Sensor
J207 - Starting Interlock Relay

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J217 - Transmission Control Module (1CM)

32 U10 - Trailer Socket (2) 15A
U1 - Cigarette lighter 15A
33
U1 - Cigarette lighter (1) 20A
U5 - 12V Socket 30A
34
U5 - l2V Socket (1) 20A
U - Socket 30A
35
U - Socket (1) 20A
J519 - Vehicle Electrical System Control Module
36 30A
V12 - Rear Window Wiper Motor
J519 - Vehicle Electrical System Control Module
37 30A
V11 - Headlamp Washer Pump
G303 - Radar Interior Monitoring Control Module 1
38 H12 - Alarm Horn 15A
J393 - Comfort System Central Control Module
T8 - 8 pin Connector, black, radio connector III
39 R - Radio 20A
R12 - Amplifier
H2 - High Tone Horn
40 H7 - Low Tone Horn 25A
J4 - Horn Relay
J364 - Auxiliary Heater Control Module
41 30A
R64 - Auxiliary Heater Radio Receiver
42 J104 - ABS Control Module 25A
Engine Timing
G70 - Mass Air Flow (MAF) Sensor
G212 - EGR Potentiometer
43 J363 - SIMOS Control Module Power Supply Relay 15A
J623 - Engine Control Module (ECM)
J757 - Engine Component Power Supply Relay
N18 - EGR Vacuum Regulator Solenoid Valve
J255 - Climatronic Control Module (3)
44 30A
J255 - Climatronic Control Module (4)
(1) Valid from February 2005

(2) Applicable from 2006 model year

(3) Through 2005 model year

(4) From 2006 model year

Some of the equipment items listed are optional or only available on certain model configurations.

1:16:19 AM Page 8
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2005-08 ELECTRICAL Fuses & Circuit Breakers - A4 & S4, Except Cabriolet

AUTOMATIC CIRCUIT BREAKERS:

The electric power windows and the electric seat adjusters are protected with Circuit breakers which reset
automatically after the circuit overload has been corrected.

NOTE: Whenever replacing a fuse, always consult the sticker on the inside of the fuse
panel cover. It contains the most up-to-date information regarding the fuse
arrangement.

RELAYS

Relay Panel (4 Position) In Electronics Box, Plenum Chamber

For fuse and relay positions within the panel, see Fig. 7.

For relay number, position number and circuits protected, see the appropriate IDENTIFYING RELAYS table.

For fuse number, position number, amperage rating and circuits protected, see the appropriate IDENTIFYING
FUSES table.

NOTE: The relay panel (4 position) carrier is located in electronics box, plenum
chamber, in the left rear corner of the engine compartment.

Fig. 7: Identifying Relay Carrier (4 Position)

Courtesy of AUDI OF AMERICA, INC.

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Fig. 8: Relay Panel (4 Position) In E-Box (Engine Code BBJ )

Courtesy of AUDI OF AMERICA, INC.

Relay Panel (4 Position) In E-Box (Engine Code BGB, BPG)

For identification of the relay panel 4 position carrier and it's layout, refer to Fig. 7.

IDENTIFYING RELAYS (4 POSITION) IN E-BOX (ENGINE CODE BGB, BPG)

Position Socket Color Circuit Protected
1.2 Blue J207- Starter Interlock Relay

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2 Brown J271- Motronic (ECM) Power Supply Relay

3 Black J757 - Engine Component Power Supply Relay
Note: The remaining items in the relay carrier are not used.

IDENTIFYING FUSES (4 POSITION) IN E-BOX (ENGINE CODE BGB, BPG)

Position No. Socket Color Amp Rating Circuit Protected
A Blue 15A S282 - Engine Electronics Fuse
B Brown 15A S345 - Engine Electronics Fuse 3
C Grey 15A S102 - Engine Control Module (ECM)
Fuse
D Yellow 20A S131 - Safety Fuse 1
E Black 15A S344- Engine Electronics Fuse 2
G Purple 15A S286 - Automatic Transmission After-Run
Fuse
Note: The remaining items in the relay carrier are not used.

Relay Panel (4 Position) In E-Box (Engine Code BFB, BBK)

For identification of the relay panel 4 position carrier and it's layout, refer to Fig. 7.

IDENTIFYING RELAYS (4 POSITION) IN E-BOX (ENGINE CODE BFB, BBK)

Position Socket Color Circuit Protected
1.1 Blue J151- Coolant Circulation PumpRelay
1.2 Blue J207- Starter Interlock Relay
J434 - Starter, Clutch Pedal Switch Locking Relay
(1)

2 Brown J271- Motronic (ECM) Power Supply Relay

3 Black J299- Secondary Air Injection Pump Relay
(1) Engine codes BBK, BHF only.

Note: The remaining items in the relay carrier are not used.

IDENTIFYING FUSES (4 POSITION) IN E-BOX (ENGINE CODE BFB, BBK)

Position No. Socket Color Amp Rating Circuit Protected
A Blue 15A S344 - Engine Electronics Fuse 2
B Black 40A S130- Secondary Air Injection (AIR)
Pump fuse
C Grey 15A S286 - Automatic Transmission After-Run
Fuse
D Yellow 20A S102 - Engine Control Module (ECM)
Fuse
E Black 15A S116- Injector fuses

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2005-08 ELECTRICAL Fuses & Circuit Breakers - A4 & S4, Except Cabriolet

G Red 15A S282 - Engine Electronics Fuse

Note: The remaining items in the relay carrier are not used.

Relay Panel (4 Position) In E-Box (Engine Code AUK, BKH)

For identification of the relay panel 4 position carrier and it's layout, refer to Fig. 7.

IDENTIFYING RELAYS (4 POSITION) IN E-BOX (ENGINE CODE AUK, BKH)

Position Socket Color Circuit Protected
1.1 Blue J496 - Auxiliary Engine Coolant (EC) Pump Relay
2 Brown J271 - Motronic (ECM) Power Supply Relay
3 Black J757 - Engine Component Power Supply Relay
Note: The remaining items in the relay carrier are not used.

IDENTIFYING FUSES (4 POSITION) IN E-BOX (ENGINE CODE AUK, BKH)

Position No. Socket Color Amp Rating Circuit Protected
A Blue 15A S344 - Engine Electronics fuse 2
B Brown 15A S282 - Engine Electronics fuse
C Grey 15A S102 - Engine Control Module (ECM) fuse
D Yellow 20A S131 - Safety fuse 1
E Black 15A S73 - Heated Oxygen Sensor (HO2S)
Circuit Breaker
G Purple 15A S286 - Automatic Transmission After-Run
Fuse
Note: The remaining items in the relay carrier are not used.

Relay Panel (4 Position) In E-Box (Engine Code BNS)

For identification of the relay panel 4 position carrier and it's layout, refer to Fig. 7.

IDENTIFYING RELAYS (4 POSITION) IN E-BOX (ENGINE CODE BNS)

Position No. Socket Color Circuit Protected
1.1 Blue J151- Coolant Circulation Pump Relay
1.2 Blue J569 - Brake Booster Relay
2 Brown J271- Motronic (ECM) Power Supply Relay
3 Black J757 - Engine Component Power Supply Relay
4 Black J299 - Secondary Air Injection (AIR) Pump Relay

IDENTIFYING FUSES (4 POSITION) IN E-BOX (ENGINE CODE BNS)

Position No. Socket Color Amp Rating Circuit Protected
A Yellow 10A S344 - Engine Electronics Fuse 2
B Black 15A S282 - Engine Electronics Fuse
C Red 15A S102 - Engine Control Module (ECM)

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Fuse
D Blue 30A S131 - Safety fuse 1
E Black 15A S73 - Heated Oxygen Sensor (HO2S)
Circuit Breaker
E Red 15A S283 - Brake Vacuum Pump Fuse
H (1) Black 50A S130 - Secondary Air Injection (AIR)
Pump Fuse
(1) On under side of relay carrier

Note: The remaining items in the relay carrier are not used.

Relay Panel (4 Position) In E-Box (Engine Code BBJ - With Automatic Transmission AG5)

For identification of the relay panel 4 position carrier and it's layout, refer to Fig. 8.

NOTE: Four pin relay carrier is located in electronics box, plenum chamber, in the left
rear corner of the engine compartment.

IDENTIFYING RELAYS (4 POSITION) IN E-BOX (ENGINE CODE BBJ - WITH AUTOMATIC

TRANSMISSION AG5)
Position Socket Color Circuit Protected
1.1 (1) Blue J151- Coolant Circulation PumpRelay
1.2 (1) Blue J207- Starter Interlock Relay
2 (1) Brown J271- Motronic (ECM) Power Supply Relay
3 (1) Black J271- Secondary Air Injection Pump Relay
(1) Applies to vehicles equipped with automatic transmission (AG5) only.

Note: The remaining items in the relay carrier are not used.

IDENTIFYING FUSES (4 POSITION) IN E-BOX (ENGINE CODE BBJ - WITH AUTOMATIC

TRANSMISSION AG5 )
Position No. Socket Color Amp Rating Circuit Protected
A (1) Yellow 20A S102- Engine Control Module (ECM)
B (1) Black 40A S130- Secondary Air Injection (AIR)
Pump fuse
C (1) Red 15A S282- Engine Electronics fuse
D (1) Blue 15A S344- Engine Electronics fuse 2
E (1) Black 15A S116- Injector fuses
(1) Applies to vehicles equipped with automatic transmission (AG5) only.

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Note: The remaining items in the relay carrier are not used.

Relay Panel (4 Position) In E-Box (Engine Code BBJ - With Transmission 01J / 0AN)

For identification of the relay panel 4 position carrier and it's layout, refer to Fig. 7.

IDENTIFYING RELAYS (4 POSITION) IN E-BOX (ENGINE CODE BBJ - WITH TRANSMISSION

01J / 0AN)
Position No. Socket Color Circuit Protected
1.1 (1) Blue J151- Coolant Circulation Pump Relay
1.2 (1) Blue J207- Starter Interlock Relay
2 (1) Brown J271- Motronic (ECM) Power Supply Relay
3 (1) Black J299- Secondary Air Injection (AIR) Pump Relay
(1) Manual transmission or automatic transmission (multitronic 01J/ multitronic 0AN) only.

Note: The remaining items in the relay carrier are not used.

IDENTIFYING FUSES (4 POSITION) IN E-BOX (ENGINE CODE BBJ - WITH TRANSMISSION

01J / 0AN)
Position No. Socket Color Amp Rating Circuit Protected
A (1) Blue 15A S344 - Engine Electronics fuse 2
B (1) Black 40A S130- Secondary Air Injection (AIR)
Pump fuse
C (1) Grey 15A S286 - Automatic Transmission After-Run
Fuse
D (1) Yellow 20A S102 - Engine Control Module (ECM)
Fuse
E (1) Black 15A S116- Injector fuses
G Red 15A S282 - Engine Electronics Fuse
(1) Manual transmission or automatic transmission (multitronic 01J/ multitronic 0AN) only.

Note: The remaining items in the relay carrier are not used.

Relay Panel (4-Position) With Threaded Connection

For fuse and relay positions within carrier, see Fig. 9. For relay number, position number and circuits protected,
see RELAY IDENTIFICATION (RELAY PANEL (4-POSITION) WITH THREADED CONNECTION)
table. For fuse number, position number, amperage rating and circuits protected, see FUSE
IDENTIFICATION (RELAY PANEL (4-POSITION) WITH THREADED CONNECTION) table.

NOTE: The relay panel (4-position) carrier is located under driver's side of instrument
panel.

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Fig. 9: Identifying Relay Panel (4-Position) With Threaded Connection

Courtesy of AUDI OF AMERICA, INC.

RELAY IDENTIFICATION (RELAY PANEL (4-POSITION) WITH THREADED CONNECTION)

Position No. Socket Color Circuit Protected
3 White J662 - NG Engine Throttle Relay 1 (not applicable to
USA/CDN models)
4 Blue J663 - NG Engine Throttle Relay 2 (not applicable to
USA/CDN models)
4 Blue J610 - Alarm - On/Hands-free Control Module (not
applicable to USA/CDN models)
Note: The remaining items in the relay carrier are not used.

FUSE IDENTIFICATION (RELAY PANEL (4-POSITION) WITH THREADED CONNECTION)

Position No. Socket Color Amp Rating Circuit Protected
F Black 10A S51 - Fuse (Driver Fan training vehicle) (3)
40A S42 - Coolant Fan Fuse (1)
40/60A
S42 - Coolant Fan Fuse (2)
G Black 30A S214 - Radiator After run Fuse (2)
40A S214 - Radiator After run Fuse (1)
40/60A
S42 - Coolant Fan Fuse (4)
H Brown 40A S123 ABS Control Module Fuse 1

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2005-08 ELECTRICAL Fuses & Circuit Breakers - A4 & S4, Except Cabriolet

(1) Engine code BBK, BHF, BNS only.

(2) Engine code BKN only.

(3) Not for Engine code BBK, BHF.

(4) Not for Engine code BKN, BBK, BHF.

Note: The remaining items in the relay carrier are not used.

Relay Panel (9-Position) At Vehicle Electrical System Control Module -J519-

For fuse and relay position within carrier, see Fig. 10. For relay number, position number and circuits protected,
see RELAY IDENTIFICATION (RELAY PANEL (9-POSITION)) table. For fuse number, position
number, amperage rating and circuits protected, see FUSE IDENTIFICATION (RELAY PANEL (9-
POSITION)) table.

NOTE: The relay panel (9-position) is located behind instrument panel, driver's side,
behind 3-position relay panel.

Fig. 10: Identifying Relay Panel (9-Position) At Vehicle Electrical System Control Module -J519-
Courtesy of AUDI OF AMERICA, INC.

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RELAY IDENTIFICATION (RELAY PANEL (9-POSITION))

Position No. Socket No. Circuit Protected
1 Green J17 - Fuel Pump (FP) Relay
2 Red J236 - Servotronic Control Module
3 Green J695 - Starter Relay 2 (1)
4 Brown J53 - Starter Relay 2 (1)
J569 - Brake Booster Relay (2), (3)
5 Purple J9 - Rear Window Defogger Relay
6 Black J59 - Load Reduction Relay
8 Black J4 - Horn Relay
4 Brown J569 - Brake Booster Relay (2), (4)
(1) For engine code AUK, BKH, BNS only.

(2) Not applicable for engine code AUK, BKH.

(3) Through 2005 m.y.

(4) From 2006 m.y.

Note: The remaining items in the relay carrier are not used.

FUSE IDENTIFICATION (RELAY PANEL (9-POSITION))

Position No. Socket Color Amp Rating Circuit Protected
A Brown 10A S100 - Rear Shade Circuit Breaker (Right)
B Brown 10A S100 - Rear Shade Circuit Breaker (Left)
D Brown 30A S280 - Power Windows Fuse 2
E Red 10A S45 - Driver's Power Seat Adjustment Circuit
Breaker 2
E Red 10A S45 - Driver's Power Seat Adjustment Circuit
Breaker 2 (Lumbar Support Adjustment)
F Black 30A S37 - Power Windows Fuse
G (1) Green 30A S87 - Trailer Circuit Breaker 1) (where applicable)
(1) Through 2005 model year.

Note: The remaining items in the relay carrier are not used.

CONNECTOR STATION
CONNECTOR STATION - RIGHT A PILLAR

The connector station is located at the right side footwell below the A-pillar trim. For pin and fuse position in
connector station, see illustrations below.

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Fig. 11: Locating Connector Station (Right A Pillar)

Courtesy of AUDI OF AMERICA, INC.

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Fig. 12: Identifying Connector Station Fuses (Right A Pillar)

Courtesy of AUDI OF AMERICA, INC.

PIN & FUSE IDENTIFICATION (CONNECTOR STATION - RIGHT)

Fuse Position Socket Color Amp Rating Circuit Protected
(1) Black 30A S46 - Power Seat
E (2) Black 10A S46 - Power Seat
Pin Connectors Designation Component
13 T6p, 6 pin connector, Violet Satellite radio
14 T6q, 6 pin connector, Violet Satellite radio
15 T17c, 17 pin connector, Blue Headlamp
16 T10y, 10 pin connector, Red Headlamp
(1) Applies to vehicles equipped with manual seats with power lumbar.

(2) Applies to vehicles equipped with power seats.

Note: The remaining items in the connector point are not used.

CONNECTOR STATION - LEFT A PILLAR

The connector station is located at the left side footwell below the A-pillar trim. For pin and fuse position in

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connector station, see illustrations below.

Fig. 13: Locating Connector Station (Left A Pillar)

Courtesy of AUDI OF AMERICA, INC.

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Fig. 14: Identifying Connector Station Fuses (Left A Pillar)

Courtesy of AUDI OF AMERICA, INC.

PIN & FUSE IDENTIFICATION (CONNECTOR STATION - LEFT)

Position No. Designation Component
8 T10i - 10 pin connector, blue Parking aid (where applicable)
9 T17g - 17 pin connector, dark brown Roof (connector 1)
10 T17f - 17 pin connector, orange Roof (connector 2)
11 T6r - 6 pin connector, brown Servotronic
12 T10k - 10 pin connector, white Not applicable to USA.CDN models
13 T10c - 10 pin connector, Violet Wiper motor
14 T10d -10 pin connector, Grey Fan/compressor
15 T17b - 17 pin connector, Green Left headlight (connector 3)
16 T17a - 17 pin connector, Red Left headlight (connector 2)
17 T17 - 17 pin connector, Black Left headlight (connector 1)
Note: The remaining items in the connector point are not used.

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CONNECTOR STATION - LF/RF SEAT WIRING

The connector stations are located under the passenger seat and under the driver seat. For pin position in
connector station, see illustration below.

Fig. 15: Connector Station - LF/RF Seat Wiring

Courtesy of AUDI OF AMERICA, INC.

PIN IDENTIFICATION (CONNECTOR STATION - RIGHT SEAT WIRING)

Position No. Designation Component
1 T3d - 3 pin connector, Yellow Side airbag
2 T10p - 10 pin connector, Red Supply
3 T6e - 6 pin connector, Green Seat heating
4 T8c - 8 pin connector, Black Seat belt buckle

PIN IDENTIFICATION (CONNECTOR STATION - LEFT SEAT WIRING)

Position No. Designation Component
1 T3c - 3 pin connector, Yellow Side airbag
2 T10o - 10 pin connector, Red Supply
3 T6d - 6 pin connector, Green Seat heating
4 T8b - 8 pin connector, Black Seat belt buckle

CONNECTOR STATION WITH THREADED CONNECTION

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The connector station is located In the electronic box in plenum chamber on left side of engine compartment.
For pin position in connector station, see illustration below.

Fig. 16: Identifying Connector Station With Threaded Connection

Courtesy of AUDI OF AMERICA, INC.

PIN IDENTIFICATION (CONNECTOR STATION WITH THREADED CONNECTION - E-BOX)

Position No. Designation Component
2 T17j - 17 pin connector, Brown Engine/Transmission (connector 3)
3 T17d - 17 pin connector, Red Engine/Transmission (connector 2)
6 T17e - 17 pin connector, White Engine/Transmission (connector 1)
Note: The remaining items in the connector point are not used.

FUSES - CIRCUIT PROTECTION

WARNING: Never replace a fuse with one that has a higher amperage rating. A fuse
with a too high amperage could damage the electrical part and cause a
fire.

For access to fuse box, refer to Fig. 6.

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Fig. 17: Identifying Fuses Box Panel Cover

Courtesy of AUDI OF AMERICA, INC.

REPLACING A FUSE

A problem in the electrical system may be caused by a blown fuse.

 Switch off the ignition and the electrical component affected.

 Carefully pry the face cover off the instrument panel using the ignition key or a screwdriver. See Fig. 6.
 Check the fuse index to find out which fuse belongs to the component which has failed. See FUSE
INDEX INFORMATION.
 Remove the blown fuse with the plastic clip provided. The clip is located on the holder in the fuse box.
 Replace a blown fuse (recognizable by the melted metal strip inside) with a fuse of the same amperage.
 Firmly snap the cover back onto the instrument panel face.

The various electrical circuits are protected by fuses. The fuses are clustered in a centralized unit. The unit is
located behind the face panel at the end of the instrument panel. The crank for operating the sunroof in case of a
power failure is also stored behind the face panel (If equipped with sunroof).

Two spare fuses end a sticker identifying the fuses are located on the inside of the fuse box cover.

You are well advised to keep a supply of spare fuses in your vehicle. Fuses with the proper ampere ratings are
available at your Audi dealer.

NOTE:  On no account should fuses be repaired (e.g. with tin foil or wire) as this
may cause serious damage elsewhere in the electrical circuit or cause fire.

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2005-08 ELECTRICAL Fuses & Circuit Breakers - A4 & S4, Except Cabriolet

 If a fuse blows repeatedly, do not keep replacing it. Track and fix shorted
or overloaded circuit.

FUSE - COLOR CODES

Identifying fuse color and ampere rating, refer to table below.

WARNING: Never replace a fuse with one that has a higher amperage rating. A fuse
with a too high amperage could damage the electrical part and cause a
fire.

IDENTIFYING FUSE BY COLOR

Current Rating Amperes Color
1A Black
3A Violet
5A Light Brown
7.5A Brown
10A Red
15A Blue
20A Yellow
25A White or Natural
30A Green
35A Green-Blue
40A Orange
50A Red

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97 WIRING
RELAY AND FUSE PANELS

General information

CAUTION: Before beginning repairs on the electrical system:

 Where applicable, obtain anti-theft radio security code.

 Switch off all electrical consumers.
 Switch the ignition off and remove ignition key.
 Disconnect negative ( - ) battery terminal.

 On vehicles equipped with Audi Telematics by OnStar (R) , switch-off

the emergency (back-up) battery for the Telematic/Telephone Control
Module prior to disconnecting vehicle battery --> 91 -
COMMUNICATION
 After reconnecting vehicle battery, re-code and check operation of
anti-theft radio. Also check operation of clock and power windows
according to Repair Information and/or Owners Manual.
 After reconnecting vehicle battery on vehicles equipped with Audi
Telematics by OnStar (R) , switch-on the emergency (back-up) battery
for the Telematic/Telephone Control Module --> 91 -
COMMUNICATION

Fuse panel, removing and installing

Removing

 Disconnect battery. Audi A4 S4 --> Battery in engine compartment, disconnecting and reconnecting.
Audi RS4 --> Battery in luggage compartment, disconnecting and connecting.
 Where applicable, remove drivers storage compartment --> 68 - INTERIOR EQUIPMENT .

12:20:31 AM
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Fig. 575: Identifying Bolts For Fuse Box

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 1 - for fuse panel - 2 -.

 Release upper an d lower retaining clips and detach fuse panel from central tube for instrument panel.
 Disengage wiring harness at central tube for instrument panel and set aside.

Fig. 576: Fuse Panel Cover And Cable Tie

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Cut open cable tie - 1 -.

 Release cover for fuse panel - arrows -.
 Remove fuses at fuse panel.

Fig. 577: Removing Retaining Strip For Connectors

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove retaining strip for connectors - arrows - and take connectors out of fuse panel.
 Unclip socket - 1 -.

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ELECTRICAL Electrical Equipment

Fig. 578: Identifying Main Fuse Panel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:  Refer to the applicable wiring diagram for exact identification of

connections on fuse box Wiring Diagrams.

Installing

Install in reverse order of removal, noting the following:

 Install drivers storage compartment --> 68 - INTERIOR EQUIPMENT .

 Reconnect battery. Required steps Audi A4 S4 Reconnecting. Required steps Audi RS4 Connecting.

Tightening torque

Component - fastener Nm
Fuse carrier to central tube for instrument panel - screw 3

Vehicle Electrical System Control Module J519 , removing and installing

NOTE:  Should Vehicle Electrical System Control Module J519 require

replacement, follow replacement procedures as specified using VAS
5051/5052 in mode "Guided Fault Finding".

Removing

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

 Where applicable, remove drivers storage compartment --> 68 - INTERIOR EQUIPMENT .

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Fig. 579: Identifying Nuts And Vehicle Electrical System Control Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nuts - arrows - and remove Vehicle Electrical System Control Module J519 - 1 -.

Fig. 580: Identifying Fuse Carrier And Connectors

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Unclip fuse carriers - 1... 3 -.

 Release retaining clip at connector - 4 - and disconnect connector.
 Disconnect electrical connections - 5 - and - 6 -.

Installing

Install in reverse order of removal, noting the following:

 Install drivers storage compartment --> 68 - INTERIOR EQUIPMENT .

Tightening torque

Component - fastener Nm
Control module to central tube for instrument panel - nut 2.4

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9-position relay carrier, removing and installing

Removing

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

 Where applicable, remove drivers storage compartment --> 68 - INTERIOR EQUIPMENT .

Fig. 581: Identifying Nuts, And Relay Carrier

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nuts - 3 - remove Vehicle Electrical System Control Module J519 with wires attached.
 Remove 9-position relay carrier - 4 -.

NOTE:  Disregard - 1 - and - 2 -.

 Unclip the fuse carriers at the 9-position relay carrier.
 Remove relays and control modules and then unclip appropriate relay
carrier.

Fig. 582: Identifying 9-Way Relay Carrier

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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NOTE:  Refer to the applicable wiring diagram for exact identification of

connections on relay carrier Wiring Diagrams.

Installing

Install in reverse order of removal, noting the following:

 Install drivers storage compartment --> 68 - INTERIOR EQUIPMENT .

Tightening torque

Component - fastener Nm
9-position relay carrier to central tube for instrument panel - nut 2.4

3-position relay carrier, removing and installing

Removing

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

 Where applicable, remove drivers storage compartment --> 68 - INTERIOR EQUIPMENT .

Fig. 583: Identifying Nuts, And Relay Carrier

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 1 - and detach 3-position relay carrier - 2 -.

NOTE:  Disregard - 3 - and - 4 -.

 Unclip the fuse carriers at the 3-position relay carrier.
 Remove relays and control modules and then unclip appropriate relay
carrier.

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ELECTRICAL Electrical Equipment

Fig. 584: Identifying 3-Position Relay Carrier

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:  Refer to the applicable wiring diagram for exact identification of

connections on relay carrier Wiring Diagrams.

Installing

Install in reverse order of removal, noting the following:

 Install drivers storage compartment --> 68 - INTERIOR EQUIPMENT .

Tightening torque

Component - fastener Nm
3-position relay carrier to central tube for instrument panel - nut 3

4-position relay carrier, removing and installing

Removing

 Disconnect battery. Audi A4 S4 --> Battery in engine compartment, disconnecting and reconnecting.
Audi RS4 --> Battery in luggage compartment, disconnecting and connecting.
 Where applicable, remove drivers storage compartment --> 68 - INTERIOR EQUIPMENT .

12:20:32 AM Page 7
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ELECTRICAL Electrical Equipment

Fig. 585: Identifying Bolts For Fuse Box

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 1 - for fuse panel - 2 -.

 Remove fuse panel from central tube for instrument panel.
 Disengage wiring harness at central tube for instrument panel and set aside.

Fig. 586: Identifying Nuts And Vehicle Electrical System Control Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nuts - arrows - and detach Vehicle Electrical System Control Module J519 - 1 - with wiring
attached.

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ELECTRICAL Electrical Equipment

Fig. 587: Identifying Screw Connections, Bolts, And Nuts, For Fuse Carrier
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull the relays or control modules out of 4-position relay carrier.

 Mark assignment of wires at threaded connections - 2 - , - 3 - and - 5 -.
 Remove wires at threaded connections.
 Remove bolt - 1 - and nut - 4 -.

 Unclip fuse carriers at 4-position relay carrier.

 Remove relays and control modules and then unclip appropriate relay carrier.

Fig. 588: Identifying 4-Way Relay Carrier

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:  Refer to the applicable wiring diagram for exact identification of

connections on relay carrier Wiring Diagrams.

Installing

Install in reverse order of removal, noting the following:

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ELECTRICAL Electrical Equipment

Fig. 589: Identifying Screw Connections, Bolts, And Nuts, For Fuse Carrier
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Install wires at threaded connections - 2 - , - 3 - and - 5 - according to markings.

 Reconnect battery. Required steps Audi A4 S4 Reconnecting. Required steps Audi RS4 Connecting.
 Install drivers storage compartment --> 68 - INTERIOR EQUIPMENT .

Tightening torques

Component - fastener Nm
4-pin relay carrier to chassis Nut 2.4
Screw 1.7
Wiring terminal connections - nut 9

Left connector station, removing and installing

Removing

Fig. 590: Locating Left Connection Point

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Location: Left connector station - arrow - is located in left footwell beneath A-pillar trim.

12:20:32 AM Page 10
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ELECTRICAL Electrical Equipment

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

 Remove A-pillar trim: --> 70 - INTERIOR TRIM .

 Press retaining clip and detach connector point from A-pillar - arrow -.
 Unclip fuse panel at connector point.
 Remove relays or control modules and then unclip appropriate relay carrier.

Fig. 591: Identifying Connection Point

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:  Refer to the applicable wiring diagram for exact identification of

connections on connector station Wiring Diagrams.

Installing

Install in reverse order of removal, noting the following:

 Install A-pillar trim: --> 70 - INTERIOR TRIM .

Comfort System Central Control Module J393 , removing and installing

Removing

 Remove A-pillar trim: --> 70 - INTERIOR TRIM .

 Remove drivers seat --> 72 - SEAT - FRAMES .

NOTE:  Safety belts at seat frame do not have to be unfastened.

 Fold back floor covering.

12:20:32 AM Page 11
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ELECTRICAL Electrical Equipment

Fig. 592: Identifying Cover For Drivers Side Electronics Box

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release cover for electronics box (drivers side) - arrows - and fold cover towards right.

Fig. 593: Identifying Retaining Clips, Comfort System Central Control Module J393, And Electrical
Connections
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clips - arrows - and remove Comfort System Central Control Module J393 - 1 - from
electronics box.
 Disconnect electrical connections - 2... 6 -.

NOTE:  Refer to the applicable wiring diagram for exact identification of

connections on electronics box Wiring Diagrams.

Installing

Install in reverse order of removal, noting the following:

 Install A-pillar trim: --> 70 - INTERIOR TRIM .

 Install drivers seat --> 72 - SEAT - FRAMES .

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Right connector station, removing and installing

Removing

Fig. 594: Locating Right Connection Point

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Location: Right connector station - arrow - is located in right footwell beneath A-pillar trim.

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

 Remove A-pillar trim: --> 70 - INTERIOR TRIM .

 Press retaining clip and detach connector point from A-pillar - arrow -.
 Unclip fuse panel at connector point.
 Remove relays or control modules and then unclip appropriate relay carrier.

Fig. 595: Identifying Connection Point

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:  Refer to the applicable wiring diagram for exact identification of

connections on connector station Wiring Diagrams.

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Installing

Install in reverse order of removal, noting the following:

 Install A-pillar trim: --> 70 - INTERIOR TRIM .

Main fuse panel in left rear luggage compartment - Audi RS4, removing and installing

Removing

 Disconnect battery --> Battery in luggage compartment, disconnecting and connecting.

 Remove left luggage compartment side trim --> 70 - INTERIOR TRIM .

Fig. 596: Identifying Quick-Release Fasteners, Main Fuse Box Cover, And Luggage Compartment
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Loosen quick-release fasteners - 1 - and - 3 - and open main fuse box cover - 2 - in luggage compartment
- arrow -.

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Fig. 597: Removing Nuts And Main Fuse

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nuts - arrows -.

 Remove main fuse.

Fig. 598: Identifying Main Fuse

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:  Refer to the applicable wiring diagram for exact identification of relays and
fuses Wiring Diagrams.

Installing

Install in reverse order of removal, observing the following:

 Install left luggage compartment side trim --> 70 - INTERIOR TRIM .

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 Connect battery. Required steps Connecting.

Tightening torque

Component Nm
Main fuse to main fuse box 7,5

Electronics box in plenum chamber, removing and installing

Removing

CAUTION:  Switch off all electrical consumers.

 Switch ignition off and remove ignition key.

Fig. 599: Identifying Plenum Chamber Cover & Removing Rubber Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove rubber seal of plenum chamber cover in direction of - arrow -.

 Remove plenum chamber cover - 1 - to front.

Fig. 600: Removing Securing Clips And Cowl

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Use screwdriver to pry off the two caps - 3 -.

 Loosen nuts - 4 - (do not remove).
 Remove wiper arms - 2 - from wiper shaft by tilting slightly.
 Remove nuts completely and remove wiper arms.

 Pull off retaining clips - 1 - and detach cowl panel grille - 5 -.

Fig. 601: Removing Screws And Cover From E-Box In Plenum Chamber
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove cover for electronics box in plenum chamber - arrows -.

Fig. 602: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use screwdriver to pry off retaining strap - arrows -.

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Fig. 603: Releasing Connector Latches And Pulling Off Connectors On Engine Control Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release connector locks tabs - arrows - and disconnect electrical connections - 1 - and - 2 - for Motronic
Engine Control Module (ECM) J220 (where applicable).
 Where applicable, release retaining clip for transmission control module.

Fig. 604: Releasing Connector Lock And Disconnecting From Transmission Control Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release connector lock - arrow - and disconnect from transmission control module.

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Fig. 605: Identifying Electrical Connections And Wire

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Disconnect electrical connections - 2 - at rear of connector console.

 Remove wire - 1 -.

Fig. 606: Releasing Retaining Clips And Lifting Auxiliary Relay Carrier Out Of Electronics Box
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clips - arrows - and lift auxiliary relay carrier out of electronics box.
 Remove the engine wiring harness at electronics box and bulkhead and set aside.

Fig. 607: Identifying Securing Nuts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove nuts - arrows -.

 Lift electronics box and remove upwards.

Installing

Install in reverse order of removal.

Tightening torque

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Component Nm
Plenum chamber electronics box to body 3

Electronics box fan in plenum chamber, removing and installing

NOTE:  Depending on market version, the plenum chamber electronics box may
be equipped with a fan motor.

Removing

 Remove the electronics box (plenum chamber) --> Electronics box in plenum chamber, removing and
installing.

Fig. 608: Identifying Bolts, Fan, And Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screws - 4 - and remove fan - 2 - with air cowl - 3 - from electronics box in plenum chamber - 1 -
.

Installing

Install in reverse order of removal.

Tightening torque

Component Nm
Fan to plenum chamber electronics box 3

4-way relay carrier in electronics box in plenum chamber, removing and installing

Removing

CAUTION:  Switch off all electrical consumers.

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 Switch ignition off and remove ignition key.

Fig. 609: Identifying Plenum Chamber Cover & Removing Rubber Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove rubber seal of plenum chamber cover in direction of - arrow -.

 Remove plenum chamber cover - 1 - to front.

Fig. 610: Removing Securing Clips And Cowl

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use screwdriver to pry off the two caps - 3 -.

 Loosen nuts - 4 - (do not remove).
 Remove wiper arms - 2 - from wiper shaft by tilting slightly.
 Remove nuts completely and remove wiper arms.

 Pull off retaining clips - 1 - and detach cowl panel grille - 5 -.

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Fig. 611: Removing Screws And Cover From E-Box In Plenum Chamber
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove cover for electronics box in plenum chamber - arrows -.

Fig. 612: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use screwdriver to pry off retaining strap - arrows -.

 Lay aside engine control module with wires attached.
 Where applicable, release the retaining clip for the transmission control module.
 Lay aside transmission control module with wires attached.

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Fig. 613: Releasing Retaining Clips And Lifting Auxiliary Relay Carrier Out Of Electronics Box
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clips - arrows - and lift auxiliary relay carrier out of electronics box.
 Unclip the fuse carriers at the 4-position relay carrier.
 Remove relays and control modules and then unclip appropriate relay carrier.

Fig. 614: Removing Motronic Engine Control Module (ECM) Power Supply Relay J271 From E-Box
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:  Refer to the applicable wiring diagram for exact identification of

connections on electronics box Wiring Diagrams.

Installing

Install in reverse order of removal.

Connector junction, electronics box in plenum chamber, removing and installing

Removing

 Disconnect battery. Audi A4 S4 --> Battery in engine compartment, disconnecting and reconnecting.
Audi RS4 --> Battery in luggage compartment, disconnecting and connecting.

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 Where applicable, remove drivers storage compartment --> 68 - INTERIOR EQUIPMENT .

 Remove electrical wire at bottom of connector point in plenum chamber electronics box.

Fig. 615: Identifying Plenum Chamber Cover & Removing Rubber Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove rubber seal of plenum chamber cover in direction of - arrow -.

 Remove plenum chamber cover - 1 - to front.

Fig. 616: Removing Securing Clips And Cowl

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use screwdriver to pry off the two caps - 3 -.

 Loosen nuts - 4 - (no not remove).
 Remove wiper arms - 2 - from wiper shaft by tilting slightly.
 Remove nuts completely and remove wiper arms.

 Pull off retaining clips - 1 - and detach cowl panel grille - 5 -.

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Fig. 617: Removing Screws And Cover From E-Box In Plenum Chamber
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove cover for electronics box in plenum chamber - arrows -.

Fig. 618: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use screwdriver to pry off retaining strap - arrows -.

 Lay aside engine control module with wires attached.
 Release retaining clip for transmission control module.
 Lay aside transmission control module with wires attached.

 Disconnect electrical connections at rear of connector console.

Vehicles through 10.04:

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Fig. 619: Identifying Wire Connection And Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove electrical wire - 2 -.

 Remove screws - 1 - and - 3 -.
 Unclip appropriate socket.

Fig. 620: Identifying Connection Point E-Box Plenum Chamber

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:  Refer to the applicable wiring diagram for exact identification of

connections on connector station Wiring Diagrams.

Vehicles from 11.04:

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Fig. 621: Identifying Electrical Wire, Screws, And Socket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove electrical wire - 3 -.

 Remove screws - 2 - and - 4 -.
 Unclip appropriate socket - 1 -.

Fig. 622: Identifying Electronics Box

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:  Refer to the applicable wiring diagram for exact identification of

connections on connector station Wiring Diagrams.

Installing

Install in reverse order of removal, noting the following:

 Reconnect battery. Required steps Audi A4 S4 Reconnecting. Required steps Audi RS4 Connecting.

Tightening torques

Component Nm

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Connector point in plenum chamber electronics box to central tube for instrument panel 3
Bolt connection for electrical wires 9

Main fuse panel - vehicles with battery in engine compartment, removing and installing

Removing

 Disconnect battery --> Battery in engine compartment, disconnecting and reconnecting.

Fig. 623: Identifying Plenum Chamber Cover & Removing Rubber Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove rubber seal of plenum chamber cover in direction of - arrow -.

 Remove plenum chamber cover - 1 - to front.

Fig. 624: Identifying Cap, Nut At Electric Cable, And Nut For Carrier Fuse On Positive Post
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Fold cover - 2 - aside and remove nut - 3 - at terminal.

 Remove nut - 1 - for fuse (positive terminal).

Installing

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Install in reverse order of removal, noting the following:

 Reconnect battery. Required steps Audi A4 S4 Reconnecting. Required steps Audi RS4 Connecting.

Tightening torques

Component - fastener Nm
Fuse panel to positive terminal - nut 6
Fuse to fuse panel terminal - nut 6

Positive terminal in plenum chamber - Audi RS4, removing and installing

Removing

 Disconnect battery --> Battery in luggage compartment, disconnecting and connecting.

Fig. 625: Identifying Plenum Chamber Cover & Removing Rubber Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove plenum chamber cover rubber seal in direction of - arrow -.

 Remove plenum chamber cover - 1 - forward.

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Fig. 626: Removing Screw, Retaining Clip, And Positive Terminal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove screw - 1 -.
 Release retaining clip - 2 - in direction of - arrow A -.
 Remove positive terminal in direction of - arrow B - from bracket.

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Fig. 627: Releasing Retaining Clip And Opening Cover Over Positive Terminal Pick-Off
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Release retaining clip - arrow A - and open cover - 2 - over positive terminal.
 Release wiring cover - 1 - in direction of - arrow B -.

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Fig. 628: Removing Terminal Nuts, Cables, And Positive Terminal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Remove terminal nuts - 1 - and - 4 - and remove cables.

 Remove positive terminal.

Installing

Install in reverse order of removal, noting the following:

 Connect battery. Required steps Connecting.

Tightening torques

Component Nm
Positive cables to positive terminal grip 15
Positive terminal grip to bracket 9

WIRING HARNESS AND CONNECTORS, SERVICING

General information

CAUTION: Before beginning repairs on the electrical system:

 Where applicable, obtain anti-theft radio security code.

 Switch off all electrical consumers.
 Switch the ignition off and remove ignition key.
 Disconnect negative ( - ) battery terminal.

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 On vehicles equipped with Audi Telematics by OnStar (R) , switch-off

the emergency (back-up) battery for the Telematic/Telephone Control
Module prior to disconnecting vehicle battery --> 91 -
COMMUNICATION
 After reconnecting vehicle battery, re-code and check operation of
anti-theft radio. Also check operation of clock and power windows
according to Repair Information and/or Owners Manual.
 After reconnecting vehicle battery on vehicles equipped with Audi
Telematics by OnStar (R) , switch-on the emergency (back-up) battery
for the Telematic/Telephone Control Module --> 91 -
COMMUNICATION

Special tools, testers and auxiliary items required

Fig. 629: Wiring Harness Repair Kit V.A.S 1978

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Wiring harness repair set VAS 1978

Fig. 630: Opened Wiring Harness Repair Kit VAS 1978

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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NOTE:  Wiring harness and connector repairs on the vehicle electrical system are
only to be performed using wiring harness repair set VAS 1978.
 An instruction manual is included in the wiring harness repair set VAS
1978 , in which the procedure for repairs is described in detail.

Safety precautions for repairing wiring harnesses and connectors

CAUTION:  Wiring harness and connector repairs on the vehicle electrical

system are only to be performed using wiring harness repair set VAS
1978.
 Pay attention to the relevant regulations in the individual countries.
 Disconnecting the battery negative ( - ) terminal prevents accidents
when working on electrical system. Disconnect battery. Audi A4 S4 --
> Battery in engine compartment, disconnecting and reconnecting.
Audi RS4 --> Battery in luggage compartment, disconnecting and
connecting.
 Heed stickers on vehicle pointing out components with high voltage.
Remaining voltage must be dissipated before commencing repair
work.

 Before commencing repair work, always eliminate cause of damage,

e.g. sharp body edges, malfunctioning electrical components,
corrosion etc.
 Do not loosen ground straps on body if this can be avoided (danger
of corrosion).
 Further information, for example about removal and installation of
individual components, can be found in the appropriate Workshop
Manual.

Notes on repairs on wiring harnesses and connectors

CAUTION:  Do not solder components of the vehicle electrical system.

 Do not perform repairs on heat-shrink sleeves. Route a new wire
along the faulty wire if necessary.
 Shielded wires, e.g. on speed sensor and knock sensors, are NOT to
be repaired. These wires must be replaced complete if damaged.
 Only use yellow wires for repairs to wiring. Mark location of repair
with yellow insulating tape.

 Yellow wiring and locations with yellow insulating tape on wiring

harness designate a previous repair.

Notes on repairs to airbag and safety belt tensioner wiring harness

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CAUTION:  To maintain the repair standards required by the factory, repairs on

airbag and belt tensioner wiring harness may only be performed on
in-vehicle wiring using wiring harness repair set VAS 1978 and
genuine spare parts (connector housings, contacts, wiring).
 Wires on the individual airbag modules are NOT to be repaired.
 If wires or connectors at airbag modules are damaged, the
corresponding airbag modules must be replaced for safety reasons.
 Repair operations must be recorded in the Audi Service Schedule
under "Workshop entries" with a brief outline of the repair work
completed, company stamp and signature.

 Any warranty claims are invalid if airbag wiring harness repairs have
not been performed using genuine spare parts and wiring harness
repair set VAS 1978.

Notes for repairs on CAN-Bus wires

Fig. 631: Repairing Twisted Wire Pairs

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Use an unshielded two-wire line - 1 - and - 2 - (cross-section 0.35 mm 2 or 0.5 mm 2 ) as CAN-Bus bus
wire.
 color coding of CAN-Bus bus wires:

Drive CAN-Bus High orange/black

Convenience CAN-Bus High orange/green
Infotainment CAN-Bus High orange/violet
CAN-Bus Low (all) orange/brown

 Only use yellow wires for repairs to wiring. Mark location of repair with yellow insulating tape.
 Both bus wires must be of the same length when repairing. When twisting the wires - 1 - and - 2 - , length
of twist - A - = 20 mm must be attained.

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 When making repairs, there must be no untwisted section of wire which is longer than - B - = 50 mm, e.g.
in the vicinity of heat-shrink sleeves - arrow -.

Repairing a wire with cross-section 0.22 mm 2 or 0.35 mm 2

Procedure

NOTE:  Wiring harness repair set VAS 1978 contains repair wires of three different
cross-sections (0.5 mm 2 , 1.5 mm 2 , 4.0 mm 2 ) and the corresponding
crimp connectors.
 0.5 mm 2 repair wire must be used for repairing 0.35 mm 2 wire.

Perform the repair as follows:

Fig. 632: Stripping Insulation At Wiring Using Stripping Pliers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Strip the ends of the 0.22 mm 2 and 0.35 mm 2 wires to a length of 12... 14 mm using the stripping pliers
VAS 1978/3.
 Fold back half of the stripped wire ends.
 Strip the ends of the 0.5 mm 2 repair wire to a length of 6 to 7 mm using the stripping pliers VAS 1978/3.

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Fig. 633: Crimping On Both Sides With Crimping Pliers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Slip crimp connector over ends of wires and crimp on both sides using crimping tool VAS 1978/1.

NOTE:
 Be sure to select the correct red crimp insert VAS 1978/24 for 0.5 mm 2
wires.
 Do NOT crimp the insulation on the wires.

Fig. 634: Heating Crimp Connection Using Hot Air Gun

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 After crimping, you must shrink-fit the crimp connector using the hot-air blower, 220 V/ 50 Hz VAS
1978/14 and hot-air blower shrink fitting VAS 1978/15.

 Crimp connector must be heated working outwards from center until it is completely sealed and adhesive
emerges.
 Set the hot air blower to the correct temperature; refer to operating manual for VAS 1978.

 When shrink-fitting, ensure no other wires, plastic components or insulating materials are damaged by the
hot nozzle.
 If repair wire was previously wrapped, yellow insulating tape must again be wound around this point;

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reattach wire with a cable tie if necessary.

 Reconnect battery. Required steps Audi A4 S4 Reconnecting. Required steps Audi RS4 Connecting.

Antenna cables, replacing

A new repair concept has been developed for repairing antenna cables. Instead of a complete antenna cable,
connecting wires of different lengths and various adapter leads are now available as replacement parts.

Spare part numbers.

NOTE:  Antenna cables are NOT to be repaired, rather replaced using connecting
cables and adapter leads available as genuine replacement parts.
 These genuine replacement parts are suitable for all cable cross-sections
and antenna cables which have to be replaced.
 Replacing of individual antenna connectors during repair work is not
intended.
 The cables are now to be used retrospectively for all Audi models and for
all antenna cable-cross sections fitted.
 All adapter leads and connecting cables are suitable for all transmission
and reception signals.
 The repair concept can also be used for testing and service installation
purposes (e.g. retrofitting).

Antenna connector cable, replacing

Example:

Fig. 635: Assembly Overview Of Antenna Wire

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Faulty antenna cable from radio to antenna

The following are required for repair purposes:

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1. Adapter wire for connection to radio; length approx. 30 cm

2. Connecting wire; available in various lengths
3. Adapter wire for connection to antenna; length approx. 30 cm

 Disconnect electrical connections of faulty antenna cable from devices.

 Determine routing of faulty antenna cable in vehicle and measure out overall length of antenna
connection to be replaced in vehicle.

Total length of antenna connection = length of adapter leads - 1 - and - 3 - required as well as connecting wire -
2 -.

 Subtract 60 cm from total length of antenna connection measured to calculate required length of
connecting wire needed.
 Procure the necessary adapter leads and connecting wire in the calculated length as genuine replacement
parts.
 Cut connectors off faulty antenna cable.

 Leave remains of faulty antenna cable in vehicle.

 Connect adapter leads to units in vehicle.

 Fit connectors with a piece of foam sheathing to prevent rattling noise.
 Lay and secure connecting wire parallel to old antenna cable.

CAUTION: Antenna cable must not be kinked or bent excessively during installation.
Do not attempt to bend antenna cable in a radius smaller than 50mm.

 Attach connecting wire to adapter leads.

 To prevent rattling noise, apply a suitable piece of foam sheathing to antenna connectors.
 Check operation.

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2005 SYSTEM WIRING DIAGRAMS Audi - A4

2005 SYSTEM WIRING DIAGRAMS

Audi - A4

USING MITCHELL1'S WIRING DIAGRAMS

For information on using these wiring diagrams, see USING MITCHELL1'S SYSTEM WIRING
DIAGRAMS article.

AIR CONDITIONING

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

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Fig. 1: Automatic A/C Circuit (1 of 2)

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

Fig. 2: Automatic A/C Circuit (2 of 2)

ANTI-LOCK BRAKES

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

Fig. 3: Anti-lock Brakes Circuit, W/O Convertible Early Production, W/ Convertible

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

Fig. 4: Anti-lock Brakes Circuit, W/O Convertible Late Production

ANTI-THEFT

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

Fig. 5: Anti-theft Circuit, W/ Convertible

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

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2005 SYSTEM WIRING DIAGRAMS Audi - A4

Fig. 6: Anti-theft Circuit, W/O Convertible

BODY CONTROL MODULES

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

Fig. 7: Body Control Modules Circuit, W/ Convertible

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

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 2005 Audi A4
2005 SYSTEM WIRING DIAGRAMS Audi - A4

Fig. 8: Body Control Modules Circuit, W/O Convertible

COMPUTER DATA LINES

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Fig. 9: Data Link Connector Circuit

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Fig. 10: High/Low Bus Circuit

COOLING FAN

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Fig. 11: Cooling Fan Circuit

CRUISE CONTROL

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Fig. 12: Cruise Control Circuit

DEFOGGERS

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Fig. 13: Heated Mirrors Circuit

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Fig. 14: Rear Defogger Circuit, W/ Convertible

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Fig. 15: Rear Defogger Circuit, W/O Convertible

ELECTRONIC POWER STEERING

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Fig. 16: Electronic Power Steering Circuit

ENGINE PERFORMANCE

1.8L

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Fig. 17: 1.8L, Engine Performance Circuit (1 of 4)

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Fig. 18: 1.8L, Engine Performance Circuit (2 of 4)

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Fig. 19: 1.8L, Engine Performance Circuit (3 of 4)

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Fig. 20: 1.8L, Engine Performance Circuit (4 of 4)

3.0L

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Fig. 21: 3.0L, Engine Performance Circuit (1 of 4)

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Fig. 22: 3.0L, Engine Performance Circuit (2 of 4)

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Fig. 23: 3.0L, Engine Performance Circuit (3 of 4)

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Fig. 24: 3.0L, Engine Performance Circuit (4 of 4)

EXTERIOR LIGHTS

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Fig. 25: Back-up Lamps Circuit, Avant Early Production (High Line)

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Fig. 26: Back-up Lamps Circuit, Avant Early Production (Low Line)

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Fig. 27: Back-up Lamps Circuit, Avant Late Production

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Fig. 28: Back-up Lamps Circuit, Convertible

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Fig. 29: Back-up Lamps Circuit, Sedan

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Fig. 30: Exterior Lamps Circuit, Avant Early Production (High Line)

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Fig. 31: Exterior Lamps Circuit, Avant Early Production (Low Line)

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Fig. 32: Exterior Lamps Circuit, Avant Late Production

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Fig. 33: Exterior Lamps Circuit, Convertible

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Fig. 34: Exterior Lamps Circuit, Sedan Early Production, Convertible Early Production

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Fig. 35: Exterior Lamps Circuit, Sedan Late Production, Convertible Late Production

GROUND DISTRIBUTION

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Fig. 36: Ground Distribution Circuit, W/ Convertible (1 of 2)

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Fig. 37: Ground Distribution Circuit, W/ Convertible (2 of 2)

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Fig. 38: Ground Distribution Circuit, W/O Convertible (1 of 2)

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Fig. 39: Ground Distribution Circuit, W/O Convertible (2 of 2)

HEADLIGHTS

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Fig. 40: Headlamps & Fog Lamps Circuit, W/ Convertible W/ High Intensity Gas Discharge Headlights

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Fig. 41: Headlamps & Fog Lamps Circuit, W/ Convertible W/ Standard Headlights

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Fig. 42: Headlamps & Fog Lamps Circuit, W/O Convertible W/ Bi-Xenon & Cornering Headlights
Circuit

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Fig. 43: Headlamps & Fog Lamps Circuit, W/O Convertible W/ Bi-Xenon Headlights Circuit

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Fig. 44: Headlamps & Fog Lamps Circuit, W/O Convertible W/ High Intensity Gas Discharge Headlights
High Option Content

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Fig. 45: Headlamps & Fog Lamps Circuit, W/O Convertible W/ High Intensity Gas Discharge Headlights
Low Option Content

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Fig. 46: Headlamps & Fog Lamps Circuit, W/O Convertible W/ Standard Headlights

HORN

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Fig. 47: Horn Circuit, W/ Convertible

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Fig. 48: Horn Circuit, W/O Convertible

INSTRUMENT CLUSTER

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Fig. 49: Instrument Cluster Circuit, W/ Convertible

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Fig. 50: Instrument Cluster Circuit, W/O Convertible

INTERIOR LIGHTS

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Fig. 51: Courtesy Lamps Circuit, Avant (1 of 2)

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Fig. 52: Courtesy Lamps Circuit, Avant (2 of 2)

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Fig. 53: Courtesy Lamps Circuit, Convertible

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Fig. 54: Courtesy Lamps Circuit, Sedan, Convertible (1 of 2)

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Fig. 55: Courtesy Lamps Circuit, Sedan, Convertible (2 of 2)

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Fig. 56: Instrument Illumination Circuit, W/ Convertible (1 of 2)

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Fig. 57: Instrument Illumination Circuit, W/ Convertible (2 of 2)

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Fig. 58: Instrument Illumination Circuit, W/O Convertible (1 of 2)

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Fig. 59: Instrument Illumination Circuit, W/O Convertible (2 of 2)

MEMORY SYSTEMS

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Fig. 60: Memory Systems Circuit, W/ Convertible (1 of 4)

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Fig. 61: Memory Systems Circuit, W/ Convertible (2 of 4)

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Fig. 62: Memory Systems Circuit, W/ Convertible (3 of 4)

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Fig. 63: Memory Systems Circuit, W/ Convertible (4 of 4)

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Fig. 64: Memory Systems Circuit, W/O Convertible (1 of 2)

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Fig. 65: Memory Systems Circuit, W/O Convertible (2 of 2)

NAVIGATION

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Fig. 66: Navigation Circuit, W/O RNS-E

POWER DISTRIBUTION

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Fig. 67: Power Distribution Circuit, W/ Convertible (1 of 2)

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Fig. 68: Power Distribution Circuit, W/ Convertible (2 of 2)

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Fig. 69: Power Distribution Circuit, W/O Convertible (1 of 2)

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Fig. 70: Power Distribution Circuit, W/O Convertible (2 of 2)

POWER DOOR LOCKS

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Fig. 71: Power Door Locks Circuit, W/ Convertible

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Fig. 72: Power Door Locks Circuit, W/O Convertible, W/ Rear Power Windows (1 of 2)

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Fig. 73: Power Door Locks Circuit, W/O Convertible, W/ Rear Power Windows (2 of 2)

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Fig. 74: Power Door Locks Circuit, W/O Convertible, W/O Rear Power Windows (1 of 2)

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Fig. 75: Power Door Locks Circuit, W/O Convertible, W/O Rear Power Windows (2 of 2)

POWER MIRRORS

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Fig. 76: Automatic Day/Night Mirror Circuit, W/ Convertible

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Fig. 77: Automatic Day/Night Mirror Circuit, W/O Convertible

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Fig. 78: Power Mirror Circuit

POWER SEATS

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Fig. 79: Front Seat Heater Circuit, W/ Convertible

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Fig. 80: Front Seat Heater Circuit, W/O Convertible

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Fig. 81: Lumbar Circuit

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Fig. 82: Power Seat Circuit, W/ Convertible (1 of 2)

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Fig. 83: Power Seat Circuit, W/ Convertible (2 of 2)

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Fig. 84: Power Seat Circuit, W/O Convertible

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Fig. 85: Rear Seat Heater Circuit

POWER TOP/SUNROOF

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Fig. 86: Convertible Top Circuit (1 of 2)

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Fig. 87: Convertible Top Circuit (2 of 2)

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Fig. 88: Sunroof Circuit

POWER WINDOWS

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Fig. 89: Power Windows Circuit, W/ Convertible

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Fig. 90: Power Windows Circuit, W/O Convertible

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Fig. 91: Rear Window Sun Shade Circuit, W/O Convertible

RADIO

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Fig. 92: Bose Symphony Concert Circuit, W/O Convertible W/ Amplifier (1 of 2)

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Fig. 93: Bose Symphony Concert Circuit, W/O Convertible W/ Amplifier (2 of 2)

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Fig. 94: Bose Symphony Concert Circuit, W/O Convertible W/ Bose (1 of 2)

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Fig. 95: Bose Symphony Concert Circuit, W/O Convertible W/ Bose (2 of 2)

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Fig. 96: Bose Symphony Concert Circuit, W/O Convertilbe W/O Amplifier

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Fig. 97: Bose Symphony II Circuit, W/ Convertible W/ Bose

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Fig. 98: Bose Symphony II Circuit, W/O Convertible W/ Amplifier (1 of 2)

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Fig. 99: Bose Symphony II Circuit, W/O Convertible W/ Amplifier (2 of 2)

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Fig. 100: Bose Symphony II Circuit, W/O Convertible W/ Bose (1 of 2)

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Fig. 101: Bose Symphony II Circuit, W/O Convertible W/ Bose (2 of 2)

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Fig. 102: Radio/Navigation Circuit, W/O Convertible W/ RNS-E W/ Amplifier (1 of 2)

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Fig. 103: Radio/Navigation Circuit, W/O Convertible W/ RNS-E W/ Amplifier (2 of 2)

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Fig. 104: Radio/Navigation Circuit, W/O Convertible W/ RNS-E W/ Bose (1 of 2)

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Fig. 105: Radio/Navigation Circuit, W/O Convertible W/ RNS-E W/ Bose (2 of 2)

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Fig. 106: Symphony II Circuit, W/ Convertible W/ Amplifier (Late Production)

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Fig. 107: Symphony II Circuit, W/ Convertible W/ Bose (Late Production)

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Fig. 108: Symphony II Circuit, W/ Convertible W/O Bose (Early Production)

SHIFT INTERLOCK

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Fig. 109: Shift Interlock Circuit, 5 Speed A/T

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Fig. 110: Shift Interlock Circuit, 6 Speed A/T

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Fig. 111: Shift Interlock Circuit, CVT

STARTING/CHARGING

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Fig. 112: Charging Circuit

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Fig. 113: Starting Circuit, 5 Speed A/T

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Fig. 114: Starting Circuit, 6 Speed A/T

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Fig. 115: Starting Circuit, M/T

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Fig. 116: Starting Circuit, W/ CVT

SUPPLEMENTAL RESTRAINTS

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Fig. 117: Supplemental Restraints Circuit, Early Production W/O Convertible (1 of 2)

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Fig. 118: Supplemental Restraints Circuit, Early Production W/O Convertible (2 of 2)

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Fig. 119: Supplemental Restraints Circuit, Late Production W/O Convertible (1 of 2)

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Fig. 120: Supplemental Restraints Circuit, Late Production W/O Convertible (2 of 2)

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Fig. 121: Supplemental Restraints Circuit, W/ Convertible (1 of 2)

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Fig. 122: Supplemental Restraints Circuit, W/ Convertible (2 of 2)

TRANSMISSION

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Fig. 123: A/T Circuit, 5 Speed A/T

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Fig. 124: A/T Circuit, 6 Speed A/T

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Fig. 125: A/T Circuit, W/ CVT

TRUNK, TAILGATE, FUEL DOOR

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Fig. 126: Trunk & Fuel Door Release Circuit, W/ Convertible

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Fig. 127: Trunk & Fuel Door Release Circuit, W/O Convertible Early Production

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Fig. 128: Trunk & Fuel Door Release Circuit, W/O Convertible Late Production

WARNING SYSTEMS

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Fig. 129: Brake Wear Sensor Circuit

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Fig. 130: Tire Pressure Monitoring Circuit

WIPER/WASHER

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Fig. 131: Jet Heater Circuit

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Fig. 132: Wiper/Washer Circuit

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Audi A4 Wiring diagram No. 2/ 1

St andard Equipm ent

from 2002 m . y.

M ain fuse

A97--0220

Connector st at ion E-box, plenum cham -

ber

1 2 3 4

5 6 7

A97--0248

4-Pin Relay Carrier w it h t hreaded

connect ion

C D
B
A

3
1 2
4
E
F
G H

A97--0245

Edit ion 08/ 01

W42.USA.5504.01.21
Audi A4 Wiring diagram No. 2/ 2

Fuse holder

Fuse Colors

30 A - Green

15 14 13 12

19 18 17 16

23 22 21 20
8
25 A - White
5

9
11 10
1

6
20 A - Yellow
2

7
15 A - Blue
24

31

38
Res

Res 10 A - Red
25

32

39
Res
7,5A - Orange
26

33

40

Res
5A - Beige
27

34

41

Res
28

35

42
29

36

43
30

37

44

Fuse in fusebox from 23 onwards are numbered 223

onwards in Current Flow Diagram.
A97--0242

9-Pin Relay Carrier in t he inst rum ent

panel
Relay Locat ion :

3 - Horn Relay

A B
7 8 9 6 - Load Reduction Relay

1 2 3 4 5 6

A97--0243

Edit ion 08/ 01

W42.USA.5504.01.21
Audi A4 Wiring diagram No. 2/ 3

rs = pink
ws = w hite
sw = black
ro = red
br = brow n
gn = green
T4k/4 bl = blue
35,0 4,0 4,0 2,5 2,5 6,0 6,0 2,5 gr = grey
sw br br br br br br br
li = lilac
3 12 83 12 179 179 345 78 249 50 86
ge = yellow
44 347
or = orange
1 2 3 4 5 6 7 8 9 10 11 12 13 14
97--52805

T4k - 4-Pin Connector, black, near front bumper 179 - Ground connection, in left headlight w iring
harness
3 - Ground strap, engine to body 249 - Ground connection -2-, in w iring harness
interior
12 - Ground connection, in engine compartment, 345 - Ground connection (in bumper w iring harness),
left Fanfare/Fog light
44 - Ground connection (lower left A-pillar) 347 - Ground connection (in roof w iring harness)

50 - Ground connection, in luggage compartment,

left
78 - Ground connection (lower right B-pillar)

83 - Ground connection -1-, in right front w iring

harness
86 - Ground connection -1-, in rear w iring harness

Edit ion 08/ 01 Ground connect ions

W42.USA.5504.01.21
Audi A4 Wiring diagram No. 2/ 4

rs = pink
ws = w hite
sw = black
ro = red
br = brow n
gn = green
bl = blue T10c
gr = grey 6,0 6,0 6,0 4,0 6,0 1,5 1,5 /1
br br br br br br br
li = lilac
ge = yellow 44 32 44 81 43 238 43 176 43 135 135 261
or = orange
15 16 17 18 19 20 21 22 23 24 25 26 27 28
97--53043

T10c - 10-Pin Connector, violet, connector station 238 - Ground connection -1-, in w iring harness
A-pillar, left interior
261 - Ground connection, in w iring harness heated
32 - Ground connection, behind instrument panel, spray jet
left
43 - Ground connection (lower right A-pillar)

44 - Ground connection (lower left A-pillar)

81 - Ground connection -1-, in instrument panel

w iring harness
135 - Ground connection -2-, in instrument panel
w iring harness
176 - Ground connection, in right headlight w iring
harness
Ground connect ions Edit ion 08/ 01
W42.USA.5504.01.21
Audi A4 Wiring diagram No. 2/ 5

B
2,5
sw
T1
2,5
A 32 ro/sw
163 190 208 T10a/4
2,5 2,5
ro ro
81 82
6,0 6,0 6,0 6,0 2,5 2,5 2,5
ro ro ro ro ro ro ro/sw
3/30 7/30 5/50b
501
0 1 0 1 2 3 D
8/86s 4/P 2/75 6/15 1/50
16,0 0,5 0,35 0,5 1,0 4,0 0,35
ro ro gr/ge ge/sw ge/sw sw bl
a

500 A2
A 33 b
16,0 0,22 1,0 4,0 0,35 0,35
ro ge/sw ge/sw sw sw sw

141 199 203 227 92

S 88
150A
+ c
d
rs = pink
A 21 ws = w hite
A
-- e sw = black
0,22 ro = red
ro br = brow n
gn = green
221 bl = blue
35,0
gr = grey
br li = lilac
ge = yellow
11
or = orange
29 30 31 32 33 34 35 36 37 38 39 40 41 42
97--54123

A -Battery A2 - Plus connection (15), in instrument panel w iring

B -Starter harness
D -Ignition/Starter Sw itch A21 - Wire connection (86s), in instrument panel
S88 -Fuse Strip (main fuse) w iring harness
T1 -1-Pin Connector, black, engine compartment, A32 - Plus connection (30), in instrument panel w iring
right harness
T10a - 10-Pin Connector, brow n, connector station A33 - Wire connection (75), in instrument panel
E-box, plenum chamber w iring harness

11 - Ground connection, in battery box

500 - Threaded connection -1- (30), on the relay plate

501 - Threaded connection -2- (30), on the relay plate

Edit ion 12/ 01 Ignit ion/ St arter Sw it ch, m ain fuse

W42.USA.5504.02.21
Audi A4 Wiring diagram No. 2/ 6

J...
170
E 45
0,35
bl/gn

T17e/10
0,22 1,0
bl/gn ro/ge
T16a/5 T16a/2 J 527

T16a/15 T16a/13 T16a/12 T16a/16 T16a/14 T16a/1

0,35 0,5 0,5 0,35 0,22
bl sw ge/sw gr/ge ro
a

A2
b

c
rs = pink
ws = w hite d A 21
sw = black e
ro = red
br = brow n
gn = green
bl = blue
gr = grey 1,0
li = lilac br
ge = yellow
135
or = orange
43 44 45 46 47 48 49 50 51 52 53 54 55 56
97--53371

E45 - Cruise Control Sw itch 135 - Ground connection -2-, in instrument panel
J... - Engine Control M odule (ECM ) w iring harness
J527 - Steering Column Electronic Systems Control A2 - Plus connection (15), in instrument panel w iring
M odule harness
T16a - 16-Pin Connector, black, on steering Column A21 - Wire connection (86s), in instrument panel
Electronic Systems Control M odule w iring harness
T17e - 17-Pin Connector, w hite, connector station
E-box, plenum chamber

Steering Colum n Elect ronic System s Cont rol M odule, Cruise Cont rol Edit ion 12/ 01
W42.USA.5504.02.21
Audi A4 Wiring diagram No. 2/ 7

E2 E 22

J 527

H G85

rs = pink
ws = w hite
sw = black
ro = red
br = brow n
gn = green
bl = blue
gr = grey
li = lilac
ge = yellow
or = orange
57 58 59 60 61 62 63 64 65 66 67 68 69 70
97--52809

E2 - Turn signal sw itch

E22 - Windshield Wiper/Washer Sw itch
G85 - Steering Angle Sensor
H - Signal horn activation
J527 - Steering Column Electronic Systems Control
M odule

Edit ion 08/ 01 Turn signal sw it ch, w indshield Wiper/ Washer Sw it ch, steering Angle Sensor,
W42.USA.5504.01.21 signal horn act ivat ion, steering Colum n Elect ronic System s Cont rol M odule
Audi A4 Wiring diagram No. 2/ 8

36 37
0,22 0,22 0,22 0,22 0,22 0,22 2,5 2,5
or/br or/gn or/br or/gn or/gn or/br A146 A147 ro ro
T32b/13 T32b/12 T10b/9 T10b/10 J 519

T32b T10b/3 T10b/4 T23/1 T23/2 T10b/2 T10b/7 T23/20

187 188 0,35/11 2,5 2,5 0,5 0,5 1,5
gn/li gn/ge sw/ws sw/li bl/li ro/ws

T16a/8 T16a/9

J 527
T16a/10 T16a/11

0,22 0,22
or/sw or/br T10c T10c T10c T17 T17 T1a
/2 /4 /8 /8 /7

232 230

0,35 1,5 1,5 0,5 0,5 1,5

gn/li gn/ge sw/ws sw/li br ro/ws
3/53e 1/53b 2/53 1 2
rs = pink M
ws = w hite M M

sw = black V V5 V 11
4/31 2 1
ro = red
br = brow n
gn = green
bl = blue
gr = grey 1,0 0,35
1,5 2,5
li = lilac br br br br
ge = yellow
or = orange 261 44 135 135

71 72 73 74 75 76 77 78 79 80 81 82 83 84
97--53372

J519 - Vehicle Electrical System Control M odule V - Windshield Wiper M otor

J527 - Steering Column Electronic Systems Control V5 - Windshield Washer Pump
M odule V11 - Headlight Washer Pump
T1a - 1-Pin Connector, black, connector station
A-pillar, left 44 - Ground connection (lower left A-pillar)
T10b - 10-Pin Connector, black, on vehicle Electrical
System Control M odule 135 - Ground connection -2-, in instrument panel
T10c - 10-Pin Connector, violet, connector station w iring harness
A-pillar, left 261 - Ground connection, in w iring harness heated
T16a - 16-Pin Connector, black, on steering Column spray jet
Electronic Systems Control M odule A146 - Comfort System High-bus Connection (in
T17 - 17-Pin Connector, black, connector station instrument panel w iring harness)
A-pillar, left A147 - Comfort System Low-bus Connection (in
T23 - 23-Pin Connector, black, on vehicle Electrical instrument panel w iring harness)
System Control M odule
T32b - 32-Pin Connector, grey, on vehicle Electrical
System Control M odule
Vehicle Elect rical System Cont rol M odule, steering Colum n Elect ronic Edit ion 08/ 01
System s Cont rol M odule, w indshield Wiper M otor, Washer Pum p W42.USA.5504.01.21
Audi A4 Wiring diagram No. 2/ 9

J 519

T32b T32b T32b T32b T32b/25 T32b/27

/28 /29 /32 /26 0,35
gr 163 41 164 245

A3
0,35 0,35 0,35 0,22 0,5 0,35 0,5 0,35 0,5
ws/gn bl li ge ro sw sw/ge gr/ws gr/bl
15/30 1/XZ 2/XR 9/NSL 17/58d
0 1 2 A
E 23
E1
14/58 11/56 3/TFL 7/A 8/NL 10/31
0,35 0,35
gr ge

A 51

241 243 * 102 123

0,22 0,22 0,22

gr/bl * gr/bl * ge *
1/58S 8/58S 2/56b
rs = pink
E 102 * ws = w hite
5/31 3/G sw = black
0,5 0,35 0,35
ro = red
gr/ge A114 gr/ge gr/ge br = brow n
gn = green
bl = blue
0,22 0,5 gr = grey
br br li = lilac
ge = yellow
238 135
or = orange
85 86 87 88 89 90 91 92 93 94 95 96 97 98
97--53373

E1 - Light sw itch 135 - Ground connection -2-, in instrument panel

E23 - Fog Light Sw itch w iring harness
E102 - Headlight Adjuster 238 - Ground connection -1-, in w iring harness
J519 - Vehicle Electrical System Control M odule interior
T32b - 32-Pin Connector, grey, on vehicle Electrical A3 - Plus connection (58), in instrument panel w iring
System Control M odule harness
A51 - Wire connection (56), in instrument panel
w iring harness
A114 - Wire connection (headlight Adjuster), in
instrument panel w iring harness

* - Not applicable to USA/CDN

Edit ion 08/ 01 Light sw it ch, headlight adjuster, Vehicle Elect rical System Cont rol M odule
W42.USA.5504.01.21
Audi A4 Wiring diagram No. 2/ 10

J 519

T23 T23/23 T23/18 T32b/3 T23/9 T32b/21

/21

0,5 1,0 1,0 0,5 0,5 0,5

ws/gn ge/sw ws/sw gr/sw sw/bl sw/gn

94
E117 A6 A181

0,5 1,0 0,5 0,5

gn/ge ws/sw sw/bl sw/gn

T17/16 T17a/8 T17a T17a/15 T17a/1 T17a/2 T17a/3

/16
1,0
ws/gn

*
T4k/1
1,0 0,35 0,5 1,5 1,0 0,5 0,5 0,5
ws/gn gn/ge ge/sw ge/sw ws/sw gr/sw sw/bl gn
1 6/G 2/56b 5/56b 1/56a 7/58L 9/BL +
rs = pink
ws = w hite L 22 V48 L1 M1 M5 M18
sw = black
ro = red
2 * 4/31 10/31 8/31 --

br = brow n
gn = green
bl = blue
gr = grey 1,0 0,5 1,0 2,5 0,5
br br br br br
li = lilac
ge = yellow
345 179 179 179 179
or = orange
99 100 101 102 103 104 105 106 107 108 109 110 111 112
97--53374

J519 - Vehicle Electrical System Control M odule 179 - Ground connection, in left headlight w iring
L1 - Tw in filament bulb for headlight, left harness
L22 - Left Front Fog Light 345 - Ground connection (in bumper w iring harness),
M1 - Left Parking Light Fanfare/Fog light
M5 - Left Front Turn Signal Light A6 - Plus connection (left turn signal), in instrument
M 18 - Left Side Turn Signal Light panel w iring harness
T4k - 4-Pin Connector, black, near front bumper A181 - Left Turn Signal Plus Connection -2- (in

T17 - 17-Pin Connector, black, connector station instrument panel w iring harness)
A-pillar, left E117 - Connector (56a left), in instrument panel w iring

T17a - 17-Pin Connector, red, connector station harness

A-pillar, left
* - Not applicable to USA/CDN
T23 - 23-Pin Connector, black, on vehicle Electrical
System Control M odule
T32b - 32-Pin Connector, grey, on vehicle Electrical
System Control M odule
V48 - Left Headlight Beam Adjusting M otor*
Left headlight , left Fog Light Edit ion 08/ 01
W42.USA.5504.01.21
Audi A4 Wiring diagram No. 2/ 11

J 519

T32b/22 T23/7 T32b/5 T23/16 T23/22 T23/19

0,5 0,5 0,5 1,0 1,0 0,5

bl/sw gn/sw gr/ro ws/ge ge/ws ws/bl

95
A180 A5 A 85 E116

0,5 0,5 0,5 1,0 1,5 0,5

bl/sw gn/sw gr/ro ws/ge ge/ws gr/ge

T17c/3 T17c/2 T17c/1 T17c T17c/16 T17c/8 T17/15

/15
1,0
ws/bl
* *
T4k/2
0,5 0,5 0,5 1,5 1,5 0,5 0,35 1,0
gn sw/gr gr/ro ws/ge ge/ws ge/ws gr/ge ws/bl
+ 9/BR 7/58R 1/56a 5/56b 2/56b 6/G 1
rs = pink
M 19 M7 M3 L2 V49 L 23 ws = w hite
sw = black
-- 10/31 8/31 4/31 * 2
ro = red
br = brow n
gn = green
bl = blue
0,5 1,0 2,5 0,5 1,0 gr = grey
br br br br br
li = lilac
ge = yellow
176 176 176 176 345
or = orange
113 114 115 116 117 118 119 120 121 122 123 124 125 126
97--53375

J519 - Vehicle Electrical System Control M odule 176 - Ground connection, in right headlight w iring
L2 - Tw in filament bulb for headlight, right harness
L23 - Right Front Fog Light 345 - Ground connection (in bumper w iring harness),
M3 - Right Parking Light Fanfare/Fog light
M7 - Right Front Turn Signal Light A5 - Plus connection (right turn signal), in instrument
M 19 - Right Side Turn Signal Light panel w iring harness
T4k - 4-Pin Connector, black, near front bumper A85 - Wire connection (58R), in instrument panel
T17 - 17-Pin Connector, black, connector station w iring harness
A-pillar, left A180 - Right Turn Signal Plus Connection -2- (in

T17c - 17-Pin Connector, red, connector station instrument panel w iring harness)
A-pillar, right E116 - Connector (56a, right), in instrument panel

T23 - 23-Pin Connector, black, on vehicle Electrical w iring harness

System Control M odule
* - Not applicable to USA/CDN
T32b - 32-Pin Connector, grey, on vehicle Electrical
System Control M odule
V49 - Right Headlight Beam Adjusting M otor*
Edit ion 08/ 01 Right headlight , right Fog Light
W42.USA.5504.01.21
Audi A4 Wiring diagram No. 2/ 12

J 519

T23/5 T23/15 T23/6 T32b T23/12 T23/14 T23/10 T32b T23/4 T23/8 T32b/6
/4 /7

1,0 0,5 0,5 0,35 0,5 0,35 0,5 0,35 0,5 1,0 0,35
bl/ro gr/ws gn/bl gr/sw ro/sw sw/ro ro/sw gr/ro sw/gn bl/ro gr

B132

0,35
gr

B186 B187 T4l/3

0,5 0,5 0,35

gn/bl sw/gn ro
3/RF 2/NSL 5/BL 4/58L 6/54L 1/54 2/54R 4/58R 1/BR 3/RF 1
rs = pink
ws = w hite M16 L46 M6 M9 M 25 M 10 M8 M17 X
sw = black M4 M4 1/31 2/31 5/31 M2 M2 2
ro = red 0,35
br = brow n * * bl
gn = green
bl = blue T4l/4
gr = grey 1,5 0,35 1,5 0,35
br br br br
li = lilac
ge = yellow
86 86 249 86
or = orange
127 128 129 130 131 132 133 134 135 136 137 138 139 140
97--53376

J519 -
Vehicle Electrical System Control M odule 86 - Ground connection -1-, in rear w iring harness
L46 -
Left Rear Fog Light
M2 -
Right Tail Light 249 - Ground connection -2-, in w iring harness
M4 -
Left Tail Light interior
M6 -
Left Rear Turn Signal Light B132 - Connector (license plate light), in w iring
M8 -
Right Rear Turn Signal Light harness interior
M9 -
Left Brake Light B186 - Connector -2- (BL), in w iring harness interior

M 10 -
Right Brake Light
M 16 -
Left Back-Up Light B187 - Connector -2- (BR), in w iring harness interior
M 17 -
Right Back-Up Light
M 25 -
High-mount Brake Light * - M 2/M 4 tw in filament bulb (5W), not required
T4l -
4-Pin Connector, black, in rear lid
T23 -
23-Pin Connector, black, on vehicle Electrical
System Control M odule
T32b - 32-Pin Connector, grey, on vehicle Electrical
System Control M odule
X - License Plate Light
Rear light s Edit ion 08/ 01
W42.USA.5504.01.21
Audi A4 Wiring diagram No. 2/ 13

J 519

T32b T32b T32b T32b T32b/19 T32b/1

/17 /8 /9 /18
0,35
gn/ge
176
A 90
0,22 0,22 0,22 0,22 2,5 1,5
ge/sw ro/ge ws/li ge/ro ro/ge ro/ge
2/30 4/85
J4
37 T17f T17f T4k/3
/13 /14 3
8/87 6/86
2,5 0,35 2,5
sw/ws gn/ge sw/ws
B260 E112 X 66
0,22 0,22 0,22 0,22 2,5 2,5 1,5 1,5
ge/bl ro/ge ws/li ge/ro sw/ws sw/ws sw/ws sw/ws
1 2 6 1 3

T17a/17
H2 H7
E 229 3 4 2 G 213
1,5 1,5
br br

345
2,5
br

rs = pink
T4k/4 ws = w hite
sw = black
ro = red
br = brow n
gn = green
bl = blue
0,22 0,22 0,22 2,5 gr = grey
br br br br
li = lilac
ge = yellow
135 135 347 179
or = orange
141 142 143 144 145 146 147 148 149 150 151 152 153 154
97--53377

E229 - Sw itch for emergency flasher 135 - Ground connection -2-, in instrument panel
G213 - Rain Sensor w iring harness
H2 - High Tone Horn 179 - Ground connection, in left headlight w iring
H7 - Low Tone Horn harness
J4 - Horn Relay 345 - Ground connection (in bumper w iring harness),
J519 - Vehicle Electrical System Control M odule Fanfare/Fog light
T4k - 4-Pin Connector, black, near front bumper 347 - Ground connection (in roof w iring harness)
T17a - 17-Pin Connector, red, connector station
A-pillar, left A90 - Connector (two-tone horn), in instrument panel
T17f - 17-Pin Connector, orange, connector station w iring harness
A-pillar, left B260 - Connector (emergency flasher), in w iring
T32b - 32-Pin Connector, grey, on vehicle Electrical harness interior
System Control M odule E112 - Connector (Horn-87h) in instrument panel
w iring harness
X66 - Horn Connection (in front bumper w iring
harness)

Edit ion 08/ 01 Sw it ch for em ergency flasher, t w o-tone horn, rain Sensor,
W42.USA.5504.01.21 vehicle Elect rical System Cont rol M odule
Audi A4 Wiring diagram No. 2/ 14

29
6,0
ro A 57
J 519 a
0,5
ro
T32b T32b T10b/8 T10b/5 T32b/2
/10 /15 91
A 34

0,22 0,22 0,5 0,5 4,0 0,5 4,0 2,5

ws/ro ro/sw sw/ge ro ro sw/ge sw/ge sw/ge
3 1 36 37
J 59 94 S 236 S 237
A154 A 18 6 30A 20A
4 2 36a 37a
1,0 1,0 4,0 2,5 2,5
ws/ro ro/sw sw/ge sw/ge sw/gn

2 4

F
3 1

0,5 1,0 1,0

ro/ws *
* sw/br* ro/br
204

b
rs = pink
ws = w hite A104
sw = black
ro = red 0,5
br = brow n ro/ws
gn = green
bl = blue
gr = grey T10a/8
li = lilac
ge = yellow
or = orange
155 156 157 158 159 160 161 162 163 164 165 166 167 168
97--53378

F - Brake Light Sw itch A18 - Wire connection (54), in instrument panel

J59 - Load Reduction Relay w iring harness
J519 - Vehicle Electrical System Control M odule A34 - Wire connection (75x), in instrument panel
S236 - Fuse in fuse holder w iring harness
S237 - Fuse in fuse holder A57 - Plus connection -3- (30), in instrument panel
T10a - 10-Pin Connector, brow n, connector station w iring harness
E-box, plenum chamber A154 - Wire connection (Brake Light Sw itch), in
T10b - 10-Pin Connector, black, on vehicle Electrical instrument panel w iring harness
System Control M odule A104 - Plus connector -2-, in instrument panel w iring
T32b - 32-Pin Connector, grey, on vehicle Electrical harness
System Control M odule

Brake Light Sw it ch, load Reduct ion Relay, vehicle Elect rical System Edit ion 08/ 01
Cont rol M odule W42.USA.5504.01.21
Audi A4 Wiring diagram No. 2/ 15

A 57
a

6,0 2,5 1,5

ro ro ro
12 13 14 15 39 40 33 22
S 12 S 13 S 14 S 15 S 239 S 240 S 233
10A 10A 10A 10A 20A 25A 15A
12a 13a 14a 15a 39a 40a 33a
0,5 1,0 1,0 1,0 2,5 2,5 1,5
ro/sw ro/ge ro/br ro/bl ro/bl ro/ge ro/bl

A 50 A129 A 46

0,5
ro/bl

260 54 225 147 249 251

0,35 2,5 0,35 0,22
gr ro/bl gr/bl gr/bl
b 2 1 1
L28 rs = pink
T8/2 T8/7 T8/8 ws = w hite
U1 L15 sw = black
3 2
ro = red
br = brow n
gn = green
bl = blue
1,5 1,5 0,22 gr = grey
br br br
li = lilac
ge = yellow
610 135 238
or = orange
169 170 171 172 173 174 175 176 177 178 179 180 181 182
97--53379

L15 - Ashtray Light 135 - Ground connection -2-, in instrument panel

L28 - Cigarette Lighter Light w iring harness
S12 - Fuse in fuse holder/relay panel 238 - Ground connection -1-, in w iring harness
S13 - Fuse in fuse holder/relay panel interior
S14 - Fuse in fuse holder/relay panel 610 - Ground connection (Audio) (under center
S15 - Fuse in fuse holder/relay panel console, front)
S233 - Fuse in fuse holder A46 - Plus connection (30-from radio), in instrument
S239 - Fuse in fuse holder panel w iring harness
S240 - Fuse in fuse holder A50 - Plus connection (30as), in instrument panel
w iring harness
T8 - 8-Pin Connector, black, radio connector III
A57 - Plus connection -3- (30), in instrument panel
U1 - Cigarette Lighter
w iring harness
A129 - Wire connection (quiet sw itch), in instrument
panel w iring harness

Edit ion 12/ 01 Asht ray Light , cigarette Lighter, fuses, radio connector III
W42.USA.5504.02.21
Audi A4 Wiring diagram No. 2/ 16

30
6,0
ro

24 2 26
S2 S 226
5A 30A
2a 26a
A 87 0,5 4,0
73 74 ro/li ws/ge

1,0 0,22 0,22

bl/ro or/gn or/gn

2 III/7 V/12 V/13 F/5

A 29
C 18
W6 J 393 E 87 Z1
1 I/4 II/6 II/13 F/6
1,0 0,5 0,5 0,5 0,35 0,5 0,35 4,0
bl/ro br/gr ro/ge ro/ge ro/gr ro/li ro/li ws/li

T17d T12d T12d/2 T12d/1 B180

/15 /4 0,5 4,0
ro/li ws/li
2 1 2 B248
rs = pink
ws = w hite C 18
E 26 W 10 W9
sw = black
1 2 1
ro = red 1,0 0,5 0,5 0,35
br = brow n bl/ro br ro/gr ro/gn
gn = green
bl = blue 206 T12d/7 C 18
gr = grey 0,5 4,0
br br
li = lilac
ge = yellow
238 73 73
or = orange
183 184 185 186 187 188 189 190 191 192 193 194 195 196
97--54468

C18 - Windshield Antenna Suppression Filter 73 - Ground connection, on roof bow, rear
E26 - Glove compartment light
E87 - A/C Control Head 238 - Ground connection -1-, in w iring harness
J393 - Central control module for comfort system interior
S2 - Fuse in fuse holder/relay panel A29 - Wire connection (interior light), in instrument
S226 - Fuse in fuse holder panel w iring harness
T12d - 12-Pin Connector, brow n, near glove A87 - Connector (reverse lamp), in instrument panel
Compartment w iring harness
T17d - 17-Pin Connector, red, connector station E-box, B180 - Connection (heated rear w indow ), in w iring
plenum chamber harness interior
W6 - Glove Compartment Light B248 - Heated Rear Window Connection -2- (in interior
W9 - Left Footwell Light w iring harness)
W10 - Right Footwell Light
Z1 - Heated rear w indow

Glove Com part m ent Light , left Foot w ell Light , right Foot w ell Light , Edit ion 12/ 01
heated rear w indow W42.USA.5504.02.21
Audi A4 Wiring diagram No. 2/ 17

31
6,0
ro

38 39
A 52
1,0 4,0 2,5
ge/sw * sw ro
3 5 7 31 35
S3 S5 S7 S 231 S 235
5A 10A 10A 15A 30A
3a 5a 7a 31a 35a
0,5 1,0 1,5 1,5 2,5
gr/gn * sw/ro sw/br sw/bl ro/gr

A 74 A 20 A 70
T10c/3
1,0 1,0 0,5 1,5
sw/ro sw/br sw/bl sw/bl

T10a/5
0,5 0,5 1,5
gr/gn* gr/gn* sw/bl
1 1 3 2
rs = pink
223 156 258 ws = w hite
Z 20 Z 21 F4 U
2
sw = black
2 2 1
1,0 ro = red
bl/ro br = brow n
gn = green
183 bl = blue
0,5 0,5 2,5 gr = grey
br * br * br
li = lilac
ge = yellow
261 261 249
or = orange
197 198 199 200 201 202 203 204 205 206 207 208 209 210
97--54469
F4 - Back-Up Light Sw itch 249 - Ground connection -2-, in w iring harness
S3 - Fuse in fuse holder/relay panel interior
S5 - Fuse in fuse holder/relay panel 261 - Ground connection, in w iring harness heated
S7 - Fuse in fuse holder/relay panel spray jet
S231 - Fuse in fuse holder A20 - Wire connection (15a), in instrument panel
S235 - Fuse in fuse holder w iring harness
T10a - 10-Pin Connector, brow n, connector station A52 - Plus connection -2- (30), in instrument panel
E-box, plenum chamber w iring harness
T10c - 10-Pin Connector, violet, connector station A70 - Connector (15a, fuse 231), in instrument panel
A-pillar, left w iring harness
U - Socket A74 - Connector (15a, fuse 5), in instrument panel
Z20 - Left Washer Nozzle Heater w iring harness
Z21 - Right Washer Nozzle Heater
3 - Only heated spray jets

Edit ion 12/ 01 Fuses, Socket , heated spray jet

W42.USA.5504.02.21
Audi A4 Wiring diagram No. 2/ 18

D2
2 1
34

0,22 0,22 0,22

ro sw gn
T32/22 T32/30 T32/31

G3 G1

J 285

T32/1 T32/2 T32/4 T32/3 T32/11 T32/21 T32/23 T32/32

0,22 0,35 0,35 0,35 0,35 0,35 0,35
br/ro bl/ge bl/br li/sw li/sw * ge/gr ro/gr 203

T17/9 T10/7 T10/9 T10d T10a

/9 /9
0,35 1,0
ge/gr sw/ro

T14/4 T10a
/2
0,5 0,5 0,35 0,35 0,35 0,5
br/ro bl/ge bl/br ge/gr ro/gr sw/ro
1 2 2 2 2 3 1
rs = pink
ws = w hite G2 G G*169 F38
sw = black F77 3 F66 2 3 3 1 2
ro = red G 266
0,35 0,35 0,35 0,35 0,35 0,35
br = brow n br/ge br/ge br/ge br/ge br/ge br/ge
gn = green
T17 T10 T14/3 T10d
bl = blue /10 /6 /10
gr = grey 0,35
327
0,35 0,5 0,5 0,35 0,5 0,22
li = lilac br/ge br/ge br/ge br/ge * br/ge br br/ge
ge = yellow 269 269
269 269 269 83 269
or = orange
211 212 213 214 215 216 217 218 219 220 221 222 223 224
97--54137

D2 - Induction Coil of Anti-theft Immobilizer T10d - 10-Pin Connector, grey, connector station
F38 - Ambient Temperature Sw itch A-pillar, left
F66 - Engine Coolant Level (ECL) Warning Sw itch T14 - 14-Pin Connector, black, in engine
F77 - Windshield Washer Fluid Level Warning Sw itch compartment, left
G - Sender for fuel gauge T17 - 17-Pin Connector, black, connector station
G1 - Fuel Gauge A-pillar, left
G2 - Engine Coolant Temperature (ECT) Sensor T32 - 32-Pin Connector, blue, on instrument panel
G3 - Engine Coolant Temperature (ECT) Gauge insert
G169 - Fuel Level Sensor 2
G266 - Oil Level Thermal Sensor 83
- Ground connection -1-, in right front w iring
harness
J285 - Control module w ith indicator unit in instrument
panel insert 269 - Ground connection (sensor Ground) -1-, in
instrument panel w iring harness
T10 - 10-Pin Connector, black, connector station
E-box, plenum chamber 327 - Ground connection (sensor Ground), in engine
compartment w iring harness
T10a - 10-Pin Connector, brow n, connector station
E-box, plenum chamber
3 - only quattro
Cont rol m odule w it h indicator unit in inst rum ent panel insert Edit ion 12/ 01
W42.USA.5504.02.21
Audi A4 Wiring diagram No. 2/ 19

J 234
172 40 68

0,5 0,35 0,35

ro/bl sw ws/ge
T32a/2 T32a/3 T32a/7

G 21 K 75 G5 K2

J 285

T32a/5 T32a/9 T32a/12 T32a/13 T32a/14 T32a/16

0,35 0,35 0,22 0,22 0,35 0,35
br/ro ge/bl or/br or/sw bl ws/gr

J ... J ...
T10/10 T10c/10 A 17 T10/3

0,22 0,22 0,35

or/br or/sw bl

T17d T17d T10/1

/13 /14
0,5 0,5 0,22 0,22 0,35 0,5
br/ro ge/bl or/br or/sw bl ws/gr
1 2/G 1
A122 A121
rs = pink
T2/1 ws = w hite
G 22 F34 F1
3/31 2 sw = black
0,35
ro = red
0,22 0,22
or/br or/sw bl br = brow n
D+/61
gn = green
73 71 bl = blue
C gr = grey
0,5 0,5
br br li = lilac
83 261
ge = yellow
or = orange
225 226 227 228 229 230 231 232 233 234 235 236 237 238
97--53383

C - Generator (GEN) T10c - 10-Pin Connector, violet, connector station

F1 - Oil Pressure Sw itch A-pillar, left
F34 - Brake Fluid Level Warning Sw itch T17d - 17-Pin Connector, red, connector station E-box,
G5 - Tachometer plenum chamber
G21 - Speedometer T32a - 32-Pin Connector, green, on instrument panel
G22 - Speedometer Vehicle Speed Sensor insert
J... - Engine Control M odule (ECM )
J234 - Airbag Control M odule 83 - Ground connection -1-, in right front w iring
J285 - Control module w ith indicator unit in instrument harness
panel insert 261 - Ground connection, in w iring harness heated
K2 - Generator (GEN) Warning Light spray jet
K75 - Airbag M alfunction Indicator Lamp (M IL) A17 - Wire connection (61), in instrument panel
w iring harness
T2 - Double Connector, black, engine compartment,
A121 - Wire connection (High-bus), in instrument panel
right
w iring harness
T10 - 10-Pin Connector, black, connector station
A122 - Wire connection (Low-bus), in instrument panel
E-box, plenum chamber
w iring harness
Edit ion 12/ 01 Cont rol m odule w it h indicator unit in inst rum ent panel insert
W42.USA.5504.02.21
Audi A4 Wiring diagram No. 2/ 20

J 489
1 3 2
0,35 0,35 0,35
ge ro/gn br/ws
T4m/1 T4m/2 T4m/4

Y8 J 285

T32a/17
0,5
gr/bl

85 87 98 179 181

0,22 0,22 0,5 0,35 0,22

A175 gr/bl gr/bl gr/bl gr/bl gr/bl

0,22 0,22 0,22 0,22 0,22 0,22 0,22

gr/bl gr/bl gr/bl gr/bl gr/bl gr/bl gr/bl
1 1 1 1 1 1 1
rs = pink
ws = w hite
sw = black L67 L68 L69 L120 L121 L122 L50
ro = red 2 2 2 2 2 2 2
br = brow n
gn = green
bl = blue
gr = grey 0,22 0,22 0,22 0,22 0,22 0,22 0,22
li = lilac br br br br br br br
ge = yellow
or = orange 81 238 238 238 238 238 238

239 240 241 242 243 244 245 246 247 248 249 250 251 252
97--53384

J285 - Control module w ith indicator unit in instrument 81 - Ground connection -1-, in instrument panel
panel insert w iring harness
J489 - Radio Frequency Controlled Clock Receiver 238 - Ground connection -1-, in w iring harness
L50 - Rear Center Ashtray Light interior
L67 - Left Instrument Panel Vent Illumination A175 - Wire connection (58s), in instrument panel
L68 - Center Instrument Panel Vent Illumination w iring harness
L69 - Right Instrument Panel Vent Illumination
L120 - Storage Compartment Illumination
L121 - Cup Holder Illumination
L122 - Coin Holder Illumination
T4m - 4-Pin Connector, black, on instrument panel
insert
T32a - 32-Pin Connector, green, on instrument panel
insert
Y8 - Radio Frequency Controlled Clock

Cont rol m odule w it h indicator unit in inst rum ent panel insert , Inst rum ent Edit ion 12/ 01
Panel Vent Illum inat ion, radio Frequency Cont rolled Clock W42.USA.5504.02.21
Audi A4 Wiring diagram No. 2/ 21

J 285

T32a T32a T32a/22 T32a/23 T32a/32

/18 /19 0,22
0,22 0,22 br/gn
sw/ro gn/ro

T17b/4 A 76 T17b/3
205 169
0,35 0,5 0,35 0,5 0,35
sw/ro sw/bl gn/ro ro/sw br/gn
17 T16/1 T16/7 T16/16
J 104

T16/4 T16/5
rs = pink
G 34 G 35 ws = w hite
2 1 1 2 sw = black
ro = red
br = brow n
gn = green
T4n/2 T4n/1 T4o/2 T4o/1 bl = blue
0,22 0,22 0,35 0,35 0,35 0,35 gr = grey
br br br br br sw li = lilac
135 135 179 179 179
ge = yellow
or = orange
253 254 255 256 257 258 259 260 261 262 263 264 265 266
97--53385

G34 - Left Front Brake Pad Wear Sensor 135 - Ground connection -2-, in instrument panel
G35 - Right Front Brake Pad Wear Sensor w iring harness
J104 - ABS Control M odule (w /EDL) 179 - Ground connection, in left headlight w iring
J285 - Control module w ith indicator unit in instrument harness
panel insert A76 - Wire connection (K-diagnosis w ire), in
T4n - 4-Pin Connector, black, left front instrument panel w iring harness
T4o - 4-Pin Connector, black, right front
T16 - 16-Pin Data Link Connector (DLC), black, under
instrument panel, left
T17b - 17-Pin Connector, green, connector station
A-pillar, left
T32a - 32-Pin Connector, green, on instrument panel
insert

Edit ion 12/ 01 Brake Pad Wear Sensor, cont rol m odule w it h indicator unit in
W42.USA.5504.02.21 inst rum ent panel insert , Dat a Link Connector (DLC)
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 Audi A8 Current Flow Diagram No. 38 / 1

Audi A8 3.0 litre fuel injection engine (162 kW/160 kW - Motronic - 6-cylinder), engine codes ASN/BBJ
From model year 2003

Audi A8 3.0 litre fuel injection engine (162 kW/ 160 kW - Motronic - 6-cylinder), engine code ASN, from model year 2003
Fuse box, dash panel, left

8 12 16 20

5 9 13 17 21
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 3 6 10 14
permitted 18
unless 22
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2 4 7 11 15 respect
with 19 to the
23correctness of information in this document. Copyright by AUDI AG.

24 31 38 Res

25 32 39 Res

26 33 40 Res

27 34 41 Res

28 35 42 Res

29 36 43

30 37 44

A97--0119

Fuse colours
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
1 A - black
SB - Fuses in fuse box, dash panel, left
SC - Fuses in fuse box, dash panel, right
SD - Fuses in fuse box, luggage compartment, left
SF - Fuses in fuse box, luggage compartment, right

Edition 02.2004
 Audi A8 Current Flow Diagram No. 38 / 1
Fuse box, dash panel, right

A97--0407
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Relay carrier, electronics box, plenum chamber

E F G

A B C D

A97--0404

Position of relays

1 - Secondary air pump relay (J299)

3 - Motronic current supply relay (J271)

Edition 02.2004
 Audi A8 Current Flow Diagram No. 38 / 1
B - Secondary air pump fuse (S130)
Relay and fuse carrier, behind dash panel, left

A97--0403

Position of relays

3 - Terminal 15 voltage supply relay (J329)

Relay carrier, front passenger's footwell

F
E

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

A
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

C D
with respect to the correctness of information in this document. Copyright by AUDI AG.

A97--0405

Edition 02.2004
 Audi A8 Current Flow Diagram No. 38 / 1
Position of relays

1.1 - Brake servo relay (J569)

1.2 - Continued coolant circulation relay (J151)
2 - Starter motor relay (J53)
3 - Starter motor relay -2- (J695)
4 - Fuel pump relay (J17)
Position of components in: main fuse carrier, A pillar, right

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

A97--0406

Position of fuses

1 - Radiator fan single fuse (S42, 60 A)

1A - Screw connection for radiator fan 1
2 - Radiator fan fuse, 2nd speed (S104, 60 A)
2A - Screw connection for radiator fan 2
3 - Screw connection for terminal 30 (battery)
4 - Screw connection for terminal 30 (starter)

Edition 02.2004
 Audi A8 Current Flow Diagram No. 38 / 1
Relay and fuse carrier, luggage compartment, right

A D
BC

A97--0409

Position of relays

3 - Electric fuel pump II relay (J49)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Edition 02.2004
Audi A8 Current Flow Diagram No. 38 / 2
Battery, energy management control unit, battery cut-off
relay
A Battery
J234 Airbag control unit
J644 Energy management control unit
J655 Battery cut-off relay
S131 Fuse 1, 110 A, in luggage compartment, rear right
S132 Fuse 2, 60 A, in luggage compartment, rear right
S133 Fuse 3, 150 A, in luggage compartment, rear right
188
Z2 B303 SC15 Fuse -15- on fuse box
4,0 16,0 10,0 12,0 6,0 SC38 Fuse -38- on fuse box
ro ro ro ro ro SC40 Fuse -40- on fuse box
T46b 46-pin connector, black, CAN separating connector, right
17 30
Z2 Heated windscreen

38 40 15 3A 2A 1A ✱ 3 Earth strap, engine - body

SC38 SC40 SC15 S133 S132 S131
5A 15A 5A 150A 60A 110A
38a 40a 15a
13 Earth point, in engine compartment, right

18 Earth point, on cylinder block

1,5 35,0
ro/gn sw 379 Earth connection -14-, in main wiring harness
J 234 J 234
143 76 4 15
B303 Positive (+) connection -7- (30), in main wiring harness
+ 50,0 0,5 0,5 0,5
sw ws ge sw • CAN bus (data wire)
* In luggage compartment, rear right
A
A 3 4 1/15

27
J 655
T46b T46b --
B 2/31
/15H /15L

0,35 •• 0,35 • 0,5 0,35 0,5 50,0 80,0

or/gn or/br sw/ge ro/gn ro/ws sw sw

19
CAN-H CAN-L
9 10 8 14 11 B--

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ws = white
J 644 sw = black
with respect to the correctness of information in this document. Copyright by AUDI AG.

ro = red
35,0 0,5 35,0 br = brown
sw br/ge sw
gn = green
bl = blue
gr = grey
13 18 379 18 3 li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A97-84436
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 38 / 3
Starter, alternator, terminal 15 voltage supply relay, starter
motor relay
B Starter
C Alternator
C1 Voltage regulator
J53 Starter motor relay
J329 Terminal 15 voltage supply relay
J518 Entry and start authorisation control unit
J695 Starter motor relay -2-
0,5 0,5 0,5 4,0 B165 4,0 0,5 1,0 1,5 S42 Radiator fan single fuse
sw sw sw sw sw sw sw sw S104 Radiator fan fuse, 2nd speed
13 183 187 42 SC9 Fuse -9- on fuse box
2 4 9 T2a 2-pin connector, black, in engine compartment, front right
B273
2 SC9 T2f 2-pin connector, black, on alternator
B298
J 53 5A
8 6 9a
B165 Positive (+) connection -2- (15), in interior wiring harness

0,5 4,0 1,0 4,0 0,5 0,5 1,0

ro sw sw sw/bl bl/sw sw sw/bl B273 Positive (+) connection (15), in main wiring harness

205 39 129
3/86 2/87 2 4 B276 Positive (+) connection (50), in main wiring harness
3 3
J 329 J 695 B298 Positive (+) connection -2- (30), in main wiring harness
8 6
4/85 1/30
J 518
11 157 39 A51

6,0 12,0 4,0 0,5 4,0 0,5 4,0 0,35 0,5 B302 Positive (+) connection -6- (30), in main wiring harness
ro ro ro bl ro ro/sw sw/ro sw/ro br/ro

B302 A58
* Main fuse carrier, A pillar, right
38
J 518 3
B276
2,5 0,5
sw/ro sw/ge
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

9 T2a/2 T2a/1
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
80,0 50,0 2,5 25,0 1,5
sw sw ro/sw sw bl

T2f/1
3 4 ✱ 30 50 B+ D+ DF
1 2
G
S42 S104 M
60A 60A
ws = white
1a 2a B C C1 sw = black
ro = red
6,0 6,0 br = brown
ro/sw ro/ws
gn = green
bl = blue
170 174
gr = grey
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28
A97-84439
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 38 / 4
Engine control unit, Motronic current supply relay
J271 Motronic current supply relay
J623 Engine control unit
SC21 Fuse -21- on fuse box
SC28 Fuse -28- on fuse box
SC30 Fuse -30- on fuse box
T17a 17-pin connector, black, in electronics box, plenum chamber
T17c 17-pin connector, brown, in electronics box, plenum chamber
T17d 17-pin connector, blue, in electronics box, plenum chamber
35 23 28

4,0 B147 1,0 0,5 1,5 1,5 17 Earth point, on intake manifold
ro/sw ro ro/sw sw/bl sw

30 21 28
43 Earth point, lower part of right A pillar
SC30 SC21 SC28
30A 5A T17c T17d T17c 15A
30a 77 21a /15 /6 /16 28a
85 Earth connection -1-, in engine compartment wiring harness
2,5 4,0 1,5 1,0 1,0 0,35 0,5 0,5 0,5
ro/gn ro/sw ro/sw ro/ws ro/gr ro/ws gr/ws sw/bl sw/bl
131 Earth connection -2-, in engine compartment wiring harness
49 141

8/87 5/87a 1/T 62/30 42/50 21/15 J 623 B147 Positive (+) connection -2- (87), in interior wiring harness
3
B272 J 271
2/30 4/86 23 32 119 1/31 2/31 B272 Positive (+) connection (30), in main wiring harness

6,0 6,0 2,5 0,5 0,35 0,35 0,35 2,5 2,5 B300 Positive (+) connection -4- (30), in main wiring harness
ro ro ro sw br/sw li/gr li/bl br br

12

T17a T17a T17a

/4 /7 /5

B300

4,0 1,0 4,0 0,5 0,5

ro ro ro br/ro bl/sw

184 35 138 26 25

T17a ws = white
/17 sw = black
Protected by copyright. Copying for private or commercial purposes, in partro = redis not
or in whole,
4,0 4,0 6,0 permitted unless authorised by AUDI AG. AUDI AG does not guarantee orbr accept=anybrown
liability
br br br/ws
gn = green
with respect to the correctness of information in this document. Copyright by AUDI AG.
bl = blue
gr = grey
85 43 131 17 85 85 li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42
A97-84442
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 38 / 5
Engine control unit, injectors for cylinders 1 - 4, ignition coils
for cylinders 1 - 4
J623 Engine control unit
N30 Injector, cylinder 1
N31 Injector, cylinder 2
N32 Injector, cylinder 3
N33 Injector, cylinder 4
N70 Ignition coil 1 with output stage
D95
N127 Ignition coil 2 with output stage
N291 Ignition coil 3 with output stage
0,35 0,35 D95 0,35 0,35
bl/ws bl/ws bl/ws bl/ws
N292 Ignition coil 4 with output stage
P Spark plug connector
1 1 1 1 Q Spark plugs
T10c 10-pin connector, red, in electronics box, plenum chamber
N30 N31 N32 N33
2 2 2 2
85 Earth connection -1-, in engine compartment wiring harness

0,35 0,35 0,35 0,35

gn/ro gn/bl ws/gn ws/ge 131 Earth connection -2-, in engine compartment wiring harness

96 112 J 623 88 97
D95 Connection (injectors), in engine compartment wiring harness

102 110 94 103 3

E6 Positive (+) connection -1- (15), in Motronic wiring harness

0,35 0,35 0,35 0,35 1,5

gn/li gn sw/gr E6 gn/ro ro/bl
E6
1,5 1,5 2,5 1,5 1,5
ro/gn ro/gn ro/gn ro/gn ro/gn

3 N70 1 3 N127 1 3 N291 1 3 N292 1

2/31 4/31 I 2/31 4/31 II 2/31 4/31 III 2/31 4/31 IV

T10c
/1
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
P P P P
Q Q Q Q ws = white
sw = black
ro = red
1,5 1,5 1,5 1,5 2,5 1,5 1,5 1,5 1,5 br = brown
br br/ws br br/ws ro/gn br br/ws br br/ws
gn = green
29
bl = blue
gr = grey
85 131 85 131 85 131 85 131 li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56
A97-84445
or = orange
rs = pink

Edition 02.2004
 Audi A8 Current Flow Diagram No. 38 / 6
Engine control unit, injectors for cylinders 5 and 6, ignition
coils for cylinders 5 and 6, throttle valve module, accelerator
pedal position senders
G79 Accelerator pedal position sender
G185 Accelerator pedal position sender 2
G186 Throttle valve drive (electric power control)
G187 Throttle valve drive angle sender 1 (electric power control)
G188 Throttle valve drive angle sender 2 (electric power control)
D95 J338 Throttle valve module
D95 J623 Engine control unit
0,35 0,35 2,5
bl/ws bl/ws bl/ws N83 Injector, cylinder 5
G186 G187 G188 N84 Injector, cylinder 6
1 1
N323 Ignition coil 5 with output stage
M N324 Ignition coil 6 with output stage
N83 N84 T10c/8 J 338 P Spark plug connector
2 2 3/M+ 5/M-- 6 1 4 2
Q Spark plugs
T10c 10-pin connector, red, in electronics box, plenum chamber
0,35 0,35 2,5 1,0 1,0 0,35 0,35 0,35 0,35 T17c 17-pin connector, brown, in electronics box, plenum chamber
gn/gr gn/bl bl/ws ro/gn br/gn br/ro gr/ro gn/ws sw/gn

85 Earth connection 1, in engine compartment wiring harness

110

113 89 J 623 117 118 91 92 84 83

131 Earth connection 2, in engine compartment wiring harness
111 95 73/5V 36/-- 35/S1 34/S2 33/-- 72/5V

0,35 0,35 D95 Connection (injectors), in engine compartment wiring harness

gn/sw E6 bl/ro
E6
1,5 1,5 0,5 0,5 0,5 0,5 0,5 0,5 E6 Positive (+) connection 1 (15), in Motronic wiring harness
ro/gn ro/gn ge br sw ge/gr br ge/bl

3 N323 1 3 N324 1

T17c T17c T17c T17c T17c T17c

2/31 4/31 2/31 4/31 /3 /5 /4 /7 /8 /6
V VI

0,35 0,35 0,35 0,35 0,35 0,35

ge/br br ge/gr br/ws ge/ws ge/ro

2/+ 3/-- 4/S1 6/S2 5/-- 1/+

P P
Q Q ws = white
G79 G185
sw = black
ro = red
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
br = brown
with respect to the correctness of information in this document. Copyright by AUDI AG.
1,5 1,5 1,5 1,5 gn = green
br br/ws br br/ws
bl = blue
gr = grey
85 131 85 131 li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
A97-84448
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 38 / 7
Engine control unit, knock sensor 1, knock sensor 2, engine
speed sender
G28 Engine speed sender
G61 Knock sensor 1
G62 Coolant temperature sender
G66 Knock sensor 2
J623 Engine control unit
SC8 Fuse 8 on fuse box
T3a 3-pin connector, blue, at knock sensor 1
T46b/6L T46b/6H 34
T3b 3-pin connector, blue, at knock sensor 2
1,5
ro/sw
T3c 3-pin connector, grey, on engine speed sender
0,35 0,35
or/br or/sw T17a 17-pin connector, black, in electronics box, plenum chamber
8 T17c 17-pin connector, brown, in electronics box, plenum chamber
SC8 T46b 46-pin connector, black, CAN bus separating connector, right
10A
T17a/10 T17a/11 8a Earth connection (sender earth), in engine compartment wiring
327
180 178 171 175 harness

0,35 • 0,35 • 1,5 1,5 0,5 1,0 1,0

or/br or/sw ro/ge ro/ge ro/ge ro/ge ro/ge B350 Positive (+) connection 1 (87a), in main wiring harness
B350
B350
CAN-L CAN-H
58 60 J 623 D102for private
Protected by copyright. Copying Connection 2, in engine
or commercial compartment
purposes, wiring
in part or in whole, harness
is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• CAN bus (data wire)
with respect to the correctness of information in this document. Copyright by AUDI AG.

106/S 99/-- 107/S 108 90/-- 82/+ 93

0,35 0,35 0,35 0,35 0,35 0,35

ge bl D102 gr br bl gr

327
327

0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,5

sw gn sw bl sw br bl br

T3a/3 T3a/1 T3a/2 T3b/3 T3b/1 T3b/2 T3c/1 T3c/2 T3c/3 T17c
/12

1 2
ϑ 0,5
br

G66 G61 G28 G62 ws = white

152 sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
A97-84451
or = orange
rs = pink

Edition 02.2004
 Audi A8 Current Flow Diagram No. 38 / 8
Engine control unit, Hall senders, camshaft timing
adjustment valves
G40 Hall sender
G163 Hall sender 2
G300 Hall sender 3
G301 Hall sender 4
J623 Engine control unit
N205 Inlet camshaft timing adjustment valve 1
N208 Inlet camshaft timing adjustment valve 2
E19 N318 Exhaust camshaft timing adjustment valve -1-
1,5 1,0 1,0
ro/gr ro/gr ro/gr N319 Exhaust camshaft timing adjustment valve -2-
T17a 17-pin connector, black, in electronics box, plenum chamber
2 2 T17c 17-pin connector, brown, in electronics box, plenum chamber
N205 N208
Earth connection (sender earth), in engine compartment wiring
N318 N319 327
harness
T17a 1 3 1 3
/16
Earth connection -2- (sender earth), in engine compartment
1,0 1,0 0,5 1,0 2,5 328
ro/ge ws/br gn/br ge/br bl/br
wiring harness
B350
B350 B350 Positive (+) connection -1- (87a), in main wiring harness
115 22 120 18 J 623
D141 Connection (5V), in engine wiring harness
87 98 86 81 54
+5V
D174 Connection -2- (5V), in engine wiring harness
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1,5 0,5 0,35 0,5 0,5 0,5 0,5
br gn permitted
ws unless authorised
gr by AUDI AG.
ws AUDI AG does gn not guarantee or acceptgrany liability E19 Connection -4-, in Motronic wiring harness
with respect to the correctness of information in this document. Copyright by AUDI AG.
D141 D174

327 328
327 328

0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5

br ws br ws ws ws br ws br

3/-- 2/S 1/+ 3/-- 2/S 1/+ 1/+ 2/S 3/-- 1/+ 2/S 3/--

ws = white
G40 G163 G300 G301
sw = black
T17c/13 ro = red
br = brown
0,5
sw gn = green
bl = blue
153 gr = grey
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98
A97-84454
or = orange
rs = pink

Edition 02.2004
 Audi A8 Current Flow Diagram No. 38 / 9
Engine control unit, lambda probe, lambda probe 2
G39 Lambda probe
G108 Lambda probe 2
J623 Engine control unit
SC5 Fuse -5- on fuse box
SC6 Fuse -6- on fuse box
SC7 Fuse -7- on fuse box
SC29 Fuse -29- on fuse box
SC31 Fuse -31- on fuse box
T6s 6-pin connector, black, for lambda probe
2,5 B146 2,5 4,0 T6u 6-pin connector, brown, for lambda probe 2
sw ro/sw ro/sw
T10c 10-pin connector, red, in electronics box, plenum chamber
5 6 7 31 29 Z19 Lambda probe heater
184
SC5 SC6 SC7 SC31 SC29 Z28 Lambda probe 2 heater
15A 15A 15A 20A 20A
Earth connection -2- (sender earth), in engine compartment
5a 6a 7a 31a 29a 328
wiring harness

2,5 1,0 1,5 2,5 2,5 B146 Positive (+) connection -1- (87), in interior wiring harness
ro/bl ro/sw ro/ws sw/ge bl/ws

138 105 117 202 62

E28 Connection (lambda probe heating), in Motronic wiring harness
J 623

5 52 71 51 70 4 15 14 12 13

1,0 0,35 0,35 0,35 0,35 1,0 0,35 0,35 0,35 0,35
br/ws gr/gn gr/li li ro br/ge gr/bl gr/ro ge gn

0,35 0,35
sw sw

328
328 328

T6s/4 T6s/6 T6s/2 T6s/5 T6s/1 T6u/4 T6u/6 T6u/2 T6u/5 T6u/1
105
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1,0 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ro/sw with respect to the correctness of information in this document. Copyright by AUDI AG.

Z19 G39 Z28 G108 ws = white

sw = black
T6s/3 T10c/5 T6u/3 ro = red
br = brown
1,0 1,5 1,0 gn = green
ro/sw ro/sw ro/sw
E28 bl = blue
gr = grey
li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
A97-84457
or = orange
rs = pink

Edition 02.2004
 Audi A8 Current Flow Diagram No. 38 / 10
Engine control unit, lambda probes downstream of catalytic
converter, air mass meter, intake manifold change-over
valve, secondary air inlet valve, activated charcoal filter
system solenoid valve 1 (pulsed)
G70 Air mass meter
G83 Coolant temperature sender - radiator outlet
G130 Lambda probe downstream of catalytic converter
G131 Lambda probe 2 downstream of catalytic converter
E7 J623 Engine control unit
0,5 E7 0,5 0,5 0,5 N80 Activated charcoal filter system solenoid valve 1 (pulsed)
ro/ws ro/ws ro/ws ro/ws N112 Secondary air inlet valve
G70 2 1 1 1 N156 Intake manifold change-over valve
T4s 4-pin connector, green, for lambda probe 1 downstream of
catalytic converter
N156 N112 N80
1/5V 3/-- 4/S 5/T 2 2 2 T4t 4-pin connector, brown, for lambda probe 2 downstream of
catalytic converter
T17c 17-pin connector, brown, in electronics box, plenum chamber
0,35 0,35 0,35 0,35 0,35 0,35 0,5 Z29 Lambda probe 1 heater, downstream of catalytic converter
sw/ge br/gr gn/li li ge/ws br/ro ge/gn
Z30 Lambda probe 2 heater, downstream of catalytic converter
Earth connection -2- (sender earth), in engine compartment
J 623 328
53 27 29 26 48 44 64 wiring harness

63 68 69 6 Copying
10 for private
11 17 E7 Connection (87a), in Motronic wiring harness
Protected by copyright. or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
0,5 0,35 0,35 0,5 0,35 0,35 0,35
E17 Connection -2-, in Motronic wiring harness
gn/ge br ws br/gn bl gr bl
* Models with coolant temperature sender - radiator outlet

0,35 0,35
sw sw

328
328

T4s/2 T4s/3 T4s/4 T4t/2 T4t/3 T4t/4 0,35

br
106
2 1
1,5 ϑ
ro/ws
ws = white
Z29 G130 Z30 G131 G83 ✱
sw = black
T4s/1 T17c/17 T4t/1 ro = red
br = brown
1,0 1,5 1,0 gn = green
ro/ge ro/ge ro/ge bl = blue
E17 gr = grey
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
A97-84460
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 38 / 11
Engine control unit, electro/hydraulic engine mounting
solenoid valves, gearbox mounting valves, secondary air
pump motor, secondary air pump relay, high pressure
sender
G65 High pressure sender
J255 Climatronic control unit
J299 Secondary air pump relay
J518 Entry and start authorisation control unit
E7 J623 Engine control unit
0,5 0,5 0,5 E7 0,5 2,5 N144 Electro/hydraulic engine mounting solenoid valve, left
ro/ws ro/ws ro/ws ro/ws ro/ws N145 Electro/hydraulic engine mounting solenoid valve, right
1 1 1 1 N262 Gearbox mounting valve 1
N263 Gearbox mounting valve 2
S130 Secondary air pump fuse
N145 N144 N262 N263 T17a/15
2 2 2 2 T10c 10-pin connector, red, in electronics box, plenum chamber
104 140 T17a 17-pin connector, black, in electronics box, plenum chamber
V101 Secondary air pump motor
0,5 0,5 0,5 0,5 1,5 2,5 0,5
ws/sw ws/gr ws/sw ws/sw ro/bl ro/bl ro/bl
B148 366 Earth connection -1-, in main wiring harness

J 623 105 116 9 121

375 Earth connection -10-, in main wiring harness

30 46
B148 Positive (+) connection -3- (87), in interior wiring harness
27 36

1,0 0,35 4,0 0,35

sw/bl gr/bl ro ge/gr B279 Positive (+) connection -3- (15a), in main wiring harness

1 E7 Connection (87a), in Motronic wiring harness

B279 B

J 255 T17a/12 S130 T10c

50A
C8 2 /3

0,35 0,35 0,35 4,0 4,0 0,5

gr/ro sw/bl sw/gr ro/ge ro/sw ge/gr

ϑ
2 3 A17 2/30 4/85
J 518 M
1
G65 V101 J 299 ws = white
1/31 1 8/87 6/86
sw = black
ro = red
0,35 4,0 0,5 br = brown
br br ro/bl
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not gn = green
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability bl = blue
140
with respect to the correctness of information in this document. Copyright by AUDI AG. gr = grey
375 366
li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
A97-84463
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 38 / 12
Engine control unit, brake servo relay, vacuum pump for
brakes, brake servo pressure sensor
G294 Brake servo pressure sensor
J217 Automatic gearbox control unit
J518 Entry and start authorisation control unit
J569 Brake servo relay
J623 Engine control unit
T10c 10-pin connector, red, in electronics box, plenum chamber
T16 16-pin connector, black, diagnosis connection
T17a 17-pin connector, black, in electronics box, plenum chamber
D166 E26 T17c 17-pin connector, brown, in electronics box, plenum chamber
0,35 0,35 0,35 0,5
gn/sw gn gn gn T17d 17-pin connector, blue, in electronics box, plenum chamber
V192 Vacuum pump for brakes
6 4
T17a/8 T17d/1 375 Earth connection -10-, in main wiring harness
J 217 J 217 J 217
18
Connection (K diagnosis wiring), in engine compartment wiring
0,35 0,35 0,35 0,5 0,35 D166
gn/sw gr/ws gn gn bl/ge harness

K
A54 E26 Connection (selector lever lock), in Motronic wiring harness
J 623 K/W T16/7 P/N
J 518 TD
43 20 37

114 85
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
0,35 with respect to the correctness of information
0,5 in this document. Copyright by AUDI AG.
bl/gn bl

T10c/10 T17c/11
84 92

0,5 1,5 0,5 0,5 0,5

bl/gn ro/gr gn br sw

1/85 4/87a 5/87 2 4 1 3

1.1
M
J 569 V192 G294
2/86 3/30 1 ws = white
sw = black
ro = red
0,5 1,5 1,5 br = brown
sw/bl ro/gn br
gn = green
bl = blue
42 3
gr = grey
375 li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 153 154
A97-84466
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 38 / 13
Engine control unit, brake light switch, kick-down switch,
cruise control system brake pedal switch, cruise control
system switch
E45 Cruise control system switch
F Brake light switch
F8 Kick-down switch
F47 Cruise control system brake pedal switch
J104 ABS with EDL control unit
18 J518 Entry and start authorisation control unit
4,0 0,5 B467 1,0 J527 Steering column electronics control unit
ro sw/gn sw/gn J623 Engine control unit
SB12 Fuse -12- on fuse box
38 12 22 B3
SB22 Fuse -22- on fuse box
SB 38 SB 12 SB 22 J 518 SB38 Fuse -38- on fuse box
30A 5A 5A
38a 12a 22a T16a 16-pin connector, on steering column electronics control unit
T17c 17-pin connector, brown, in electronics box, plenum chamber
T17d 17-pin connector, blue, in electronics box, plenum chamber
0,5 0,5 T17f 17-pin connector, black, connector A, relay carrier, footwell,
ro/ws sw/bl
driver's side

372 Earth connection -7-, in main wiring harness

J 623

B335 Connection -1- (54), in main wiring harness

56 55 74 38
BLS BTS GRA

B336 Connection -2- (54), in main wiring harness

0,35 0,35 0,35 0,35
ro/sw ws/ro br/ws sw/ws

B467 Connection -3-, in main wiring harness

1 3

T17c T17c/9 T17d/11 T17c

J 104 J 518 /10 F F47 J 104 /14
32 A34 4 2 37

0,35 0,35 0,22 1,5 0,5 0,35 0,22 0,35 0,22

ro/sw ro/sw ro/sw ro/sw ro/br ro/br ro/br gr sw/ws

B335 B336
1

F8 T17f
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
/6 AG. AUDI AG does not guarantee or accept any liability
permitted unless2 authorised by AUDI ws = white
sw = black
with respect to the correctness of information in this document. Copyright by AUDI AG.

ro = red
0,35 0,35 br = brown
br sw/ws
gn = green
T16a/5 bl = blue
J 527 gr = grey
372
E45 li = purple
ge = yellow
155 156 157 158 159 160 161 162 163 164 165 166 167 168
A97-84469
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 38 / 14
Engine control unit, radiator fan, radiator fan -2-, continued
coolant circulation relay, continued coolant circulation
pump
J151 Continued coolant circulation relay
J623 Engine control unit
T10c 10-pin connector, red, in electronics box, plenum chamber
T17a 17-pin connector, black, in electronics box, plenum chamber
V7 Radiator fan
187 183 V51 Continued coolant circulation pump
V177 Radiator fan 2
0,5 0,5
sw/bl br/gn 43 Earth point, A pillar, bottom right

85 Earth connection 1, in engine compartment wiring harness

T17a/3 T17a/9
* For countries with hot climate only
0,35 0,35
br/gn br/gn

45 65 J 623

66 104 47
PWM1 PWM2

0,35 0,35 0,35

br/gr gr br/li

T17a/13 T17a/14 T10c/9 T10c/4

18 83 20 84

6,0 1,0 0,5 6,0 1,0 0,5 0,5 1,0 1,0

ro/sw ro/ge bl/ge ro/ws ro/ge bl/li br/li ro/gr ro/gn

PWM1 PWM2
1/B+ 2 3 1/B+ 2 3 12/86 42/87a 52/87 1
1.2
M M ✱ M ✱
V7 V177 J 151 V51
4/31 4/31 22/85 32/30 2 ws = white
sw = black
ro = red
6,0 6,0 0,5 1,5 1,0 br = brown
br br ro/ge ro/ge br
gn = green
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
bl = blue
82 81
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
gr = grey
with respect to the correctness of information in this document. Copyright by AUDI AG.
43 43 85 li = purple
ge = yellow
169 170 171 172 173 174 175 176 177 178 179 180 181 182
A97-84472
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 38 / 15
Fuel pump relay, electric fuel pump 2 relay, control unit with
display in dash panel insert
G Fuel gauge sender
G6 Fuel pump (pre-supply pump)
G237 Fuel gauge sender 3
J17 Fuel pump relay
J49 Electric fuel pump 2 relay
J285 Control unit with display in dash panel insert
SF10 Fuse 10 on fuse box
T4a 4-pin connector, under cover, right, on vehicle floor
T6e 6-pin connector, under cover, right, on vehicle floor
T32 32-pin connector, blue, on dash panel insert

361 Earth connection (fuel gauge sender), in main wiring harness

675 Earth point 2, in luggage compartment, right

B299 Positive (+) connection 3 (30), in main wiring harness

7 10

10,0
SF10 J 285
20A
ro
10a

B299
18 34 19 T32/27 T32/25

0,5 4,0 0,5 4,0 2,5 0,35 0,35

sw ro sw ro sw/ws gn/ro gn/ws

3/86 1/30 3/86 1/30

4 3
J 17 J 49 T4a/1 T6e/4 T6e/1
4/85 2/87 5/85 2/87

0,5 4,0 0,5 4,0 2,5 0,35 0,35

br/gn ro/sw sw/bl ro/gr Protected bysw/ws
copyright. Copyinggr/bl gr/ws
for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
174 112 172 with respect to the correctness of information in this document. Copyright by AUDI AG.
A1/+ B2 A2

M G6 G237
G
A4/-- B4 A3 ws = white
2,5 0,35 0,35
sw = black
br br/bl br/bl ro = red
361
br = brown
T4a/3 361
gn = green
2,5
bl = blue
br gr = grey
675 li = purple
ge = yellow
183 184 185 186 187 188 189 190 191 192 193 194 195 196
A97-84475
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 38 / 16
Control unit with display in dash panel insert, fuel gauge, fuel
pump, fuel gauge senders, oil pressure warning lamp
F1 Oil pressure switch
F66 Coolant shortage indicator switch
G1 Fuel gauge
G23 Fuel pump
G169 Fuel gauge sender 2
G266 Oil level thermo sender
22 G393 Fuel gauge sender 4
B277 J285 Control unit with display in dash panel insert
1,0 1,0 0,5
sw sw/bl sw/bl K3 Oil pressure warning lamp
K28 Coolant temperature/coolant shortage warning lamp
10 209 SB10 Fuse 10 on fuse box
SB 10 T4a 4-pin connector, under cover, right, on vehicle floor
5A
T6e 6-pin connector, under cover, right, on vehicle floor
10a
T17a 17-pin connector, black, in electronics box, plenum chamber
T17d 17-pin connector, blue, in electronics box, plenum chamber
T32 32-pin connector, blue, on dash panel insert

85 Earth connection 1, in engine compartment wiring harness

361 Earth connection (fuel gauge sender), in main wiring harness

G1 J 285 K3 K 28

401 Earth connection (sender earth), in interior wiring harness

T32/22 T32/23 T32/26 T32/15 T32/21 T32/8
108 209
675 Earth point 2, in luggage compartment, right
0,35 0,35 0,35 2,5 0,35 0,35 0,35 0,5
br/bl gn/ge gn/li sw/ge gr/sw gn/ge bl/gr sw/bl
B277 Positive (+) connection 1 (15a), in main wiring harness

T6e/5 T6e/3 T6e/2 T4a/2 T17a/1 T17a T17d/14

/2

1,0 0,35 0,35 2,5 0,35 0,5 0,5

br/bl gr/ge gr/li sw/ge gr/sw bl/gr sw/bl

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
A2 B2 A1/+ with respect 1to the correctness
3 of information in3 this document.
1 Copyright by AUDI AG.
G393 G169 G23 M
F1 F66 G266
A3 B4 A4/-- 1 2/31 ws = white
sw = black
0,35 0,35 2,5 0,35 0,5
br/bl br/bl br br/gr br ro = red
361 br = brown
361
T4a/4 gn = green
bl = blue
2,5
br
gr = grey
675 401 85 li = purple
ge = yellow
197 198 199 200 201 202 203 204 205 206 207 208 209 210
A97-84478
or = orange
rs = pink

Edition 02.2004
 Audi A8 Current Flow Diagram No. 43 / 1

Audi A8 3.0 litre fuel injection engine (162 kW / 160 kW - Motronic - 6-cylinder), engine codes ASN/BBJ
From model year 2004

Audi A8 3.0 litre fuel injection engine (162 kW/ 160 kW - Motronic - 6-cylinder), engine code BBJ, from model year 2004
Fuse box, dash panel, left

8 12 16 20

5 9 13 17 21

1 3 6 10 14 18 22

2 4 7 11 15 19 23

24 31 38 Res
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
25 32 39 Res permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
26 33 40 Res
with respect to the correctness of information in this document. Copyright by AUDI AG.

27 34 41 Res

28 35 42 Res

29 36 43

30 37 44

A97--0119

Fuse colours
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
1 A - black
SB - Fuses in fuse box, dash panel, left
SC - Fuses in fuse box, dash panel, right
SD - Fuses in fuse box, luggage compartment, left
SF - Fuses in fuse box, luggage compartment, right

Edition 02.2004
 Audi A8 Current Flow Diagram No. 43 / 1
Fuse box, dash panel, right

A97--0407

Relay carrier, electronics box, plenum chamber

E F G

A B C D Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

A97--0404

Position of relays

1 - Secondary air pump relay (J299)

2 - Motronic current supply relay (J271)

Edition 02.2004
 Audi A8 Current Flow Diagram No. 43 / 1
B - Secondary air pump fuse (S130)
Relay and fuse carrier, behind dash panel, left

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

A97--0403

Position of relays

3 - Terminal 15 voltage supply relay (J329)

Relay carrier, front passenger's footwell

F
E

A
B C D

A97--0405

Edition 02.2004
 Audi A8 Current Flow Diagram No. 43 / 1
Position of relays

1.1 - Brake servo relay (J569)

1.2 - Continued coolant circulation relay (J151)
2 - Starter motor relay (J53)
3 - Starter motor relay -2- (J695)
4 - Fuel pump relay (J17)
Position of components in: main fuse carrier, A pillar, right

A97--0406

Position of fuses Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
1 - Radiator fan single fuse (S42, 60 A)
1A - Screw connection for radiator fan 1
2 - Radiator fan fuse, 2nd speed (S104, 60 A)
2A - Screw connection for radiator fan 2
3 - Screw connection for terminal 30 (battery)
4 - Screw connection for terminal 30 (starter)

Edition 02.2004
 Audi A8 Current Flow Diagram No. 43 / 1
Relay and fuse carrier, luggage compartment, right

D
C
A
B

A97--1272

Position of relays

3 - Electric fuel pump II relay (J49)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Edition 02.2004
Audi A8 Current Flow Diagram No. 43 / 2
Battery, energy management control unit, battery cut-off
relay
A Battery
J234 Airbag control unit
J644 Energy management control unit
J655 Battery cut-off relay
S131 Fuse 1, 110 A, in luggage compartment, rear right
S132 Fuse 2, 60 A, in luggage compartment, rear right
S133 Fuse 3, 150 A, in luggage compartment, rear right
B304 Z2 B272 SC15 Fuse -15- on fuse box
2,5 6,0 10,0 16,0 12,0 10,0 SC38 Fuse -38- on fuse box
ro ro ro ro ro ro SC40 Fuse -40- on fuse box
T46b 46-pin connector, black, CAN separating connector, right
17 31
Z2 Heated windscreen

38 40 15 3A 2A 1A ✱ 3 Earth strap, engine - body

SC38 SC40 SC15 S133 S132 S131
5A 15A 5A 150A 60A 110A
B305
38a 40a 15a
13 Earth point, in engine compartment, right
5 4

15 18 Earth point, on cylinder block

0,5 1,5 35,0 10,0 2,5

ro ro/gn sw ro sw 379 Earth connection -14-, in main wiring harness
J 234 J 234
35 146 188 76 4 B492
B272 Positive (+) connection (30), in main wiring harness
+ 50,0 0,5 0,5 0,5
sw ws ge sw
B304 Positive (+) connection -8- (30), in main wiring harness
A
A 3 4 1/15

27
J 655 B305 Positive (+) connection -9- (30), in main wiring harness
T46b T46b --
B 2/31
/15H /15L
B492 Positive (+) connection -3- (15), in interior wiring harness
0,35 •• 0,35 • 0,5 0,35 0,5 50,0 80,0
or/gn or/br sw/ge ro/gn ro/ws sw sw • CAN bus (data wire)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is *not In luggage compartment, rear right
19 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
CAN-H CAN-L
9 10 8 14 11 B-- with respect to the correctness of information in this document. Copyright by AUDI AG.

ws = white
J 644 sw = black
ro = red
35,0 0,35 35,0 br = brown
sw br/ge sw
gn = green
bl = blue
gr = grey
13 18 379 18 3 li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A97-84437
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 43 / 3
Starter, alternator, terminal 15 voltage supply relay, starter
motor relay
B Starter
C Alternator
C1 Voltage regulator
J53 Starter motor relay
J329 Terminal 15 voltage supply relay
J518 Entry and start authorisation control unit
J695 Starter motor relay -2-
2,5 B163 220 1,0 0,5 S42 Radiator fan single fuse
sw sw sw S104 Radiator fan fuse, 2nd speed
4,0 2,5 0,5
13 sw sw sw 42 SC9 Fuse -9- on fuse box
9 T2a 2-pin connector, black, in engine compartment, front right
B165
SC9 T2f 2-pin connector, black, on alternator
5A
B302
9a
B273 B163 Positive (+) connection -1- (15), in interior wiring harness

0,5 Copying
4,0 for 2,5 0,5 purposes, in2,5 0,5whole,1,0
Protected by copyright.
ro
private or commercial
swby AUDI
swAG. AUDI AG does sw not guarantee
part or in
sw/gn sw anysw/bl
is not
B165 Positive (+) connection -2- (15), in interior wiring harness
permitted unless authorised or accept liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
129
3/86 2/87 8/87 4 2/30 4 B273 Positive (+) connection (15), in main wiring harness
3 2 3
J 329 J 53 J 695 B276 Positive (+) connection (50), in main wiring harness
8/87 6
4/85 1/30 2/30 6
J 518
11 157 A51

4,0 12,0 6,0 0,5 4,0 0,5 0,35 2,5 0,5 B298 Positive (+) connection -2- (30), in main wiring harness
ro ro ro bl ro bl/sw ro/sw ro/sw br/ro

B298 A58 38
J 518
B276 39 B302 Positive (+) connection -6- (30), in main wiring harness
3

0,35 2,5 0,5 * Main fuse carrier, A pillar, right

ro/sw ro/sw sw/ge

39
9 T2a/2 T2a/1
80,0 50,0 2,5 25,0 1,5
sw sw ro/sw sw bl

T2f/1
3 4 ✱ 30 50 B+ D+ DF
1 2
G
S42 S104 M
60A 60A
ws = white
1a 2a B C C1 sw = black
ro = red
6,0 6,0 br = brown
ro/sw ro/ws
gn = green
bl = blue
170 174
gr = grey
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28
A97-84440
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 43 / 4
Engine control unit, Motronic current supply relay
J271 Motronic current supply relay
J623 Engine control unit
SC21 Fuse -21- on fuse box
SC28 Fuse -28- on fuse box
SC30 Fuse -30- on fuse box
T17a 17-pin connector, black, in electronics box, plenum chamber
T17c 17-pin connector, brown, in electronics box, plenum chamber
T17d 17-pin connector, blue, in electronics box, plenum chamber
1 21 28

2,5 B147 0,5 1,0 0,5 0,35 0,5 17 Earth point, on intake manifold
ro/sw ro/sw ro/sw ro ro/sw sw

30 21 28
171 160 43 Earth point, lower part of right A pillar
SC30 SC21 SC28
30A 5A T17c T17d 5A
30a 77 21a /15 /6 28a
85 Earth connection -1-, in engine compartment wiring harness
4,0 2,5 1,5 0,5 1,0 0,5 0,35 0,5
ro/gn ro/sw ro/ws ro/gr ro/gr ro/gr ro/sw sw/bl
131 Earth connection -2-, in engine compartment wiring harness
49 141

8/87 5/87a 1/T 62/30 42/50 J 623 387 Earth connection -22-, in main wiring harness
2
J 271
2/30 4/86 23 119 32 1/31 2/31 B147 Positive (+) connection -2- (87), in interior wiring harness
12

10,0 6,0 0,5 0,35 0,5 0,5 2,5 2,5 B303

Protected Positive
by copyright. (+) connection
Copying for private or -7- (30), inpurposes,
commercial main wiring harness
in part or in whole, is not
ro ro sw sw br/ro bl/sw br br
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

T17a T17a T17a

/4 /7 /5

B303

6,0 4,0 0,5 0,5

ro ro br/ro bl/sw

184 138 26 23

T17a ws = white
/17 sw = black
ro = red
4,0 4,0 2,5 6,0 br = brown
br br br/ws br
gn = green
bl = blue
gr = grey
85 387 131 17 387 43 85 85 li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42
A97-84443
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 43 / 5
Engine control unit, injectors for cylinders 1 - 4, ignition coils
for cylinders 1 - 4
J623 Engine control unit
N30 Injector, cylinder 1
N31 Injector, cylinder 2
N32 Injector, cylinder 3
N33 Injector, cylinder 4
N70 Ignition coil 1 with output stage
D95
N127 Ignition coil 2 with output stage
N291 Ignition coil 3 with output stage
0,35 0,35 D95 0,35 0,35
bl/ws bl/ws bl/ws bl/ws
N292 Ignition coil 4 with output stage
P Spark plug connector
1 1 1 1 Q Spark plugs
T17e 17-pin connector, red, in electronics box, plenum chamber
N30 N31 N32 N33
2 2 2 2
85 Earth connection -1-, in engine compartment wiring harness
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
0,35 0,35correctness of information
with respect to the 0,35 in this document. Copyright
0,35 by AUDI AG.
gn/ro gn/bl ws/gn ws/ge 131 Earth connection -2-, in engine compartment wiring harness

96 112 J 623 88 97
D95 Connection (injectors), in engine compartment wiring harness

102 110 94 103 3

E6 Positive (+) connection -1- (15), in Motronic wiring harness

0,5 0,5 0,5 0,5 1,5

ge gn gr E6 li/gn ro/gn
E6
2,5 2,5 4,0 2,5 2,5
ro/gn ro/gn ro/gn ro/gn ro/gn

3 N70 1 3 N127 1 3 N291 1 3 N292 1

2/31 4/31 I 2/31 4/31 II 2/31 4/31 III 2/31 4/31 IV

T17e
/17

P P P P
Q Q Q Q ws = white
sw = black
ro = red
2,5 0,5 2,5 0,5 4,0 2,5 0,5 2,5 0,5 br = brown
br br/ws br br/ws ro/gn br br/ws br br/ws
gn = green
29
bl = blue
gr = grey
85 131 85 131 85 131 85 131 li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56
A97-84446
or = orange
rs = pink

Edition 02.2004
 Audi A8 Current Flow Diagram No. 43 / 6
Engine control unit, injectors for cylinders 5 and 6, ignition
coils for cylinders 5 and 6, throttle valve module, accelerator
pedal position senders
G79 Accelerator pedal position sender
G185 Accelerator pedal position sender -2-
G186 Throttle valve drive (electric power control)
G187 Throttle valve drive angle sender -1- (electric power control)
G188 Throttle valve drive angle sender -2- (electric power control)
D95 J338 Throttle valve module
D95 J623 Engine control unit
0,35 0,35 2,5
bl/ws bl/ws bl/ws N83 Injector, cylinder 5
G186 G187 G188 N84 Injector, cylinder 6
1 1
N323 Ignition coil -5- with final output stage
M N324 Ignition coil -6- with final output stage
N83 N84 T17e/16 J 338 P Spark plug connector
2 2 3/M+ 5/M-- 6 1 4 2
Q Spark plugs
T17c 17-pin connector, brown, in electronics box, plenum chamber
0,35 0,35 1,5 1,0 1,0 0,35 0,35 0,35 0,35 T17e 17-pin connector, red, in electronics box, plenum chamber
gn/gr gn/bl bl/ws ro/ge br/ge br/ro gr/ro gn/ws sw/gn

85 Earth connection -1-, in engine compartment wiring harness

110

113 89 J 623 117 118 91 92 84 83

Protected by copyright. Copying for private or commercial purposes, 131

in part orEarth connection
in whole, is not -2-, in engine compartment wiring harness
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
111 95 73/5V 36/-- 35/S1 with
34/S2 33/-- 72/5V
respect to the correctness of information in this document. Copyright by AUDI AG.
0,5 0,5 D95 Connection (injectors), in engine compartment wiring harness
gn/sw E6 li/ge
E6
2,5 2,5 0,35 0,35 0,35 0,35 0,35 0,35 E6 Positive (+) connection -1- (15), in Motronic wiring harness
ro/gn ro/gn ge/br br ge br/ws ge/ws ge/ro

3 N323 1 3 N324 1

T17c T17c T17c T17c T17c T17c

2/31 4/31 2/31 4/31 /3 /5 /4 /7 /8 /6
V VI

0,35 0,35 0,35 0,35 0,35 0,35

ge/br br ge br/ws ge/ws ge/ro

2/+ 3/-- 4/S1 6/S2 5/-- 1/+

P P
Q Q ws = white
G79 G185
sw = black
ro = red
br = brown
2,5 0,5 2,5 0,5 gn = green
br br/ws br br/ws
bl = blue
gr = grey
85 131 85 131 li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
A97-84449
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 43 / 7
Engine control unit, knock sensor 1, knock sensor 2, engine
speed sender
G28 Engine speed sender
G61 Knock sensor 1
G62 Coolant temperature sender
G66 Knock sensor 2
J623 Engine control unit
SC8 Fuse -8- on fuse box
T3a 3-pin connector, blue, at knock sensor 2
T46b/6L T46b/6H 34
T3b 3-pin connector, blue, at knock sensor 1
1,5
ro/ws
T3c 3-pin connector, grey, on engine speed sender
0,35 0,35
or/br or/sw T17a 17-pin connector, black, in electronics box, plenum chamber
8 T17c 17-pin connector, brown, in electronics box, plenum chamber
SC8 T46b 46-pin connector, black, CAN bus separating connector, right
10A
T17a/10 T17a/11 8a Earth connection (sender earth), in engine compartment wiring
327
180 178 harness

0,35 • 0,35 • 1,5 0,5 0,35

or/br or/sw ro/ge ro/ge ro/ge B350 Positive (+) connection -1- (87a), in main wiring harness
B350
B350
CAN-L CAN-H
58 60 J 623 D102 Connection -2-, in engine compartment wiring harness

• CAN bus (data wire)

106/S 99/-- 107/S 108 90/-- 82/+ 93

0,35 0,35 0,35 0,35 0,35 0,35

ge bl D102 gr sw bl gr

327
327

0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,5

sw gn sw bl sw br gn br

T3a/3 T3a/1 T3a/2 T3b/3 T3b/1 T3b/2 T3c/1 T3c/2 T3c/3 T17c
/12

1 2
ϑ 0,5
br

G66 G61 G28 G62 ws = white

152 sw = black
Protected by copyright. Copying for private or commercial purposes, in part or in whole,rois not = red
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any br liability= brown
with respect to the correctness of information in this document. Copyright by AUDI AG.
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
A97-84452
or = orange
rs = pink

Edition 02.2004
 Audi A8 Current Flow Diagram No. 43 / 8
Engine control unit, Hall senders, camshaft timing
adjustment valves
G40 Hall sender
G163 Hall sender 2
G300 Hall sender 3
G301 Hall sender 4
J623 Engine control unit
N205 Inlet camshaft timing adjustment valve 1
N208 Inlet camshaft timing adjustment valve 2
N318 Exhaust camshaft timing adjustment valve -1-
0,5 0,5 N319 Exhaust camshaft timing adjustment valve -2-
ro/ge ro/ge
T17a 17-pin connector, black, in electronics box, plenum chamber
2 2 T17c 17-pin connector, brown, in electronics box, plenum chamber
N208
Earth connection (sender earth), in engine compartment wiring
N318 N319 327
harness
T17a N205 1 3 1 3
/16
Earth connection -2- (sender earth), in engine compartment
1,5 0,35 0,35 0,35 0,35 328
ro/ge ws/br gn/br ws/br bl/br
wiring harness
B350
B350 B350 Positive (+) connection -1- (87a), in main wiring harness
115 22 120 18 J 623
D141 Connection (5V), in engine wiring harness
87 98 86 81 54
+5V
D174 Connection -2- (5V), in engine wiring harness

0,5 0,5 0,35 0,5 0,5 0,5 0,5

br gn ws sw Protected byws bl for private or commercial
copyright. Copying gr purposes, in part or in whole, is not

D141 permitted unless authorised by AUDI D174

AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

327 328
327

0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5

br ws br ws ws ws br ws br

3/-- 2/S 1/+ 3/-- 2/S 1/+ 1/+ 2/S 3/-- 1/+ 2/S 3/--

ws = white
G40 G163 G300 G301
sw = black
T17c/13 ro = red
br = brown
0,5
sw gn = green
bl = blue
153 gr = grey
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98
A97-84455
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 43 / 9
Engine control unit, lambda probe, lambda probe 2
G39 Lambda probe
G108 Lambda probe 2
J623 Engine control unit
SC5 Fuse -5- on fuse box
SC6 Fuse -6- on fuse box
SC7 Fuse -7- on fuse box
SC29 Fuse -29- on fuse box
SC31 Fuse -31- on fuse box
T6s 6-pin connector, black, for lambda probe
2,5 B146 1,5 6,0 T6u 6-pin connector, brown, for lambda probe 2
sw ro/sw ro/sw
T17e 17-pin connector, red, in electronics box, plenum chamber
5 6 7 31 29 Z19 Lambda probe heater
184
SC5 SC6 SC7 SC31 SC29 Z28 Lambda probe 2 heater
15A 15A 15A 20A 10A
5a 6a 7a 31a 29a B146 Positive (+) connection -1- (87), in interior wiring harness

1,5 1,5 1,5 2,5 1,5

ro/bl ro/sw ro/ws sw/ge bl/ws

138 105 117 202 62

J 623 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
5 52 71 51 70 4 15 14 12 13

1,0 0,35 0,35 0,35 0,35 1,0 0,35 0,35 0,35 0,35
br/ws gr/gn gr/li br gn br/ge gr/bl gr/ro br bl

T6s/4 T6s/6 T6s/2 T6s/5 T6s/1 T6u/4 T6u/6 T6u/2 T6u/5 T6u/1
105

1,5
ro/sw

Z19 G39 Z28 G108 ws = white

sw = black
T6s/3 T17e/15 T6u/3 ro = red
br = brown
1,0 1,0 gn = green
ro/sw ro/sw
bl = blue
gr = grey
li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
A97-84458
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 43 / 10
Engine control unit, lambda probes downstream of catalytic
converter, air mass meter, intake manifold change-over
valve, secondary air inlet valve, activated charcoal filter
system solenoid valve 1 (pulsed)
G70 Air mass meter
G130 Lambda probe downstream of catalytic converter
G131 Lambda probe 2 downstream of catalytic converter
J623 Engine control unit
E7 N80 Activated charcoal filter system solenoid valve 1 (pulsed)
0,5 E7 0,35 0,35 0,5 N112 Secondary air inlet valve
ro/bl ro/bl ro/bl ro/bl N156 Intake manifold change-over valve
G70 2 1 1 1 T4s 4-pin connector, green, for lambda probe 1 downstream of
catalytic converter
T4t 4-pin connector, brown, for lambda probe 2 downstream of
N156 N112 N80
1/5V 3/-- 4/S 5/T 2 2 2 catalytic converter
T17c 17-pin connector, brown, in electronics box, plenum chamber
Z29 Lambda probe 1 heater, downstream of catalytic converter
0,35 0,35 0,35 0,35 0,35 0,35 0,5 Z30in part
Lambda probe 2 heater, downstream of catalytic converter
sw/gn br/gr gn/li gn ge/ws br/ro Protected
ge/gn by copyright. Copying for private or commercial purposes, or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document.E7 Connection
Copyright (87a),
by AUDI AG. in Motronic wiring harness
53 27 29 26 J 623 48 44 64

63 68 69 6 10 11

0,35 0,35 0,35 0,35 0,35 0,35

gn/ge br ge gr/bl br ro

T4s/2 T4s/3 T4s/4 T4t/2 T4t/3 T4t/4

106

1,5
ro/ws
ws = white
Z29 G130 Z30 G131
sw = black
T4s/1 T17c/17 T4t/1 ro = red
br = brown
0,5 0,5 gn = green
ro/ws ro/ws bl = blue
gr = grey
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
A97-84461
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 43 / 11
Engine control unit, electro/hydraulic engine mounting
solenoid valves, gearbox mounting valves, secondary air
pump motor, secondary air pump relay, high pressure
sender
G65 High pressure sender
J255 Climatronic control unit
J299 Secondary air pump relay
J518 Entry and start authorisation control unit
E7 J623 Engine control unit
0,5 0,5 0,5 E7 0,5 2,5 N144 Electro/hydraulic engine mounting solenoid valve, left
ro/bl ro/bl ro/bl ro/bl ro/bl N145 Electro/hydraulic engine mounting solenoid valve, right
1 1 1 1 N262 Gearbox mounting valve 1
N263 Gearbox mounting valve 2
S130 Secondary air pump fuse
N145 N144 N262 N263 T17a/15
2 2 2 2 T17a 17-pin connector, black, in electronics box, plenum chamber
104 140 T17e 17-pin connector, red, in electronics box, plenum chamber
V101 Secondary air pump motor
0,5 0,5 0,5 0,5 2,5 1,5 0,5
ge/bl ge/gn ws/ge ws/bl ro/bl ro/bl ro/bl
B148 387 Earth connection -22-, in main wiring harness

J 623 105 116 9 121

388 Earth connection -23-, in main wiring harness

30 46
B148 Positive (+) connection -3- (87), in interior wiring harness
27 36

1,0 0,35 4,0 0,35

sw/bl sw/gr ro ge/gr B279 Positive (+) connection -3- (15a), in main wiring harness

1 E7 Connection (87a), in Motronic wiring harness

B279 B

J 255 T17a/12 S130 T17e

50A
C8 2 /6

0,35 0,35 0,35 4,0 4,0 0,35

gr/ro sw/bl sw/gr ro/ge ro/sw ge/gr

ϑ
2 3 A17 2/30 4/85
J 518 M
1
G65 V101 J 299 ws = white
1/31 1 8/87 6/86
sw = black
ro = red
0,35 4,0 0,5 brProtected
= brown
by copyright. Copying for private or commercial purposes, in part or in whole, is not
br br ro/bl
gnpermitted
= green
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
bl with= respect
blue to the correctness of information in this document. Copyright by AUDI AG.
140
gr = grey
388 387
li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
A97-84464
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 43 / 12
Engine control unit, brake servo relay, vacuum pump for
brakes, brake servo pressure sensor
G294 Brake servo pressure sensor
J217 Automatic gearbox control unit
J518 Entry and start authorisation control unit
J569 Brake servo relay
J623 Engine control unit
T16 16-pin connector, black, diagnosis connection
T17a 17-pin connector, black, in electronics box, plenum chamber
T17c 17-pin connector, brown, in electronics box, plenum chamber
D166 E26 T17d 17-pin connector, blue, in electronics box, plenum chamber
0,35 0,35 0,35 0,5
gr/ws gr/ws gn gn T17e 17-pin connector, red, in electronics box, plenum chamber
V192 Vacuum pump for brakes
6 4
T17a/8 T17d/1 44 Earth point, lower part of left A pillar
J 217 J 217 J 217
18

0,35 0,35 0,35 0,5 0,35 375 Earth connection -10-, in main wiring harness
gr/ws gr/ws gn gn bl/gr

K
A54 388 Earth connection -23-, in main wiring harness
J 623 K/W T16/7 P/N
J 518 TD
43 20 37

B281 Positive (+) connection -5- (15a), in main wiring harness

21/15 114 85 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Connection (Kany
diagnosis wiring), in engine compartment wiring
D166
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept liability
with respect to the correctness of information in this document.harness
Copyright by AUDI AG.
0,5 0,35 0,5
sw/br bl/gn gn
E26 Connection (selector lever lock), in Motronic wiring harness

T17c/16 T17e/9 T17c/11

84 92

0,5 1,0 0,5 0,5 0,5

bl/gn ro/gr gn br sw

1/86 4/87a 5/87 2 4 1 3

1.1
M
J 569 V192 G294
2/85 3/30 1 ws = white
42 183 187 sw = black
ro = red
0,5 0,5 0,5 0,5 0,5 1,5 1,0 2,5 6,0 br = brown
sw/bl sw/bl sw/bl sw/bl sw/bl ro/gn br br br
gn = green
bl = blue
3
gr = grey
B281 375 375 388 44 375 li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 153 154
A97-84467
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 43 / 13
Engine control unit, brake light switch, kick-down switch,
cruise control system brake pedal switch, cruise control
system switch
E45 Cruise control system switch
F Brake light switch
F8 Kick-down switch
F47 Cruise control system brake pedal switch
J104 ABS with EDL control unit
18 32 J518 Entry and start authorisation control unit
6,0 1,0 J527 Steering column electronics control unit
ro ro/sw J623 Engine control unit
SB12 Fuse -12- on fuse box
38 12 22
SB22 Fuse -22- on fuse box
SB 38 SB 12 SB 22 SB38 Fuse -38- on fuse box
30A 5A 5A
38a 12a 22a T16a 16-pin connector, on steering column electronics control unit
T17c 17-pin connector, brown, in electronics box, plenum chamber
T17d 17-pin connector, blue, in electronics box, plenum chamber
0,5 0,5
ro/ws sw/ws 388 Earth connection -23-, in main wiring harness

J 623 B335 Connection -1- (54), in main wiring harness

56
BLS
55
BTS
74 38
GRA
B336 Connection -2- (54), in main wiring harness

0,35 0,35 0,35 0,35

ro/sw ro/br gr sw/ws

1 3

T17c T17c/9 T17d/11 T17c

J 104 J 518 /10 F F47 J 104 /14
32 A34 4 2 37

0,35 0,35 0,22 1,0 0,5 0,35 0,22 0,35 0,22

ro/sw ro/sw ro/sw ro/sw ro/br ro/br ro/br gr sw/ws

B335 B336 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 T16a/5 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
J 527 with respect to the correctness of information in this document. Copyright by AUDI AG.
F8 E45
2 ws = white
sw = black
ro = red
0,35 br = brown
br
gn = green
bl = blue
gr = grey
388 li = purple
ge = yellow
155 156 157 158 159 160 161 162 163 164 165 166 167 168
A97-84470
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 43 / 14
Engine control unit, radiator fan, radiator fan 2, continued
coolant circulation relay, continued coolant circulation
pump
J151 Continued coolant circulation relay
J623 Engine control unit
SC17 Fuse 17 on fuse box
T17a 17-pin connector, black, in electronics box, plenum chamber
T17e 17-pin connector, red, in electronics box, plenum chamber
31 187 183 V7 Radiator fan
0,5
V51 Continued coolant circulation pump
ro/sw 0,5 0,5 V177 Radiator fan 2
sw/bl br/gn
17
43 Earth point, A pillar, bottom right
SC17 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5A permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
17a T17a/3 T17a/9 with respect to the correctness of information in this document. Copyright by AUDI AG.
85 Earth connection 1, in engine compartment wiring harness

* For countries with hot climate only

0,5 0,5 0,35 0,35
ro/ge ro/ge sw/bl br/gn ** Does not apply to countries with hot climate
# Models with trailer coupling
171 175 ## Models without trailer coupling
J 623 45 65

66 61 104 47

## #
✱✱ ✱
0,5 0,35 0,5 0,35
bl/ge bl/li bl/li ro/ge

T17a/6
0,5 ✱ ✱
bl/ws
T17a/13 T17a/14 T17e/7 T17e/8

18 171 20 172

6,0 0,5 0,5 6,0 0,5 0,5 0,35 0,5 0,5

ro/sw ro/ge bl/ge ro/ws ro/ge bl/li ro/ge ro/gr ro/gn

1/B+ 2 3 1/B+ 2 3 12/86 42/87a 52/87 1

1.2
M M ✱ M ✱
V7 V177 J 151 V51
4/31 4/31 22/85 32/30 2 ws = white
sw = black
ro = red
6,0 6,0 0,35 0,5 0,5 br = brown
br br ro/ge ro/ge br
gn = green
bl = blue
82 81
gr = grey
43 43 85 li = purple
ge = yellow
169 170 171 172 173 174 175 176 177 178 179 180 181 182
A97-84473
or = orange
rs = pink

Edition 02.2004
 Audi A8 Current Flow Diagram No. 43 / 15
Fuel pump relay, electric fuel pump 2 relay, control unit with
display in dash panel insert
G Fuel gauge sender
G6 Fuel pump (pre-supply pump)
G237 Fuel gauge sender 3
J17 Fuel pump relay
J49 Electric fuel pump 2 relay
J285 Control unit with display in dash panel insert
SF2 Fuse 2 on fuse box
T4a 4-pin connector, under cover, right, on vehicle floor
T6e 6-pin connector, under cover, right, on vehicle floor
T32 32-pin connector, blue, on dash panel insert

361 Earth connection (fuel gauge sender), in main wiring harness

390 Earth connection 25, in main wiring harness

675 Earth point 2, in luggage compartment, right

7 2
B299 Positive (+) connection 3 (30), in main wiring harness
10,0
SF2 J 285
20A
ro
2a

B299
143 34 145 T32/27 T32/25

0,5 6,0 0,5 4,0 2,5 0,35 0,35

sw/bl ro sw/bl ro sw/ws gr/bl gr/ws

3/86 1/30 3/86 1/30

4 3
J 17 J 49 T4a/1 T6e/4 T6e/1
4/85 2/87 5/85 2/87

0,5 6,0 0,5 4,0 2,5 0,35 0,35

br/gn ro/sw sw/bl ro/gr sw/ws gr/bl gr/ws

181 112 179

A1/+ B2 A2

G6 M G237
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not G
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or acceptA4/-- any liability B4 A3 ws = white
with respect to the correctness of information in this document. Copyright by AUDI AG.
4,0 2,5 0,35 0,35
sw = black
br br br/bl br/bl ro = red
361
br = brown
T4a/3 361
gn = green
2,5
bl = blue
br gr = grey
675 390 390 li = purple
ge = yellow
183 184 185 186 187 188 189 190 191 192 193 194 195 196
A97-84476
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 43 / 16
Control unit with display in dash panel insert, fuel gauge,
fuel pump, fuel gauge senders, oil pressure warning lamp
F1 Oil pressure switch
G1 Fuel gauge
G23 Fuel pump
G169 Fuel gauge sender 2
G393 Fuel gauge sender 4
J285 Control unit with display in dash panel insert
K3 Oil pressure warning lamp
T4a 4-pin connector, under cover, right, on vehicle floor
T6e 6-pin connector, under cover, right, on vehicle floor
T17a 17-pin connector, black, in electronics box, plenum chamber
T32 32-pin connector, blue, on dash panel insert

361 Earth connection (fuel gauge sender), in main wiring harness

390 Earth connection 25, in main wiring harness

G1 J 285 K3

T32/22 T32/23 T32/26 T32/15

108

0,35 0,35 0,35 2,5 0,35

br/bl gr/ge gr/li sw/ge gr/sw

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
T6e/5 T6e/3 T6e/2 T4a/2 T17a/1 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1,0 0,35 0,35 2,5 0,5

br/bl gr/ge gr/li sw/ge gr/sw

A2 B2 A1/+ 1

G393 G169 G 23 M
F1
A3 B4 A4/-- ws = white
sw = black
0,35 0,35 2,5
br/bl br/bl br ro = red
361 br = brown
361
T4a/4 gn = green
bl = blue
2,5
br
gr = grey
390 li = purple
ge = yellow
197 198 199 200 201 202 203 204 205 206 207 208 209 210
A97-84479
or = orange
rs = pink

Edition 02.2004
Audi A8 Current Flow Diagram No. 43 / 17
Control unit with display in dash panel insert, oil level/oil
temperature sender, coolant shortage indicator switch
F66 Coolant shortage indicator switch
G266 Oil level/oil temperature sender
J285 Control unit with display in dash panel insert
K28 Coolant temperature/coolant shortage warning lamp
SB8 Fuse 8 on fuse box
T16 16-pin connector, black, diagnosis connection
24 T17a 17-pin connector, black, in electronics box, plenum chamber
T17d 17-pin connector, blue, in electronics box, plenum chamber
0,5
sw T32 32-pin connector, blue, on dash panel insert

8 85 Earth connection 1, in engine compartment wiring harness

SB 8
5A
8a 401 Earth connection (sender earth), in interior wiring harness

* Sender earth output

0,5
sw/bl

15
T 16/1

J 285 K 28

T32/28 T32/21 T32/8

✱

0,35 0,35 0,35 0,5

br/gr gn/ge bl/gr sw/bl

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
T17a T17d/14 with respect to the correctness of information in this document. Copyright by AUDI AG.
/2

0,5 0,5
bl/gr sw/bl

3 3 1

F66 G266 ws = white

1 2/31
sw = black
0,35 0,5
br/gr br ro = red
br = brown
gn = green
bl = blue
gr = grey
401 401 85 li = purple
ge = yellow
211 212 213 214 215 216 217 218 219 220 221 222 223 224
A97-84569
or = orange
rs = pink

Edition 02.2004
 Audi A8 Current Flow Diagram No. 73 / 1

Audi A8 3.0 litre turbo-diesel engine (171 kW, 155 kW - 6-cylinder), engine codes ASB, BNG
From model year 2004

Fuse box, dash panel, left

8 12 16 20

5 9 13 17 21

1 3 6 10 14 18 22

2 4 7 11 15 19 23

24 31 38 Res

25 32 39 Res

26 33 40 Res

27 34 41 Res

28 35 42 Res

29 36 43

30 37 44

A97--0119

Fuse colours
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
1 A - black
SB - Fuses in fuse box, dash panel, left
SC - Fuses in fuse box, dash panel, right
SD - Fuses in fuse box, luggage compartment, left
SF - Fuses in fuse box, luggage compartment, right Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Edition 08.2004
 Audi A8 Current Flow Diagram No. 73 / 1
Fuse box, dash panel, right

A97--0407

Relay carrier, electronics box, plenum chamber

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

E F G

A B C D

A97--0404

Position of relays

2 - Terminal 30 voltage supply relay (J317)

4 - Automatic glow period control unit (J179)

Edition 08.2004
 Audi A8 Current Flow Diagram No. 73 / 1
B - Fuse for glow plugs (S125, 80 A)
Relay and fuse carrier, behind dash panel, left

A97--0403

Position of relays

3 - Terminal 15 voltage supply relay (J329)

Relay carrier, front passenger's footwell

F
E

A
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

C D
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

B
with respect to the correctness of information in this document. Copyright by AUDI AG.

A97--0405

Edition 08.2004
 Audi A8 Current Flow Diagram No. 73 / 1
Position of relays

2 - Starter motor relay (J53)

3 - Starter motor relay -2- (J695)
Position of components in: main fuse carrier, A pillar, right

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

A97--0406

Position of fuses

1 - Radiator fan single fuse (S42, 60 A)

1A - Screw connection for radiator fan 1
2 - Radiator fan fuse, 2nd speed (S104, 60 A)
2A - Screw connection for radiator fan 2
3 - Screw connection for terminal 30 (battery)
4 - Screw connection for terminal 30 (starter)

Edition 08.2004
 Audi A8 Current Flow Diagram No. 73 / 1
Relay and fuse carrier, luggage compartment, right

D
C
A
B

A97--1272

Position of relays

3 - Fuel pump relay (J17)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Edition 08.2004
Audi A8 Current Flow Diagram No. 73 / 2
Battery, energy management control unit, battery cut-off
relay, fuses
A Battery
J234 Airbag control unit
J644 Energy management control unit
J655 Battery cut-off relay
S131 Fuse 1, 110 A, in luggage compartment, rear right
S132 Fuse 2, 60 A, in luggage compartment, rear right
S133 Fuse 3, 150 A, in luggage compartment, rear right
B304 B272 SC15 Fuse -15- on fuse box
2,5 6,0 10,0 25,0 10,0 12,0 6,0 SC38 Fuse -38- on fuse box
ro ro ro sw ro ro ro T46b 46-pin connector, black, CAN separating connector, right
3A 2A 1A ✱
42 38 15 16 40 3 Earth strap, engine - body
SC38 SC15 S133 S132 S131
5A 150A 60A 110A 114 15
38a 15a 5 4 13 Earth point, in engine compartment, right
0,5 2,5
sw sw

B492
18 Earth point, on cylinder block
B303

379 Earth connection -14-, in main wiring harness

35,0 10,0 10,0
sw ro ro
B272 Positive (+) connection (30), in main wiring harness
185 29
J 234 J 234
27 28

B303 Positive (+) connection -7- (30), in main wiring harness

+ 50,0 0,5 0,5
sw ro/li ws/br

A B304 Positive (+) connection -8- (30), in main wiring harness

A 1 2

27
N253 B492 Positive (+) connection -3- (15), in interior wiring harness
T46b T46b --
B
/15H /15L
• CAN bus (data wire)
0,35 •• 0,35 • 0,5 0,35 0,5 50,0 80,0 * In luggage compartment, rear right
or/gn or/br sw/ge ro/gn ro/ws sw sw

18
9 10 8 14 11 B--

ws = white
J 644 sw = black
Protected by copyright. Copying forroprivate
= orred
commercial purposes, in part or in whole, is not
50,0 35,0 br AG.= AUDI
permitted unless authorised by AUDI brownAG does not guarantee or accept any liability
sw sw
with respect to the correctness gn = green
of information in this document. Copyright by AUDI AG.
bl = blue
gr = grey
3 18 13 18 li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14
97-58490
or = orange
rs = pink

Edition 08.2004
Audi A8 Current Flow Diagram No. 73 / 3
Starter, alternator, terminal 15 voltage supply relay, starter
motor relay
B Starter
C Alternator
C1 Voltage regulator
J53 Starter motor relay
J329 Terminal 15 voltage supply relay
J518 Entry and start authorisation control unit
J695 Starter motor relay 2
2,5 4,0 B163 1,0 0,5
S42 Radiator fan single fuse
sw sw sw sw S104 Radiator fan fuse, 2nd speed
T2a 2-pin connector, black, in engine compartment, front right
14 222 180 66
T2v 2-pin connector, red, on alternator
2,5 0,5
B306 B273
sw
B165
sw B163 Positive (+) connection -1- (15), in interior wiring harness

B165 Positive (+) connection -2- (15), in interior wiring harness

0,5 4,0 2,5 0,5 2,5 0,5
ro sw sw sw sw/gn sw

B273 Positive (+) connection (15), in main wiring harness

3/86 2/87 8/87 4 2/30 4
3 2 3
B276 Positive (+) connection (50), in main wiring harness
J 329 J 53 J 695
8/87 6
4/85 1/30 2/30 6
J 518
161 52 A51 B298 Positive (+) connection -2- (30), in main wiring harness
1,5 6,0 0,5 4,0 0,35 0,5 0,35 2,5 0,5
ro ro bl ro ro/sw bl/sw ro/sw ro/sw br/ro
B302 Positive (+) connection -6- (30), in main wiring harness
A58 53 51
B302 B276
J 518 3
* Main fuse carrier, A pillar, right
2,5 0,5
ro/sw sw/ge

12 10 T2a/2 T2a/1
10,0 12,0 80,0 70,0 2,5 25,0 1,5
ro ro sw sw ro/sw sw bl

T2v/1
3 4 ✱ 30 50 B+ D+ DF
1 2
B298 G
S42 S104 M
60A 60A
ws = white
1a 2a B C C1 sw = black
ro = red
6,0 6,0 br = brown
ro/sw ro/ws
gn =for green
Protected by copyright. Copying private or commercial purposes, in part or in whole, is not
bl by =AUDI
permitted unless authorised blue
AG. AUDI AG does not guarantee or accept any liability
169 173
gr = ofgrey
with respect to the correctness information in this document. Copyright by AUDI AG.
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28
97-58491
or = orange
rs = pink

Edition 08.2004
Audi A8 Current Flow Diagram No. 73 / 4
Automatic glow period control unit, terminal 30 voltage
supply relay, glow plugs, fuse for glow plugs
J179 Automatic glow period control unit
J317 Terminal 30 voltage supply relay
Q10 Glow plug 1
Q11 Glow plug 2
Q12 Glow plug 3
Q13 Glow plug 4
11 Q14 Glow plug 5
B147 Q15 Glow plug 6
10,0 1,5 0,5 2,5 1,0 0,5
ro ro/sw ro/sw sw ro/sw ro/sw
S125 Fuse for glow plugs

1
B 85 Earth connection 1, in engine compartment wiring harness
58 170 119 164 184
S125
80A
2 B147 Positive (+) connection 2 (87), in interior wiring harness
122 45 46 43

10,0 0,5 0,5 0,5 6,0 0,5 B305 Positive (+) connection 9 (30), in main wiring harness
ro/gn ro/bl gr/br gr/bl ro/sw sw

11
4 J 179 6 9 10 2/87 3/86
2
J 317
1 2 3 4 5 8 7/31 1/30 4/85

2,5 2,5 2,5 2,5 2,5 2,5 0,5 6,0 0,5

sw sw sw sw sw sw br ro ro

13
B305

2,5
ro

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

ws = white
Q10 Q11 Q12 Q13 Q14 Q15 sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
85 li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42
97-58492
or = orange
rs = pink

Edition 08.2004
Audi A8 Current Flow Diagram No. 73 / 5
Diesel direct injection system control unit
J248 Diesel direct injection system control unit
J518 Entry and start authorisation control unit
T17a 17-pin connector, black, in electronics box, plenum chamber
T17d 17-pin connector, blue, in electronics box, plenum chamber

43 Earth point, lower part of right A pillar

42 26 23
J 518 85 Earth connection -1-, in engine compartment wiring harness
A17

0,5 0,5 0,5 0,35

sw br/ro bl/sw sw/gr 131 Earth connection -2-, in engine compartment wiring harness

T17a/4 T17a/7 T17a/5 T17a/12

35 36

0,35 0,5 0,5 0,5 0,5 0,35

sw gr/br gr/bl br/ro bl/sw sw/gr

T94b
T94b/49 /63 T94b/30 J 248Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
T94b/8
permitted unless T94b/53
authorised by AUDI AG. AUDIT94b/86
AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

T94b/23 T94b/1 T94b/2 T94b/4

50 31 31 31

0,35 1,5 1,5 1,5

ro/sw br br br

T17d/6

0,35
ro/sw

20

T17a ws = white
/17 sw = black
ro = red
4,0 4,0 1,0 br = brown
br br br
gn = green
bl = blue
gr = grey
85 43 85 131 85 85 85 li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56
97-58493
or = orange
rs = pink

Edition 08.2004
Audi A8 Current Flow Diagram No. 73 / 6
Diesel direct injection system control unit, fuel pressure
regulating valve, fuel metering valve
J217 Automatic gearbox control unit
J248 Diesel direct injection system control unit
N276 Fuel pressure regulating valve
N290 Fuel metering valve
SC21 Fuse -21- on fuse box
SC28 Fuse -28- on fuse box
37 28 T16 16-pin connector, black, diagnosis connection
1,5 2,5 F36 0,5
T17a 17-pin connector, black, in electronics box, plenum chamber
ro/sw ro/gr sw T17c 17-pin connector, brown, in electronics box, plenum chamber
T46b 46-pin connector, black, CAN bus separating connector, right
21 28
Connection (K diagnosis wiring), in engine compartment wiring
SC21 SC28 D166
harness
15A T17c/15 5A T17c/16
21a 28a
Connection (87a), in diesel direct injection system wiring
F36
harness
2,5 1,5 1,5 1,5 0,5 0,5
ro/gr ro/gr ro/gr ro/gr sw/bl sw/br • CAN bus (data wire)

30 30 30 15
J 248 T94b/3 T94b/5 T94b/6 T94b/18

T60b/4 T60b/5 T94b/89 T94b/66 T94b/72

K

1,0 1,0 0,35 • 0,35 • 0,35

bl/ws gn/ge or/sw or/br gr/ws

1 1
D166
T17a/11 T17a/10
N290 N276
2 2

0,5 1,0 0,35 0,35 0,35 0,5

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ro/ws ro/ws or/sw or/br gr/ws gr/ws permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

T16c/3
J 217
T17c/17 T46b/6H T46b/6L T17a/8
ws = white
sw = black
ro = red
1,5 0,35 br = brown
ro/ws gr/ws
gn = green
K bl = blue
117
T16/7 gr = grey
li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
97-58494
or = orange
rs = pink

Edition 08.2004
 Audi A8 Current Flow Diagram No. 73 / 7
Diesel direct injection system control unit, fuel temperature
sender, fuel pressure sender, injectors for cylinders 1 - 6
G81 Fuel temperature sender
G247 Fuel pressure sender
J248 Diesel direct injection system control unit
N30 Injector, cylinder 1
N31 Injector, cylinder 2
N32 Injector, cylinder 3
N33 Injector, cylinder 4
N83 Injector, cylinder 5
N84 Injector, cylinder 6
G81 G247
ϑ

1 2 1/-- 2/S 3/+5V

0,35 0,35 0,5 0,5 0,5

gr/ws gr/ro br br/gr br/ge

T60b or commercial purposes, in part or in whole, is not T60b T60b

Protected by copyright. Copying for private
/39 T60b/10 J 248 /55 /40 T60b/54
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

T60b/15 T60b T60b T60b T60b T60b T60b

/31 /46 /32 /47 /33 /48

F27

F27
1,5 0,75 0,75 0,75
sw sw sw sw

0,75 0,75 0,75 0,75 0,75 0,75

bl br/bl bl br/bl bl br/bl

1 1 1
0,75 0,75 0,75
sw sw sw

N30 2 N31 2 N32 2 ws = white

sw = black
ro = red
br = brown
1,5 0,5 0,5 0,5
sw sw sw sw gn = green
221 bl = blue
gr = grey
15 li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
97-58495
or = orange
rs = pink

Edition 08.2004
Audi A8 Current Flow Diagram No. 73 / 8
Diesel direct injection system control unit, Hall sender, air
mass meter, engine speed sender, coolant temperature
sender, suppression filter
C24 Suppression filter
G28 Engine speed sender
G40 Hall sender
G62 Coolant temperature sender
G70 Air mass meter
J217 Automatic gearbox control unit
J248 Diesel direct injection system control unit
J518 Entry and start authorisation control unit
G40 G70 T3c 3-pin connector, grey, on engine speed sender
T17d 17-pin connector, blue, in electronics box, plenum chamber

1/5V 2/S 3/-- 1/S 2/-- 3/+

131 Earth connection 2, in engine compartment wiring harness

0,35 0,35 0,35 0,5 0,5 0,5

377 Earth connection 12, in main wiring harness
br/gn ge/sw ge/bl ws br bl
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
114 permitted unless authorised by AUDI AG. AUDI AGB469 does notConnection
guarantee or 5, in main
accept wiring
any liability harness
J 248 T60b
/27
T60b
/28 T60b/29 T94b/74 T94b/81 with respect to the correctness of information in this document. Copyright by AUDI AG.

D101 Connection 1, in engine compartment wiring harness

T60b T60b T60b T60b T94b/17
/43 /58 /53 /52 P/N

0,35
gn

0,35 0,35 D101

gn ge

0,35 0,35 0,35 0,35 0,5 0,5

sw sw ws/ge gn/ge gn gn

-- + T16c/10
T3c/1 T3c/3 T3c/2 1/-- 2/S
T17d/1 J 217
ϑ 2
0,5
gn
0,5
gn
C24
ws = white
G28 G62 B469
3,3μF
1
sw = black
ro = red
0,5 0,5 br = brown
gn br
gn = green
bl = blue
A54
gr = grey
131 J 518 377 li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
97-58496
or = orange
rs = pink

Edition 08.2004
Audi A8 Current Flow Diagram No. 73 / 9
Diesel direct injection system control unit, exhaust gas
recirculation valve, kick-down switch, accelerator pedal
position senders, fuses
E45 Cruise control system switch
F8 Kick-down switch
G79 Accelerator pedal position sender
G185 Accelerator pedal position sender 2
J248 Diesel direct injection system control unit
12 39 F25 J527 Steering column electronics control unit
0,5 2,5 0,5 2,5 F25 0,5 N18 Exhaust gas recirculation valve
sw sw ro/bl ro/bl ro/bl SC5 Fuse -5- on fuse box
SC6 Fuse -6- on fuse box
19 6 7 31 5 1
SC7 Fuse -7- on fuse box
SC19 SC6 SC7 SC31 SC5 34
SC19 Fuse -19- on fuse box
5A 15A 10A 20A 15A T17a N18
19a 6a 7a 31a 5a /15 2 SC31 Fuse -31- on fuse box
155 T16a 16-pin connector, on steering column electronics control unit
T17a 17-pin connector, black, in electronics box, plenum chamber
0,5 2,5 1,5 1,5 0,35 2,5 1,0 T17c 17-pin connector, brown, in electronics box, plenum chamber
bl ro/sw ro/ws ro/bl ro/bl ro/bl br/bl
B148 T17d 17-pin connector, blue, in electronics box, plenum chamber
111 134 57
388 Earth connection -23-, in main wiring harness
J 248 T60b/30

B148 Positive (+) connection -3- (87), in interior wiring harness

T94b/39 T94b T94b T94b T94b T94b T94b/82 T94b/44
/58 /80 /60 /57 /79 GRA

F25 Connection -1-, in diesel direct injection system wiring harness

0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,35
gr br/ws ge/ws ge/ro ge/gr br ge/br sw/ws

T17d/11 T17c T17c T17c T17c T17c T17c T17c

/7 /8 /6 /4 /5 /3 /14

0,35 0,35 0,35 0,35 0,35 0,35 0,35

Protected by copyright. Copying0,22
for private or commercial purposes, in part or in whole, is not
gr br/ws ge/ws ge/ro ge br ge/br
permitted unless authorised bysw/ws
AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1 6/S 5/-- 1/+ 4/S 3/-- 2/+ T16a/5

J 527
F8 E45
2 ws = white
G79 G185 sw = black
0,35 ro = red
br br = brown
gn = green
bl = blue
gr = grey
388 li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
97-58497
or = orange
rs = pink

Edition 08.2004
 Audi A8 Current Flow Diagram No. 73 / 10
Diesel direct injection system control unit, throttle valve
module, intake manifold flap motor, exhaust gas
recirculation cooler change-over valve, intake air
temperature sender, charge air pressure sender, lambda
probe
G31 Charge air pressure sender
G39 Lambda probe
G42 Intake air temperature sender
F25 F25
J248 Diesel direct injection system control unit
F25
0,5 0,5 0,5 0,5 J338 Throttle valve module
ro/bl ro/bl ro/bl ro/bl
N345 Exhaust gas recirculation cooler change-over valve
J 338 2/+ V157 2/+ V275 2/+ 2 T6n 6-pin connector, brown, for lambda probe
T17b 17-pin connector, green, in electronics box, plenum chamber
N345 V157 Intake manifold flap motor
1/-- 4 3 1/-- 3 4 1/-- 3 4 1 V275 Intake manifold flap 2 motor
IN OUT IN OUT
Z19 Lambda probe heater
0,5 0,5 1,0 0,5 1,0 0,5 0,5 0,5 0,5 0,5
br ws gn/ge br ro/ws ws br ge sw li/gn 85 Earth connection -1-, in engine compartment wiring harness

127 131 135

T60b
/25 T60b/60
T60b
/19 T94b/31
T60b
/36 T94b/88 T94b/70
131 Earth connection -2-, in engine compartment wiring harness

F25 Connection -1-, in diesel direct injection system wiring harness

T60b/7 T60b
/56
T60b
/26
T60b/41 J 248 T94b
/51
T94b
/32
T94b
/54
T94b
/10
T94b
/11

0,5 0,5 0,5 0,5 1,0 1,0 0,35 0,35 0,35 0,35
gn/ws br ro gr ro/sw br/ws gn/li gn/bl br ws

2 1/-- 3/+5V 4/S

G31 T17b T6n/4 T6n/3 T6n/1 T6n/5 T6n/2 T6n/6

/16
G42
2,5
ro/sw

116

ws = white
Z19 G39
sw = black
127 131 135
ro = red
br = brown
0,5 0,5 0,5
br br br gn = green
bl
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
= blue
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
gr = grey
131 85 85 li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
97-58498
or = orange
rs = pink

Edition 08.2004
 Audi A8 Current Flow Diagram No. 73 / 11
Diesel direct injection system control unit, turbocharger 1
control unit, exhaust gas temperature sender, electro-
hydraulic engine mounting solenoid valve, gearbox
mounting valve, temperature sender before particulate
filter, exhaust gas pressure sensor 1
G235 Exhaust gas temperature sender 1
G448 Exhaust gas temperature sender 2, bank 1
G450 Exhaust gas pressure sensor 1
F25
G506 Temperature sender before particulate filter
0,5 F25 0,5 0,5 0,5 0,5 J248 Diesel direct injection system control unit
ro/bl ro/bl ro/bl ro/bl ro/bl
J724 Turbocharger 1 control unit
J 724 2/+ 2 2 2 2 N144 Electro-hydraulic engine mounting solenoid valve, left
N145 Electro-hydraulic engine mounting solenoid valve, right
144 N 145 N
262 N N263 N262 Gearbox mounting valve 1
3
1/-- Protected 4
by copyright. 1
Copying for private 1 purposes, in part
or commercial 1 or in whole, is 1
not N263 Gearbox mounting valve 2
IN OUT
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
131 Earth connection 2, in engine compartment wiring harness
0,5 1,0 0,5 1,0 0,5 0,5 1,0
br br/ws gr ro/ge ro/ge ro/ws ro/ws

D102 Connection 2, in engine compartment wiring harness

141 T60b
/20 T94b/85 T60b/45 T94b/48 T60b/44 T94b/29 J 248
F25 Connection 1, in diesel direct injection system wiring harness
T94b/76 T94b/78 T94b/55 T94b/56 T94b T94b T94b/20
/19 /22 * With particulate filter
0,5
br

D102

0,35 0,35 0,35 0,35 0,35 0,35 0,5 0,5 0,5

gn br br ro br bl gr br sw

2 1 1 2 1 2 1/+5V 2/-- 3/S

ϑ ϑ ϑ

ws = white
141 G235 G448 ✱ G506 ✱ G505 ✱ sw = black
0,5 ro = red
br br = brown
gn = green
bl = blue
gr = grey
131 li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 153 154
97-58499
or = orange
rs = pink

Edition 08.2004
Audi A8 Current Flow Diagram No. 73 / 12
Diesel direct injection system control unit, brake light
switch, air filter bypass flap valve
F Brake light switch
F47 Brake pedal switch
J104 ABS control unit
J248 Diesel direct injection system control unit
J393 Convenience system central control unit
J518 Entry and start authorisation control unit
17 41 N275 Air filter bypass flap valve
6,0 1,0 SB12 Fuse 12 on fuse box
ro ro/sw SB22 Fuse 22 on fuse box
SB38 Fuse 38 on fuse box
38 12 22 T17b 17-pin connector, green, in electronics box, plenum chamber
SB 38 SB 12 SB 22 T17c 17-pin connector, brown, in electronics box, plenum chamber
30A 5A 5A
38a 12a 22a
B335 Connection 1 (54), in main wiring harness

B336 Connection 2 (54), in main wiring harness

* Only applies to countries with cold climate

J 248

T94b/71 T94b/87 T94b/65

BLS BTS

0,5 0,35 0,5 0,5 0,35

bl/gn ro/sw ro/ws sw/ws ro/br

1 3

T17b/2 T17c/10 T17c/9

F F47
4 2

0,35 0,22 1,0 0,5 0,22

bl/gn ro/sw ro/sw ro/br ro/br

B335 B336
2

✱
N275 ws = white
1
sw = byblack
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
ro = red
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
0,35 0,35 0,35 0,35 0,35 br = brown
ro/bl ro/sw ro/sw ro/sw ro/br
gn = green
B20 A34 32 37
bl = blue
121
gr = grey
J 393 J 518 J 104 J 104
li = purple
ge = yellow
155 156 157 158 159 160 161 162 163 164 165 166 167 168
97-58500
or = orange
rs = pink

Edition 08.2004
Audi A8 Current Flow Diagram No. 73 / 13
Diesel direct injection system control unit, radiator fan, high
pressure sender
G65 High pressure sender
J248 Diesel direct injection system control unit
J255 Climatronic control unit
SC9 Fuse -9- on fuse box
SC17 Fuse -17- on fuse box
T17a 17-pin connector, black, in electronics box, plenum chamber
38 27 V7 Radiator fan
V177 Radiator fan 2
0,5 1,0
ro/sw sw
43 Earth point, lower part of right A pillar
17 9
SC17 SC9
5A 5A 388 Earth connection -23-, in main wiring harness
17a 9a

B279 Positive (+) connection -3- (15a), in main wiring harness

0,5 0,5
ro/ge ro/ge

170 174
J 248

T94b/73 T94b/50 T94b/52

1,0 0,5 0,5 1,0

bl/ge bl/li br/gn sw/bl

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
0,5
bl/ge permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
B279

T17a/13 T17a/14 T17a/9 J 255

C8
17 170 19 171

6,0 0,5 0,5 6,0 0,5 0,5 0,5 0,35 0,35

ro/sw ro/ge bl/ge ro/ws ro/ge bl/li br/gn sw/bl gr/ro

184
1/B+ 2 3 1/B+ 2 3 3 2

M M
V7 V177 G65
4/31 4/31 1/31 ws = white
sw = black
ro = red
6,0 6,0 0,35 br = brown
br br br
gn = green
bl = blue
gr = grey
43 43 388 li = purple
ge = yellow
169 170 171 172 173 174 175 176 177 178 179 180 181 182
97-58501
or = orange
rs = pink

Edition 08.2004
Audi A8 Current Flow Diagram No. 73 / 14
Control unit with display in dash panel insert, fuel pump
relay
G Fuel gauge sender
G6 Fuel pump (pre-supply pump)
G237 Fuel gauge sender 3
J17 Fuel pump relay
J285 Control unit with display in dash panel insert
SF2 Fuse 2 on fuse box
T4a 4-pin connector, under cover, right, on vehicle floor
T6e 6-pin connector, under cover, right, on vehicle floor
T32 32-pin connector, blue, on dash panel insert
8

10,0 361 Earth connection (fuel gauge sender), in main wiring harness
ro

390 Earth connection 25, in main wiring harness

B299
177
2,5 675 Earth point 2, in luggage compartment, right
ro/sw
0,5 4,0
br/gn ro
B299 Positive (+) connection 3 (30), in main wiring harness
3/86 1/30 2
3 SF2 Y24 J 285
J 17 20A
4/85 2/87 2a

0,5 2,5 T32/27 T32/25

ro/sw ro/sw
2,5 0,35 0,35
sw/ws gr/bl gr/ws
42 202

T4a/1 T6e/4 T6e/1

2,5 0,35 0,35

sw/ws gr/bl gr/ws
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
A1/+ B2 A2

M G6 G237
G
A4/-- B4 A3 ws = white
4,0 2,5 0,35 0,35
sw = black
br br br/bl br/bl ro = red
361
br = brown
T4a/3 361
gn = green
2,5
bl = blue
br gr = grey
390 675 390 li = purple
ge = yellow
183 184 185 186 187 188 189 190 191 192 193 194 195 196
97-58502
or = orange
rs = pink

Edition 08.2004
Audi A8 Current Flow Diagram No. 73 / 15
Control unit with display in dash panel insert, fuel gauge,
fuel pump, fuel gauge senders, oil pressure warning lamp,
oil pressure switch
F1 Oil pressure switch
G1 Fuel gauge
G23 Fuel pump
G169 Fuel gauge sender 2
G393 Fuel gauge sender 4
185 J285 Control unit with display in dash panel insert
2,5
K3 Oil pressure warning lamp
ro/sw SF1 Fuse 1 on fuse box
T4a 4-pin connector, under cover, right, on vehicle floor
1
T6e 6-pin connector, under cover, right, on vehicle floor
SF1 T17a 17-pin connector, black, in electronics box, plenum chamber
20A
1a T32 32-pin connector, blue, on dash panel insert
2,5
sw/ge 361 Earth connection (fuel gauge sender), in main wiring harness

202
390 Earth connection 25, in main wiring harness

G1 Y24 J 285 K3

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
T32/22 T32/23 T32/26
permitted unless authorised
T32/15 by AUDI AG. AUDI AG does not guarantee or accept any liability
202 with respect to the correctness of information in this document. Copyright by AUDI AG.

0,35 0,35 0,35 2,5 0,35

br/bl gr/ge gr/li sw/ge gr/sw

T6e/5 T6e/3 T6e/2 T4a/2 T17a/1

1,0 0,35 0,35 2,5 0,35

br/bl gr/ge gr/li sw/ge gr/sw

A2 B2 A1/+ 1

G393 G169 G 23 M
F1 ws = white
A3 B4 A4/--
sw = black
0,35 0,35 2,5
br/bl br/bl br ro = red
361 br = brown
361
T4a/4 gn = green
bl = blue
2,5
br
gr = grey
390 li = purple
ge = yellow
197 198 199 200 201 202 203 204 205 206 207 208 209 210
97-58503
or = orange
rs = pink

Edition 08.2004
Audi A8 Current Flow Diagram No. 73 / 16
Control unit with display in dash panel insert, coolant
shortage indicator switch, oil level and oil temperature
sender
F66 Coolant shortage indicator switch
G266 Oil level and oil temperature sender
J285 Control unit with display in dash panel insert
K28 Coolant temperature/coolant shortage warning lamp
SB8 Fuse -8- on fuse box
25 T16 16-pin connector, black, diagnosis connection
0,5
T17a 17-pin connector, black, in electronics box, plenum chamber
sw T17d 17-pin connector, blue, in electronics box, plenum chamber
T32 32-pin connector, blue, on dash panel insert
8

SB 8 85 Earth connection -1-, in engine compartment wiring harness

5A
8a

401 Earth connection (sender earth), in interior wiring harness

0,5
sw/bl * Sender earth output
15
T 16/1

K 28 Y24 J 285

T32/28 T32/21 T32/8

✱

0,35 0,35 0,35 0,5

br/gr gn/ge bl/gr sw/bl

T17a/2 T17d/14
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
0,5 0,5
with respect to the correctness of information in this document. Copyrightbl/gr
by AUDI AG. sw/bl

3 3 1

F66 G266 ws = white

1 2/31
sw = black
ro = red
0,35 0,5 br = brown
br/gr br
gn = green
bl = blue
gr = grey
401 401 85 li = purple
ge = yellow
211 212 213 214 215 216 217 218 219 220 221 222 223 224
97-58504
or = orange
rs = pink

Edition 08.2004
 Audi A8 Current Flow Diagram No. 82 / 1

Audi A8 3.0 l - Fuel injection engine (162 kW/ 160 kW - Motronic - 6-cylinder) engine code ASN/ BBJ
from model year 2005

Fuse holder, left dash panel

8 12 16 20

5 9 13 17 21

1 3 6 10 14 18 22

2 4 7 11 15 19 23

24 31 38 Res

25 32 39 Res

26 33 40 Res

27 34 41 Res
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
28 35 42 Res
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
29 36 43 with respect to the correctness of information in this document. Copyright by AUDI AG.

30 37 44

A97--0119

Fuse colours
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7,5 A - brown
5 A - beige
1 A - black
SB - Fuses in fuse holder left dash panel
SC - Fuses in fuse holder right dash panel
SD - Fuses in fuse holder left in luggage compartment
SF - Fuses in fuse holder right in luggage compartment

Edition 09.2006
 Audi A8 Current Flow Diagram No. 82 / 1
Fuse holder right dash panel

A97--0407

Relay carrier electronics box in plenum chamber

E F G
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

A B C D

A97--0404

Relay positions

1 - Secondary air pump relay (J299)

2 - Motronic current supply relay (J271)

Edition 09.2006
 Audi A8 Current Flow Diagram No. 82 / 1
B - Secondary air pump fuse (S130)
Relay and fuse carrie behind left dash panel

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
A97--0403

Relay positions

3 - Terminal 15 voltage supply relay (J329)

relay carrier front passenger footwell

F
E

A
B C D

A97--0405

Edition 09.2006
 Audi A8 Current Flow Diagram No. 82 / 1
Relay positions

1.1 - Brake servo relay (J569)

1.2 - Continued coolant circulation relay (J151)
2 - Starter motor relay (J53)
3 - Starter motor relay 2 (J695)
4 - Fuel pump relay (J17)
Assignment main fuse carrier right A-pillar

A97--0406

Fuse locations

1 - Radiator fan single fuse (S42, 60 A)

1A - Radiator fan screw point 1
2 - Radiator fan fuse for 2nd speed (S104, 60 A)
2A - Radiator fan screw point 2
3 - Terminal 30 screw point (battery)
4 - Terminal 30 screw point (starter) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Edition 09.2006
 Audi A8 Current Flow Diagram No. 82 / 1
Relay and fuse carrier right in luggage compartment

D
C
A
B

A97--1272

Relay positions

3 - Electric fuel pump 2 relay (J49)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 2
Battery, energy management control unit, battery isolation
igniter
A Battery
J234 Airbag control unit
J644 Energy management control unit
N253 Battery isolation igniter
S131 Fuse 1, 110 A, in luggage compartment, rear right
S132 Fuse 2, 60 A, in luggage compartment, rear right
S133 Fuse 3, 150 A, in luggage compartment, rear right
B304 Z2 B272 SC15 Fuse 15 on fuse holder
4,0 6,0 10,0 16,0 12,0 10,0 SC38 Fuse 38 on fuse holder
ro ro ro ro ro ro SC40 Fuse 40 on fuse holder
T46b 46-pin connector, black, CAN separating connector right
35 17 31
Z2 Heated windscreen

38 40 15 3A 2A 1A ✱ 3 Earth strap, engine - body

SC38 SC40 SC15 S133 S132 S131
5A 15A 5A 150A 60A 110A
38a 40a 15a
13 Earth point, on right in engine compartment
5 4

18 Earth point on engine block

1,5 35,0 10,0

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ro/gn sw ro B272 Positive connection
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
(30), in main wiring harness
J 234 J 234
with respect to the correctness of information in this document. Copyright by AUDI AG.
146 188 27 28
B304 Positive connection 8 (30), in main wiring harness
+ 50,0 0,5 0,5
sw ro br • CAN bus (data wire)
* In luggage compartment, rear right
A
A 1 2

27
N253
T46b T46b --
B
/15H /15L

0,35 •• 0,35 • 0,5 0,35 0,5 50,0 80,0

or/gn or/br sw/ge ro/gn ro/ws sw sw

19
CAN-H CAN-L
9 10 8 14 11 B--

ws = white
J 644 sw = black
ro = red
35,0 35,0 br = brown
sw sw
gn = green
bl = blue
gr = grey
13 18 18 3 li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14
97-85022
or = orange
rs = pink

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 3
Starter, alternator, terminal 15 voltage supply relay, starter
motor relay
B Starter
C Alternator
C1 Voltage regulator
J53 Starter motor relay
J329 Terminal 15 voltage supply relay
J518 Entry and start authorisation control unit
J695 Starter motor relay 2
220 B163 1,0 0,5 S42 Radiator fan single fuse
sw sw S104 Radiator fan fuse for 2nd speed
4,0 2,5 0,5
sw sw sw SC9 Fuse 9 on fuse holder
9 28 SC28 Fuse 28 on fuse holder
B165
SC9 SC28 T2a 2-pin connector, black, in front right engine compartment
5A 5A
B306 T2f 2-pin connector, black, on alternator
B273 9a 28a

B163 Positive connection 1 (15), in interior wiring harness

4,0 # 2,5 # 2,5 #
0,5 6,0 ## 6,0 ## 0,5 4,0 ## 0,5 1,0 0,5
ro sw sw sw sw/gn sw sw/bl sw/bl
B165 Positive connection 2 (15), in interior wiring harness
129 141
3/86 2/87 8/87 4 2/30 4
3 2 3
B273 Positive connection (15), in main wiring harness
J 329 J 53 J 695
8/87 6
4/85 1/30 2/30 6
J 518 B276 Positive connection (50), in main wiring harness
157 A51
4,0 # 2,5 # Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1,5 6,0 0,5 6,0 ## 0,5 0,35 4,0 ## 0,5 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ro ro bl ro bl/sw ro/sw ro/sw br/ro with respect to the correctnessB298 Positive
of information connection
in this 2 (30), inbymain
document. Copyright AUDIwiring
AG. harness
B302 A58 B276 38
39
J 518 3
B302 Positive connection 6 (30), in main wiring harness
0,35 2,5 0,5
ro/sw ro/sw sw/ge
B306 Positive connection 10 (30), in main wiring harness
41
11 9 T2a/2 T2a/1
* Main fuse carrier right A-pillar
10,0 12,0 80,0 50,0 2,5 25,0 1,5 # up to April 2006
ro ro sw sw ro/sw sw bl
## from May 2006
B298 T2f/1
3 4 ✱ 30 50 B+ D+ DF
1 2
G
S42 S104 M
60A 60A
ws = white
1a 2a B C C1 sw = black
ro = red
6,0 6,0 br = brown
ro/sw ro/ws
gn = green
bl = blue
170 174
gr = grey
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28
4E0-082060906
or = orange
rs = pink

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 4
Engine control unit, Motronic current supply relay
J271 Motronic current supply relay
J623 Engine control unit
SC21 Fuse 21 on fuse holder
SC30 Fuse 30 on fuse holder
T17a 17-pin connector, black, in electronics box in plenum chamber
T17c 17-pin connector, brown, in electronics box in plenum chamber
T17d 17-pin connector, blue, in electronics box in plenum chamber
T40 40-pin connector, black, on engine control unit
21
B305
T81 81-pin connector, black, on engine control unit
4,0 B147 0,5 1,0 1,0 4,0 0,5 0,5 0,35
ro/sw ro/sw ro/sw ro/sw ro ro ro ro/sw 17 Earth point, on intake manifold
30 21
171 160 77 1
SC30 SC21 43 Earth point, lower part of right A-pillar
30A 5A T17c T17d
30a 21a /15 /6

4,0 4,0 1,0 0,5 0,35

85 Earth connection 1, in engine compartment wiring harness
ro/gn ro/sw ro/gr ro/gr ro/sw

49 131 Earth connection 2, in engine compartment wiring harness

30 50
2/87 4/85 J 623 T81/62 T81/42
2 387 Earth connection 22, in main wiring harness
J 271
1/30 3/86 T81/23 T40 T81/32 T81/1 T81/2
/119 31 31
12 B147 Positive connection 2 (87), in interior wiring harness

10,0 6,0copyright. Copying

Protected by 0,5 for 0,35
private or0,5 0,5 purposes, in2,5
commercial part or in2,5
whole, is not
ro ro authorisedswby AUDIswAG. AUDI
br/ro AG bl/sw bror acceptbr any liability
permitted unless does not guarantee B303 Positive connection 7 (30), in main wiring harness
with respect to the correctness of information in this document. Copyright by AUDI AG.

B305 Positive connection 9 (30), in main wiring harness

T17a T17a T17a
/4 /7 /5

B303

6,0 4,0 0,5 0,5

ro ro br/ro bl/sw

184 138 26 23

ws = white
sw = black
T17a ro = red
/17
br = brown
2,5 6,0 4,0 4,0
br/ws br br br gn = green
387 85 bl = blue
131 gr = grey
17 43 li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42
97-85023
or = orange
rs = pink

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 5
Engine control unit, injector, cylinder 1 - 4, ignition coil 1 - 4
with output stage
J623 Engine control unit
N30 Injector, cylinder 1
N31 Injector, cylinder 2
N32 Injector, cylinder 3
N33 Injector, cylinder 4
N70 Ignition coil 1 with output stage
D95
N127 Ignition coil 2 with output stage
N291 Ignition coil 3 with output stage
0,35 0,35 D95 0,35 0,35
bl/ws bl/ws bl/ws bl/ws
N292 Ignition coil 4 with output stage
P Spark plug connector
1 1 1 1 Q Spark plugs
T17e 17-pin connector, red, in electronics box in plenum chamber
N30 N31 N32 N33 T40 40-pin connector, black, on engine control unit
2 2 2 2
T81 81-pin connector, black, on engine control unit

0,35 0,35 0,35 0,35 85 Earth connection 1, in engine compartment wiring harness
gn/ro gn/bl ws/gn ws/ge

131 Earth connection 2, in engine compartment wiring harness

T40/96 T40/112 J 623 T40/88 T40/97
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG. D95 Connection (injectors), in engine compartment wiring harness
T40/102 T40/110 T40/94 T40/103 T81/3

0,5 0,5 0,5 0,5 1,5 E6 Positive connection 1 (15), in Motronic wiring harness
ge gn gr E6 li/gn ro/gn
E6
2,5 2,5 4,0 2,5 2,5
ro/gn ro/gn ro/gn ro/gn ro/gn

3 N70 1 3 N127 1 3 N291 1 3 N292 1

2/31 4/31 I 2/31 4/31 II 2/31 4/31 III 2/31 4/31 IV

T17e
/17

P P P P
Q Q Q Q ws = white
sw = black
ro = red
2,5 0,5 2,5 0,5 4,0 2,5 0,5 2,5 0,5 br = brown
br br/ws br br/ws ro/gn br br/ws br br/ws
gn = green
29
bl = blue
gr = grey
85 131 85 131 85 131 85 131 li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56
A97-84447
or = orange
rs = pink

Edition 09.2006
 Audi A8 Current Flow Diagram No. 82 / 6
Engine control unit, injector, cylinder 5 and 6, ignition coil 5
and 6 with output stage, throttle valve module, accelerator
position sender
G79 Accelerator position sender
G185 Accelerator position sender 2
G186 Throttle valve drive (electric power control)
G187 Throttle valve drive angle sender 1 for electric throttle
G188 Throttle valve drive angle sender 2 for electric throttle
D95 J338 Throttle valve module
D95 J623 Engine control unit
0,35 0,35 2,5
bl/ws bl/ws bl/ws N83 Injector, cylinder 5
G186 G187 G188 N84 Injector, cylinder 6
1 1
N323 Ignition coil 5 with output stage
M N324 Ignition coil 6 with output stage
N83 N84 T17e/16 J 338 P Spark plug connector
2 2 3/M+ 5/M-- 6 1 4 2
Q Spark plugs
T17c 17-pin connector, brown, in electronics box in plenum chamber
0,35 0,35 1,5 1,0 1,0 0,35 0,35 0,35 0,35 T17e 17-pin connector, red, in electronics box in plenum chamber
gn/gr gn/bl bl/ws ro/ge br/ge br/ro gr/ro gn/ws sw/gn
T40 40-pin connector, black, on engine control unit
110
T81 81-pin connector, black, on engine control unit
T40/113 T40/89 J 623 T40
/117
T40
/118 T40/91 T40/92 T40/84 T40/83
85 Earth connection 1, in engine compartment wiring harness

T40/111 T40/95 T81/73 T81/36 T81/35 T81/34 T81/33 T81/72

5V -- S1 S2 -- 5V 131 Earth connection 2, in engine compartment wiring harness
0,5 0,5
gn/sw E6 li/ge
E6 D95 Connection (injectors), in engine compartment wiring harness
2,5 2,5 0,35 0,35 0,35 0,35 0,35 0,35
ro/gn ro/gn ge/br br ge/gr br/ws ge/ws ge/ro

3 N323 1 3 N324 1
E6 Positive connection 1 (15), in Motronic wiring harness

T17c T17c T17c T17c T17c T17c

2/31 4/31 2/31 4/31 /3 /5 /4 /7 /8 /6
V VI

0,35 0,35 0,35 0,35 0,35 0,35

ge/br br ge br/ws ge/ws ge/ro

2/+ 3/-- 4/S1 6/S2 5/-- 1/+

P P
Q Q ws = white
G79 G185
Protected by copyright. Copying for private or commercialsw = black
purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG doesro = red or accept any liability
not guarantee
br = Copyright
with respect to the correctness of information in this document. brown by AUDI AG.
2,5 0,5 2,5 0,5 gn = green
br br/ws br br/ws
bl = blue
gr = grey
85 131 85 131 li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
A97-84450
or = orange
rs = pink

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 7
Engine control unit, knock sensor 1, knock sensor 2, engine
speed sender
G28 Engine speed sender
G61 Knock sensor 1
G62 Coolant temperature sender
G66 Knock sensor 2
J623 Engine control unit
SC8 Fuse 8 on fuse holder
T3a 3-pin connector, blue, on knock sensor 2
T46b/6L T46b/6H 33
T3b 3-pin connector, blue, on knock sensor 1
1,0
ro/sw
T3c 3-pin connector, grey, on engine speed sender
0,35 0,35
or/br or/sw T17a 17-pin connector, black, in electronics box in plenum chamber
8 T17c 17-pin connector, brown, in electronics box in plenum chamber
SC8 T40 40-pin connector, black, on engine control unit
10A
T17a/10 T17a/11 8a
T46b 46-pin connector, black, CAN bus separating connector right
180 178 T81 81-pin connector, black, on engine control unit
Earth connection (sender earth), in engine compartment wiring
0,35 • 0,35 • 1,5 0,5 0,5
327
harness
or/br or/sw ro/ge ro/ge ro/ge
B350

CAN-L CAN-H
B350 B350 Positive connection 1 (87a), in main wiring harness
T81/58 T81/60 J 623
D102 Connection 2, in engine compartment wiring harness
T40 T40/99 T40/107 T40/108 T40/90 T40/82 T40/93
/106
S
-- S -- + • CAN bus (data wire)
0,35 0,35 0,35 0,35 0,35 0,35
ge bl D102 gr sw bl gr

327
327

0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,5

sw gn sw bl sw br gn br

T3a/3 T3a/1 T3a/2 T3b/3 T3b/1 T3b/2 T3c/1 T3c/2 T3c/3 T17c
/12

1 2
ϑ 0,5
br

G66 G61 G28 G62 ws = white

152 sw = black
ro = red
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
br = brown
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
gn = green
with respect to the correctness of information in this document. Copyright by AUDI AG.
bl = blue
gr = grey
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
A97-84453
or = orange
rs = pink

Edition 09.2006
 Audi A8 Current Flow Diagram No. 82 / 8
Engine control unit, Hall sender, inlet camshaft control valve
G40 Hall sender
G163 Hall sender 2
G300 Hall sender 3
G301 Hall sender 4
J623 Engine control unit
N205 Inlet camshaft control valve 1
N208 Inlet camshaft control valve 2
N318 Exhaust camshaft control valve 1
N319 Exhaust camshaft control valve 2
D103
1,0 0,5 0,5 T17a 17-pin connector, black, in electronics box in plenum chamber
ro/ge ro/ge ro/ge
T17c 17-pin connector, brown, in electronics box in plenum chamber
2 2 T40 40-pin connector, black, on engine control unit
N208 T81 81-pin connector, black, on engine control unit
T17a N318 N319 Earth connection (sender earth), in engine compartment wiring
/16
N205 1 3 1 3 327
harness

1,5 0,35 0,35 0,35 0,35 Earth connection 2 (sender earth), in engine compartment wiring
ro/ge ws/br gn/br ws/br bl/br 328
harness
B350
B350
T40 T40 B350 Positive connection 1 (87a), in main wiring harness
/115 T81/22 /120 T81/18 J 623

D103 Connection 3, in engine compartment wiring harness

T40/87 T40/98 T40/86 T81/81 T81/54
+5V

D141 Connection (5V), in engine wiring harness

✱
0,5 0,5 0,35 0,5 0,5 0,5 0,5
br gn ws sw ws bl gr
D174 Connection 2 (5V), in engine wiring harness
D141 D174

* up to October 2005
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
** from November 2005
permitted unless authorised by AUDI327AG. AUDI AG does not guarantee or accept any liability 328
327respect to the correctness of information in this document. Copyright by AUDI AG.
with

✱✱
0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5
br ws br ws ws ws ge br ws br

3/-- 2/S 1/+ 3/-- 2/S 1/+ 1/+ 2/S 3/-- 1/+ 2/S 3/--

ws = white
G40 G163 G300 G301
sw = black
T17c/13 ro = red
br = brown
0,5
sw gn = green
bl = blue
153 gr = grey
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98
4E0-082110306
or = orange
rs = pink

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 9
Engine control unit, lambda probe, lambda probe 2
G39 Lambda probe
G108 Lambda probe 2
J623 Engine control unit
SC5 Fuse 5 on fuse holder
SC6 Fuse 6 on fuse holder
SC7 Fuse 7 on fuse holder
SC29 Fuse 29 on fuse holder
SC31 Fuse 31 on fuse holder
T6s 6-pin connector, black, for lambda probe
2,5 B146 1,5 6,0 T6u 6-pin connector, brown, for lambda probe 2
ro/sw ro/sw ro/sw
T17e 17-pin connector, red, in electronics box in plenum chamber
5 6 7 31 29 T81 81-pin connector, black, on engine control unit
184
SC5 SC6 SC7 SC31 SC29 Z19 Lambda probe heater
15A 15A 15A 20A 15A Z28 Lambda probe 2 heater
5a 6a 7a 31a 29a
B146 Positive connection 1 (87), in interior wiring harness

1,5 1,5 1,5 2,5 1,5

ro/bl ro/sw ro/ws sw/ge bl/ws

138 105 117 202 62

J 623

T81/5 T81/52 T81/71 T81/51 T81/70 T81/4 T81/15 T81/14 T81/12 T81/13

1,0 0,35 0,35 0,35 0,35 1,0 0,35 0,35 0,35 0,35
br/ws gr/gn gr/li br gn br/ge gr/bl gr/ro br bl

T6s/4 T6s/6 T6s/2 T6s/5 T6s/1 T6u/4 T6u/6 T6u/2 T6u/5 T6u/1
105

1,5
ro/sw

Z19 G39 Z28 G108 ws = white

sw = black
T6s/3 T17e/15 T6u/3 ro = red
br or in=whole,
Protected by copyright. Copying for private or commercial purposes, in part brownis not
1,0 1,0
permitted unless authorised by AUDI AG. AUDI AG does not guarantee gn = any
or accept green
liability
ro/sw ro/sw
bl by =AUDI
with respect to the correctness of information in this document. Copyright blue
AG.
gr = grey
li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
97-85024
or = orange
rs = pink

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 10
Engine control unit, lambda probe after catalytic converter,
air mass meter, variable intake manifold change-over valve,
secondary air inlet valve, active charcoal filter system
solenoid valve 1
G70 Air mass meter
G130 Lambda probe after catalytic converter
G131 Lambda probe 2 after catalytic converter
J623 Engine control unit
E7 N80 Activated charcoal filter system solenoid valve 1
0,5 E7 0,35 0,35 0,5 N112 Secondary air inlet valve
ro/bl ro/bl ro/bl ro/bl N156 Variable intake manifold change-over valve
G70 2 1 1 1 T4s 4-pin connector, green, for lambda probe 1 after catalytic
converter
T4t 4-pin connector, brown, for lambda probe 2 after catalytic
N156 N112 N80
1/5V 3/-- 4/S 5/T 2 2 2 converter
T17c 17-pin connector, brown, in electronics box in plenum chamber
T81 81-pin connector, black, on engine control unit
0,35 0,35 0,35 0,35 0,35 0,35 0,5 Z29 Lambda probe 1 heater after catalytic converter
sw/gn br/gr gn/li gn ge/ws br/ro ge/gn
Z30 Lambda probe 2 heater after catalytic converter

T81/53 T81/27 T81/29 T81/26 J 623 T81/48 T81/44 T81/64

D106 Connection 4, in engine compartment wiring harness

T81/63 T81/68 T81/69 T81/6 T81/10 T81/11 E7 Connection (87a), in Motronic wiring harness

0,35 0,35 0,35 0,35 0,35 0,35

gn/ge br ge gr/bl br ro

T4s/2 T4s/3 T4s/4 T4t/2 T4t/3 T4t/4

106 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1,5 with respect to the correctness of information in this document. Copyright by AUDI AG.
ro/ws
ws = white
Z29 G130 Z30 G131
sw = black
T4s/1 T17c/17 T4t/1 ro = red
br = brown
0,5 1,0 0,5 gn = green
ro/ws ro/ws ro/ws bl = blue
D106 gr = grey
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
A97-84462
or = orange
rs = pink

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 11
Engine control unit, electro-hydraulic engine mounting
solenoid valve, gearbox mounting valve, secondary air
pump motor, secondary air pump relay, high pressure
sender
G65 High pressure sender
J255 Climatronic control unit
J299 Secondary air pump relay
J518 Entry and start authorisation control unit
E7 J623 Engine control unit
0,5 0,5 0,5 E7 0,5 2,5 N144 Left electrohydraulic engine mounting solenoid valve
ro/bl ro/bl ro/bl ro/bl ro/bl N145 Right electrohydraulic engine mounting solenoid valve
1 1 1 1 N262 Gearbox mounting valve 1
Protected by copyright. Copying for privateN263 Gearbox
or commercial mounting
purposes, in partvalve 2
or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
S130 Secondary air pump fuse
N145 N144 N262 N263 T17a/15 with respect to the correctness of information in this document. Copyright by AUDI AG.
2 2 2 2 T17a 17-pin connector, black, in electronics box in plenum chamber
104 140 T17e 17-pin connector, red, in electronics box in plenum chamber
T40 40-pin connector, black, on engine control unit
0,5 0,5 0,5 0,5 2,5 1,5 0,5 T81 81-pin connector, black, on engine control unit
ge/bl ge/gn ws/ge ws/bl ro/bl ro/bl ro/bl
B148 V101 Secondary air pump motor

J 623 T40/105 T40/116 T81/9 T40/121

387 Earth connection 22, in main wiring harness

T81/30 T81/46 388 Earth connection 23, in main wiring harness

27 36

1,0 0,35 4,0 0,35

B148 Positive connection 3 (87), in interior wiring harness
sw/bl sw/gr ro ge/gr

B279 Positive connection 3 (15a), in main wiring harness

1
B279 B

J 255 T17a/12 S130 T17e E7 Connection (87a), in Motronic wiring harness

50A
C8 2 /6

0,35 0,35 0,35 4,0 4,0 0,35

gr/ro sw/bl sw/gr ro/ge ro/sw ge/gr

ϑ
2 3 A17 2/30 4/85
J 518 M
1
G65 V101 J 299 ws = white
1/31 1 8/87 6/86
sw = black
ro = red
0,35 4,0 0,5 br = brown
br br ro/bl
gn = green
bl = blue
140
gr = grey
388 387
li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
A97-84465
or = orange
rs = pink

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 12
Engine control unit, brake servo relay, vacuum pump for
brakes, brake servo pressure sensor
G294 Brake servo pressure sensor
J217 Automatic gearbox control unit
J518 Entry and start authorisation control unit
J569 Brake servo relay
J623 Engine control unit
T16 16-pin connector, black, diagnosic connetion
T17a 17-pin connector, black, in electronics box in plenum chamber
T17c 17-pin connector, brown, in electronics box in plenum chamber
D166 E26 T17d 17-pin connector, blue, in electronics box in plenum chamber
0,5 0,35 0,5 0,5
gr/ws gr/ws gn gn T17e 17-pin connector, red, in electronics box in plenum chamber
T20e 20-pin connector, black, on gearbox
T20e/6 T20e/4
T40 40-pin connector, black, on engine control unit
J 217Protected T17a/8for private or commercialJ 217
by copyright. Copying purposes, in part orTin
J 217
whole, is not
17d/1 T81 81-pin connector, black, on engine control unit
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
T20e/18 V192 Vacuum pump for brakes
with respect to the correctness of information in this document. Copyright by AUDI AG.
0,35 0,35 0,35 0,5 0,5
gr/ws gr/ws gn gn bl/gr
44 Earth point, lower part of left A-pillar

K
T16/7
A54 375 Earth connection 10, in main wiring harness
J 623 K/W
T81/43
P/N
T81/20
J 518 TD
T81/37

388 Earth connection 23, in main wiring harness

T81/21 T40/114 T40/85
15
B281 Positive connection 5 (15a), in main wiring harness
0,5 0,35 0,5
sw/br bl/gn gn
Connection (K-diagnosis wiring), in engine compartment wiring
D166
harness

E26 Connection selector lever lock, in Motronic wiring harness

T17c/16 T17e/9 T17c/11
84 92

0,5 1,0 0,5 0,5 0,5

bl/gn ro/gr gn br sw

1/86 4/87a 5/87 2 4 1 3

1.1
M
J 569 V192 G294
2/85 3/30 1 ws = white
28 183 187 sw = black
ro = red
0,5 0,5 0,5 0,5 0,5 1,5 1,0 2,5 6,0 br = brown
sw/bl sw/bl sw/bl sw/bl sw/bl ro/gn br br br
gn = green
bl = blue
3
gr = grey
B281 375 375 388 44 375 li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 153 154
A97-84468
or = orange
rs = pink

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 13
Engine control unit, brake light switch, kick-down switch,
brake pedal switch, cruise control system switch
E45 Cruise control system switch
F Brake light switch
F8 Kick-down switch
F47 Brake pedal switch
J104 ABS control unit
J518 Entry and start authorisation control unit
18 32 J527 Steering column electronics control unit
6,0 1,0
J623 Engine control unit
ro ro/sw SB12 Fuse 12 on fuse holder
SB22 Fuse 22 on fuse holder
38 12 22 SB38 Fuse 38 on fuse holder
SB 38 SB 12 SB 22 T16a 16-pin connector, on steering column electronics control unit
30A 5A 5A
T17c 17-pin connector, brown, in electronics box in plenum chamber
38a 12a 22a
T17d 17-pin connector, blue, in electronics box in plenum chamber
T81 81-pin connector, black, on engine control unit
0,5 0,5
ro/ws sw/ws 44 Earth point, lower part of left A-pillar

159 160
J 623 375 Earth connection 10, in main wiring harness

T81/56 T81/55 T81/74 T81/38 388 Earth connection 23, in main wiring harness
BLS Protected
159 160 by copyright. Copying forBTS
private or commercial purposes, in part orGRA
in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
0,35 0,5 0,5 0,35 0,35 0,35 B335 Connection 1 (54), in main wiring harness
ro/sw ro/ws sw/ws ro/br gr sw/ws

B336 Connection 2 (54), in main wiring harness

1 3

T17c T17c/9 T17d/11 T17c

J 104 J 518 /10 F F47 J 104 /14
32 A34 4 2 37

0,35 0,35 0,35 1,0 0,5 0,35 0,35 0,35 0,35

ro/sw ro/sw ro/sw ro/sw ro/br ro/br ro/br gr sw/ws

B335 B336
1 T16a/5
J 527
F8 E45
2 ws = white
sw = black
ro = red
6,0 2,5 0,35 br = brown
br br br
gn = green
375 388 bl = blue
gr = grey
44 li = purple
ge = yellow
155 156 157 158 159 160 161 162 163 164 165 166 167 168
97-85025
or = orange
rs = pink

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 14
Engine control unit, radiator fan, radiator fan 2, continued
coolant circulation relay, continued coolant circulation
pump
J151 Continued coolant circulation relay
J623 Engine control unit
SC17 Fuse 17 on fuse holder
T17a 17-pin connector, black, in electronics box in plenum chamber
T17e 17-pin connector, red, in electronics box in plenum chamber
31 187 183 T40 40-pin connector, black, on engine control unit
0,5
T81 81-pin connector, black, on engine control unit
ro/sw 0,5 0,5 V7 Radiator fan
sw/bl br/gn V51 Continued coolant circulation pump
17
V177 Radiator fan 2
SC17
5A
17a T17a/3 T17a/9 43 Earth point, lower part of right A-pillar

0,5 0,5 0,35 0,35

85 Earth connection 1, in engine compartment wiring harness
ro/ge ro/ge sw/bl br/gn
* only countries with hot climate
171 175 ** without countries with hot climate
J 623 Protected byT81/45 for private or commercial purposes, in part or in whole,#is notmodels with trailer towing attachment
T81/65
copyright. Copying
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any## liabilitymodels without trailer towing attachment
with respect to the correctness of information in this document. Copyright by AUDI AG.
T81/66 T81/61 T40/104 T81/47

## #
✱✱ ✱
0,5 0,35 0,5 0,35
bl/ge bl/li bl/li ro/ge

T17a/6
0,5 ✱ ✱
bl/ws
T17a/13 T17a/14 T17e/7 T17e/8

18 171 20 172

6,0 0,5 0,5 6,0 0,5 0,5 0,35 0,5 0,5

ro/sw ro/ge bl/ge ro/ws ro/ge bl/li ro/ge ro/gr ro/gn

1/B+ 2 3 1/B+ 2 3 12/86 42/87a 52/87 1

1.2
M M ✱ M ✱
V7 V177 J 151 V51
4/31 4/31 22/85 32/30 2 ws = white
sw = black
ro = red
6,0 6,0 0,5 0,5 0,5 br = brown
br br ro/ge ro/ge br
gn = green
bl = blue
82 81
gr = grey
43 43 85 li = purple
ge = yellow
169 170 171 172 173 174 175 176 177 178 179 180 181 182
A97-84474
or = orange
rs = pink

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 15
Fuel pump relay, electric fuel pump 2 relay, control unit in
dash panel insert
G Fuel gauge sender
G6 Fuel system pressurisation pump
G237 Fuel gauge sender 3
J17 Fuel pump relay
J49 Electric fuel pump 2 relay
J285 Control unit in dash panel insert
SF2 Fuse 2 on fuse holder
T4a 4-pin connector, under right cover on vehicle floor
T6e 6-pin connector, under right cover on vehicle floor
T32 32-pin connector, blue, on dash panel insert
Y24 Display in dash panel insert

361 Earth
Protected by copyright. Copying for private or commercial connection
purposes, in part or in(fuel gauge
whole, is not sender), in main wiring harness
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
390 Earth connection 25, in main wiring harness

675 Earth point 2, on right in luggage compartment

7 2

10,0
SF2 Y24 J 285 B299 Positive connection 3 (30), in main wiring harness
20A
ro
2a

B299
143 35 145 T32/27 T32/25

0,5 6,0 0,5 4,0 2,5 0,35 0,35

sw/bl ro sw/bl ro sw/ws gr/bl gr/ws

3/86 1/30 3/86 1/30

4 3
J 17 J 49 T4a/1 T6e/4 T6e/1
4/85 2/87 5/85 2/87

0,5 6,0 0,5 4,0 2,5 0,35 0,35

br/gn ro/sw sw/bl ro/gr sw/ws gr/bl gr/ws

181 112 179

A1/+ B2 A2

M G6 G237
G
A4/-- B4 A3 ws = white
4,0 2,5 0,35 0,35
sw = black
br br br/bl br/bl ro = red
361
br = brown
T4a/3 361
gn = green
2,5
bl = blue
br gr = grey
675 390 390 li = purple
ge = yellow
183 184 185 186 187 188 189 190 191 192 193 194 195 196
A97-84477
or = orange
rs = pink

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 16
Control unit in dash panel insert, fuel pump, fuel gauge, oil
pressure warning lamp, fuel gauge sender
F1 Oil pressure switch
G1 Fuel gauge
G23 Fuel pump
G169 Fuel gauge sender 2
G393 Fuel gauge sender 4
J285 Control unit in dash panel insert
K3 Oil pressure warning lamp
T4a 4-pin connector, under right cover on vehicle floor
T6e 6-pin connector, under right cover on vehicle floor
T17a 17-pin connector, black, in electronics box in plenum chamber
T32 32-pin connector, blue, on dash panel insert
Y24 Display in dash panel insert

361 Earth connection (fuel gauge sender), in main wiring harness

390 Earth connection 25, in main wiring harness

G1 Y24 J 285 K3

T32/22 T32/23 T32/26 T32/15

108

0,35 0,35 0,35 2,5 0,35

br/bl gr/ge gr/li sw/ge gr/sw

T6e/5 T6e/3 T6e/2 T4a/2 T17a/1

1,0 0,35 0,35 2,5 0,5

br/bl gr/ge gr/li sw/ge gr/sw

A2 B2 A1/+ 1

G393 G169
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
G 23 M permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
F1 with respect to ws
A3 B4 A4/-- = whiteof information in this document. Copyright by AUDI AG.
the correctness
sw = black
0,35 0,35 2,5
br/bl br/bl br ro = red
361 br = brown
361
T4a/4 gn = green
bl = blue
2,5
br
gr = grey
390 li = purple
ge = yellow
197 198 199 200 201 202 203 204 205 206 207 208 209 210
A97-84480
or = orange
rs = pink

Edition 09.2006
Audi A8 Current Flow Diagram No. 82 / 17
Control unit in dash panel insert, coolant shortage indicator
switch, oil level and oil temperature sender, coolant
temperature and coolant shortage warning lamp
F66 Coolant shortage indicator switch
G266 Oil level and oil temperature sender
J285 Control unit in dash panel insert
K28 Coolant temperature and coolant shortage warning lamp
SB8 Fuse 8 on fuse holder
24 T16 16-pin connector, black, diagnosic connetion
0,5
T17a 17-pin connector, black, in electronics box in plenum chamber
sw T17d 17-pin connector, blue, in electronics box in plenum chamber
T32 32-pin connector, blue, on dash panel insert
8
Y24 Display in dash panel insert
SB 8
5A
8a
85 Earth connection 1, in engine compartment wiring harness

0,5
401 Earth connection (sender earth), in interior wiring harness
sw/bl Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
15
*
permitted unless authorised by AUDI AG. AUDI AG does not guarantee output sender
or accept earth
any liability
T 16/1 with respect to the correctness of information in this document. Copyright by AUDI AG.

Y24 J 285 K 28

T32/28 T32/21 T32/8

✱

0,35 0,35 0,35 0,5

br/gr gn/ge bl/gr sw/bl

T17a T17d/14
/2

0,5 0,5
bl/gr sw/bl

3 3 1

F66 G266 ws = white

1 2/31
sw = black
0,35 0,5
br/gr br ro = red
br = brown
gn = green
bl = blue
gr = grey
401 401 85 li = purple
ge = yellow
211 212 213 214 215 216 217 218 219 220 221 222 223 224
A97-84570
or = orange
rs = pink

Edition 09.2006
 Audi A8 Current Flow Diagram No. 85 / 1

Audi A8 3.0 l - TDI, Common Rail, (171 kW 155 kW - 6-cylinder) engine code ASB, BNG
from model year 2005

Notes:
For information concerning
♦ Position of relays and fuses
♦ Multi-pin connections
♦ Control units and relays
♦ Earth connections
⇒ List of Fitting Locations!
For information concerning
♦ Fault Finding Programs
⇒ guided fault finding

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Edition 04.2009
Audi A8 Current Flow Diagram No. 85 / 2
Battery, energy management control unit, battery isolation
igniter, fuses
A Battery
J234 Airbag control unit
J644 Energy management control unit
N253 Battery isolation igniter
S131 Fuse 1
S132 Fuse 2
S133 Fuse 3
B304 B272 SC15 Fuse 15 on fuse holder C
4,0 6,0 10,0 25,0 10,0 12,0 6,0 SC38 Fuse 38 on fuse holder C
ro ro ro sw ro ro ro T46b 46-pin connector, black, CAN disconnector right
3A 2A 1A ✱
42 38 15 16 40 3 Earth strap, engine - body
SC38 SC15 S133 S132 S131
5A 150A 60A 110A 114 15
38a 15a 5 4 13 Earth point, on right in engine compartment
0,5 2,5
sw sw

B492
18 Earth point on engine block
B303

B272 Positive connection (30), in main wiring harness

35,0 10,0 10,0
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
sw ro ro permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
B303
with respect Positive connection
to the correctness 7 in
of information (30), in main wiring
this document. harness
Copyright by AUDI AG.
185 29
J 234 J 234
27 28

B304 Positive connection 8 (30), in main wiring harness

+ 50,0 0,5 0,5
sw ro br

A B492 Positive connection 3 (15), in interior wiring harness

A 1 2

• CAN bus (data wire)

27
N253
T46b T46b --
B
* In luggage compartment, rear right
/15H /15L

0,35 •• 0,35 • 0,5 0,35 0,5 50,0 80,0

or/gn or/br sw/ge ro/gn ro/ws sw sw

18
9 10 8 14 11 B--

ws = white
J 644 sw = black
ro = red
50,0 35,0 br = brown
sw sw
gn = green
bl = blue
gr = grey
3 18 13 18 li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14
97-85041
or = orange
rs = pink

Edition 04.2009
Audi A8 Current Flow Diagram No. 85 / 3
Starter, alternator, terminal 15 voltage supply relay, starter
motor relay
B Starter
C Alternator
C1 Voltage regulator
J53 Starter motor relay
J329 Terminal 15 voltage supply relay
J518 Entry and start authorisation control unit
J695 Starter motor relay 2
2,5 4,0 B163 1,0 0,5
S42 Radiator fan single fuse
sw sw sw sw S104 Radiator fan fuse for 2nd speed
T2a 2-pin connector, black, in front right engine compartment
14 222 180 66
T2v 2-pin connector, red, on alternator
2,5 0,5
B306 B273
sw
B165
sw B163 Positive connection 1 (15), in interior wiring harness

B165 Positive connection 2 (15), in interior wiring harness

4,0 # 2,5 # 2,5 #
0,5 6,0 ## 6,0 ## 0,5 4,0 ## 0,5
ro sw sw sw sw/gn sw
B273 Positive connection (15), in main wiring harness
3/86 2/87 8/87 4 2/30 4
3 ✱✱ 2 ✱✱ 3 ✱✱
B276 Positive connection (50), in main wiring harness
J 329 J 53 J 695
8/87 6
4/85 1/30 2/30 6
J 518
161 52 A51 B298 Positive connection 2 (30), in main wiring harness
1,5 6,0 0,5 4,0 # 0,35 0,5 0,35 2,5 # 0,5
ro ro bl 6,0 ## ro/sw bl/sw ro/sw 4,0 ## br/ro
ro ro/sw B302 Positive connection 6 (30), in main wiring harness
A58 53 51
B302 B276
J 518 3

2,5 0,5
B306 Positive connection 10 (30), in main wiring harness
ro/sw sw/ge
* Main fuse carrier right A-pillar
12 10 T2a/2 T2a/1 ** relay carrier front passenger footwell
# up to April 2006
10,0 12,0 80,0 70,0 2,5 25,0 1,5 ## from May 2006
ro ro sw sw ro/sw sw bl

T2v/1
3 4 ✱ 30 50 B+ D+ DF
1 2
B298 G
S42 S104 M
60A 60A Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ws = white
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1a 2a B C C1 sw = black
with respect to the correctness of information in this document. Copyright by AUDI AG.
ro = red
6,0 6,0 br = brown
ro/sw ro/ws
gn = green
bl = blue
169 173
gr = grey
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28
4E0-085031007
or = orange
rs = pink

Edition 04.2009
Audi A8 Current Flow Diagram No. 85 / 4
Automatic glow period control unit, terminal 30 voltage
supply relay, glow plugs, glow plug fuse
J179 Automatic glow period control unit
J317 Terminal 30 voltage supply relay
Q10 Glow plug 1
Q11 Glow plug 2
Q12 Glow plug 3
Q13 Glow plug 4
11 Q14 Glow plug 5
B147 Q15 Glow plug 6
10,0 1,5 0,5 2,5 1,0 0,5
ro ro/sw ro/sw ro/sw ro/sw ro/sw
S125 Glow plug fuse
#
1
B 85 Earth connection 1, in engine compartment wiring harness
58 170 119 164 184
S125
80A
2 B147 Positive connection 2 (87), in interior wiring harness
122 45 46 43

10,0 0,5 0,5 0,5 6,0 0,5 B305 Positive connection 9 (30), in main wiring harness
ro/gn ro/bl gr/br gr/bl ro/sw sw

# * up to August 2007
8/87 ✱ ✱ 6/86 ✱ ✱
4 J 179 ** from September 2007
11 6 9 10 # 2/87 ✱ 3/86 ✱
2
# Relay carrier electronics box in plenum chamber
J 317
1 2 3 4 5 8 7/31 1/30 ✱ 4/85
2/30 ✱ ✱

2,5 2,5 2,5 2,5 2,5 2,5 0,5 6,0 0,5

sw sw sw sw sw sw br ro ro

13
B305
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4,0
ro

85
85
ws = white
Q10 Q11 Q12 Q13 Q14 Q15 sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42
4E0-085041007
or = orange
rs = pink

Edition 04.2009
 Audi A8 Current Flow Diagram No. 85 / 5
Engine control unit
J518 Entry and start authorisation control unit
J623 Engine control unit
T17a 17-pin connector, black, in electronics box in plenum chamber
T17b 17-pin connector, green, in electronics box in plenum chamber
T17d 17-pin connector, blue, in electronics box in plenum chamber
T81b 81-pin connector, black, connector A, on entry and start
authorisation control unit
T94b 94-pin connector, black, connector B, on engine control unit
42 26 23
J 518
T81b/17
43 Earth point, lower part of right A-pillar
0,5 0,5 0,5 0,35
sw br/ro bl/sw sw/gr

85 Earth connection 1, in engine compartment wiring harness

T17a/4 T17a/7 ✱ T17a/5 T17a/12

35 36 T17b/13 ✱ ✱ 131 Earth connection 2, in engine compartment wiring harness
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
0,35 0,5 0,5 0,5 0,5 0,35
with respect
swto the correctness
gr/br of information
gr/bl in this document. Copyright by AUDI
br/ro AG. bl/sw sw/gr 387 Earth connection 22, in main wiring harness

T94b * up to August 2007

T94b/49 /63 T94b/30 J 623 T94b/8 T94b/53 T94b/86 ** from September 2007

T94b/23 T94b/1 T94b/2 T94b/4

99 103 127 131 135 141 50 31 31 31

0,35 0,35 0,5 0,5 0,5 0,5 0,35 1,5 1,5 1,5
sw sw br br br br ro/sw br br br

T17d/6
131
220

1,0 0,35 0,5

br ro/sw br

20

85
85 ws = white
sw = black
387 ro = red
4,0 4,0 6,0
br br br br = brown
gn = green
T17a/17 bl = blue
gr = grey
43 li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56
4E0-085051007
or = orange
rs = pink

Edition 04.2009
Audi A8 Current Flow Diagram No. 85 / 6
Engine control unit, fuel pressure regulating valve, fuel
metering valve
J217 Automatic gearbox control unit
J623 Engine control unit
N276 Fuel pressure regulating valve
N290 Fuel metering valve
SC21 Fuse 21 on fuse holder C
SC28 Fuse 28 on fuse holder C
37 28 T16 16-pin connector, black, diagnosic connetion
1,5 2,5 F36 0,5
T16c 16-pin connector, black, on automatic gearbox control unit
ro/sw ro/gr sw T17a 17-pin connector, black, in electronics box in plenum chamber
T17c 17-pin connector, brown, in electronics box in plenum chamber
21 28 T46b 46-pin connector, black, CAN bus disconnector right
SC21 SC28 T60b 60-pin connector, black, connector A, on engine control unit
15A T17c/15 5A T17c/16 T94b 94-pin connector, black, connector B, on engine control unit
21a 28a
Connection (K-diagnosis wiring), in engine compartment wiring
D166
harness
2,5 1,5 1,5 1,5 0,5 0,5
ro/gr ro/gr ro/gr ro/gr sw/bl sw/br
Connection (87a), in diesel direct injection system wiring
F36
harness
87 87 87 15
J 623 T94b/3 T94b/5 T94b/6 T94b/18 • CAN bus (data wire)

T60b/4 T60b/5 T94b/89 T94b/66 T94b/72

K

1,0 1,0 0,35 • 0,35 • 0,35

bl/ws gn/ge or/sw or/br gr/ws

1 1
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
D166
T17a/11 T17a/10
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
N290 N276 with respect to the correctness of information in this document. Copyright by AUDI AG.
2 2

0,5 1,0 0,35 0,35 0,35 0,35

ro/ws ro/ws or/sw or/br gr/ws gr/ws

T16c/3
J 217
T17c/17 T46b/6H T46b/6L T17a/8
ws = white
sw = black
ro = red
1,5 0,35 br = brown
ro/ws gr/ws
gn = green
K bl = blue
117
T16/7 gr = grey
li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
4E0-085060409
or = orange
rs = pink

Edition 04.2009
Audi A8 Current Flow Diagram No. 85 / 7
Engine control unit, fuel temperature sender, fuel pressure
sender, injector, cylinder 1 - 3
G81 Fuel temperature sender
G247 Fuel pressure sender
J623 Engine control unit
N30 Injector, cylinder 1
N31 Injector, cylinder 2
N32 Injector, cylinder 3
T60b 60-pin connector, black, connector A, on engine control unit

15 Earth point, on cylinder head

G81 G247 1 1 1
221 Earth connection (engine earth), in engine wiring harness
ϑ
N30 N31 N32
1 2 1/-- 2/S 3/+5V 2 2 2

0,5
✱
0,5
✱
1,0
# F27 Connection (screening), in diesel direct injection wiring harness
gn ro/br gn/ge
✱✱ ✱✱ ✱ ✱ ✱ ✱ ✱ ✱ * phased from March 2005
0,35 0,35 0,5 0,5 0,5 1,0 1,0 1,0 1,0 1,0 1,0
gr/ws gr/ro br br/gr br/ge ro/ge br/ge ro/li br/li ro/bl br/bl ** no longer fitted, phased from March 2005
# phased-in modification
T60b T60b T60b T60b T60b T60b T60b T60b
/39 /10 /55 /40 T60b/54 /31 T60b/46 /32 T60b/47 /33 /48

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

J 623
T60b/15 T60b T60b T60b T60b T60b T60b permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
/31 /46 /32 /47 /33 /48 with respect to the correctness of information in this document. Copyright by AUDI AG.
F27

F27
1,5 ✱ ✱ 0,75 ✱ ✱ 0,75 ✱ ✱ 0,75 ✱ ✱
sw sw sw sw

✱✱ ✱✱ ✱✱ ✱✱ ✱✱ ✱✱
0,75 0,75 0,75 0,75 0,75 0,75
bl br/bl bl br/bl bl br/bl

1 1 1
0,75 ✱ ✱ 0,75 ✱ ✱ 0,75 ✱ ✱
sw sw sw

N30 2 N31 2 N32 2 ws = white

sw = black
ro = red
br = brown
1,5 ✱ ✱ 0,5 ✱ ✱ 0,5 ✱ ✱ 0,5 ✱ ✱
sw sw sw sw gn = green
221 bl = blue
gr = grey
15 li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
4E0-085071007
or = orange
rs = pink

Edition 04.2009
Audi A8 Current Flow Diagram No. 85 / 8
Engine control unit, injectors cylinder 4 up to 6
J623 Engine control unit
N33 Injector, cylinder 4
N83 Injector, cylinder 5
N84 Injector, cylinder 6
T60b 60-pin connector, black, connector A, on engine control unit

15 Earth point, on cylinder head

241 Earth connection 2 engine earth, in engine wiring harness

1 1 1
F27 Connection (screening), in diesel direct injection wiring harness

N33 N83 N84 * phased from March 2005

2 2 2
** no longer fitted, phased from March 2005

✱ ✱ ✱ ✱ ✱ ✱
1,0 1,0 1,0 1,0 1,0 1,0
ro/gn br/gn ro/gr br/gr ro/sw br/sw

T60b T60b T60b

J 623 /16 T60b/1 /17 T60b/2 /18 T60b/3

T60b T60b/1 T60b T60b/2 T60b T60b/3

/16 /17 /18
F27
✱✱ F27 ✱✱ ✱✱
0,75 0,75 0,75
sw sw sw

✱✱ ✱✱ ✱✱ ✱✱ ✱✱ ✱✱
0,75 0,75 0,75 0,75 0,75 0,75
bl br/bl bl br/bl bl br/bl

1 1 1
✱✱ ✱✱ ✱✱
0,75 0,75 0,75
sw sw swProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not

N33 2 N83 2 N
permitted unless
84 2authorised by AUDI AG. ws = does
AUDI AG whitenot guarantee or accept any liability
sw in
with respect to the correctness of information = this
black
document. Copyright by AUDI AG.
ro = red
✱✱ ✱✱ ✱✱ ✱✱ br = brown
1,5 0,5 0,5 0,5
sw sw sw sw gn = green
241 bl = blue
gr = grey
15 li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98
4E0-085080409
or = orange
rs = pink

Edition 04.2009
Audi A8 Current Flow Diagram No. 85 / 9
Engine control unit, Hall sender, air mass meter, engine
speed sender, coolant temperature sender, suppression
filter
C24 Suppression filter
G28 Engine speed sender
G40 Hall sender
G62 Coolant temperature sender
G70 Air mass meter
J217 Automatic gearbox control unit
J518 Entry and start authorisation control unit
J623 Engine control unit
G40 G62 G70 T3c 3-pin connector, grey, on engine speed sender
T16c 16-pin connector, black, on automatic gearbox control unit
ϑ
T17d 17-pin connector, blue, in electronics box in plenum chamber
1/5V 2/S 3/-- 1/-- 2/S 1/S 2/-- 3/+ T60b 60-pin connector, black, connector A, on engine control unit
T81b 81-pin connector, black, connector A, on entry and start
0,35 ✱ 0,35 ✱ 0,35 ✱ 0,5 ✱
gr/ro gr/li gr/br li authorisation control unit
✱✱ ✱✱ ✱✱ ✱✱
T94b 94-pin connector, black, connector B, on engine control unit
0,35 0,35 0,35 0,35 0,35 0,5 0,5 0,5
br/gn ge/sw ge/bl ws/ge gn/ge ws br bl
43 Earth point, lower part of right A-pillar
T60b T60b T60b 114
J 623 T60b
/27
T60b
/28 /29 /53 /52 T94b/74 T94b/81
377 Earth connection 12, in main wiring harness
T60b T60b T60b T60b T94b/17
/43 /58 /43 /58 P/N
B469 Connection 5 in main wiring harness
0,35
gn
D101 Connection 1, in engine compartment wiring harness

* phased from March 2005

0,35 # 0,35 # 0,35 # 0,35 # # 0,35 # # 0,35 # #
2
D101 ** no longer fitted, phased from March 2005
sw gn ge sw gn ge C24
# up to model year 2005
3,3μF
1
## from model year 2006, when replacing the gearbox, observe the
45 46
version of the drive plate
♦ up to October 2005
0,35 # 0,35 # # 0,5 0,5 ♦♦ from November 2005
sw sw gn gn

-- + -- + T16c
T3c/1 T3c/3 T3c/2 T3c/1 T3c/2 T3c/3
T17d/1 /10
J
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
217
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
0,5
♦ 0,5
♦ 0,5
♦
with respect to the correctness of information in this document. Copyright by AUDI AG.
gn gn br ws = white
G28 # G28 # # B469
377 sw = black
ro = red
♦♦ ♦
0,5 0,5 2,5 br = brown
gn gn br
gn = green
bl = blue
T81b/54
gr = grey
J 518 43 li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
4E0-085090906
or = orange
rs = pink

Edition 04.2009
Audi A8 Current Flow Diagram No. 85 / 10
Engine control unit, exhaust gas recirculation valve, kick-
down switch, accelerator position sender, fuses
E45 Cruise control system switch
F8 Kick-down switch
G79 Accelerator position sender
G185 Accelerator position sender 2
J338 Throttle valve module
J527 Steering column electronics control unit
12 39 F25 J623 Engine control unit
F25
N18 Exhaust gas recirculation valve
0,5 2,5 0,5 2,5 0,5
sw ro/sw ro/bl ro/bl ro/bl SC5 Fuse 5 on fuse holder C
SC6 Fuse 6 on fuse holder C
19 6 7 31 5 1 SC7 Fuse 7 on fuse holder C
SC19 SC6 SC7 SC31 SC5 34
SC19 Fuse 19 on fuse holder C
5A 15A 10A 20A 15A T by copyright. Copying
17a
Protected N18 for private or commercial purposes, in part orSC31 Fuse
in whole, 31 on fuse holder C
is not
19a 6a 7a 31a 5a /15 2
155
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept T16a any16-pin
liabilityconnector, on steering column electronics control unit
with respect to the correctness of information in this document. CopyrightT17a
by AUDI17-pin
AG. connector, black, in electronics box in plenum chamber
0,5 2,5 1,5 1,5 0,35 2,5 1,0 T17b 17-pin connector, green, in electronics box in plenum chamber
bl ro/sw ro/ws ro/bl ro/bl ro/bl br/bl T17c 17-pin connector, brown, in electronics box in plenum chamber
B148
T17d 17-pin connector, blue, in electronics box in plenum chamber
114 134 57
T17e 17-pin connector, red, in electronics box in plenum chamber
J 623 T60b/30 T60b 60-pin connector, black, connector A, on engine control unit
T94b 94-pin connector, black, connector B, on engine control unit
T94b/39 T94b T94b T94b T94b T94b T94b T94b T60b T60b T60b T60b T60b
/58 /80 /60 /57 /79 /82 /44 /42 /25 /6 /50 /49
388 Earth connection 23, in main wiring harness
114
GRA

0,35 0,5 0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,35 1,0 1,0
gr bl br/ws ge/ws ge/ro ge/gr br ge/br sw/ws ro/gn gn br br/bl ro/bl B148 Positive connection 3 (87), in interior wiring harness
#
# # # #
T17c F25 Connection 1, in diesel direct injection system wiring harness
/14 1 2 3 4 5
T17b T17c T17c T17c
/7 /7 /8 /6
* from November 2005
## ## ## ## # up to August 2007
T17d T17e T17b T17b T17b T17c T17c T17c T17c ## J 338 ✱
## from September 2007
/11 /6 /10 /11 /9 /4 /5 /3 /8

0,35 0,5 0,35 0,35 0,35 0,35 0,35 0,35 0,35

gr bl br/ws ge/ws ge/ro ge br ge/br sw/ws

111
1 6/S 5/-- 1/+ 4/S 3/-- 2/+ T16a/5
J 527
F8 E45
2 ws = white
G79 G185 sw = black
180 132 ro = red
br = brown
0,35 0,35 2,5
br br br gn = green
388
bl = blue
gr = grey
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
4E0-085101007
or = orange
rs = pink

Edition 04.2009
 Audi A8 Current Flow Diagram No. 85 / 11
Engine control unit, throttle valve module, intake manifold
flap motor, exhaust gas recirculation cooler change-over
valve, intake air temperature sender, charge air pressure
sender, lambda probe
G31 Charge air pressure sender
G39 Lambda probe
G42 Intake air temperature sender
J338 Throttle valve module
F25 F25 J623 Engine control unit
0,5
F25
0,5 0,5 0,5 N345 Exhaust gas recirculation cooler change-over valve
ro/bl ro/bl ro/bl ro/bl T6n 6-pin connector, brown, for Lambda probe
#
J 338 2/+ V157 2/+ V275 2/+ 1 T17b 17-pin connector, green, in electronics box in plenum chamber
T17e 17-pin connector, red, in electronics box in plenum chamber
N345 T60b 60-pin connector, black, connector A, on engine control unit
1/-- 4 3 1/-- 3 4 1/-- 3 4 2 T94b 94-pin connector, black, connector B, on engine control unit
IN OUT IN OUT
V157 Intake manifold flap motor
1,0 0,5 0,5
ro/ws ws ge V275 Intake manifold flap 2 motor
Z19 Lambda probe heater
0,5 0,5 1,0 0,5 1,0 ✱ ✱✱ 0,5 ✱✱✱ 0,5 0,5 ✱✱✱ 0,5 0,5
br ws gn/ge br ro/gr ro/br br bl sw li/gn
44 Earth point, lower part of left A-pillar
47 T60b 48 T60b 50 T60b
/25 T60b/60 /19 T94b/31 /36 T94b/88 T94b/70

375 Earth connection 10, in main wiring harness

T60b/7 T60b
/56
T60b
/26
T60b/41 J 623 T94b T94b T94b T94b
/10
T94b
/51 /32 /54 /11
F25 Connection 1, in diesel direct injection system wiring harness
✱ ✱ ✱
0,5 0,5 0,5 0,5 1,0 1,0 0,35 0,35 0,35 0,35
li/gn br ro/br ge/gn ro/sw br/ws gn/li gn/bl br ws * phased from March 2005
** no longer fitted, phased from March 2005
✱✱✱ ✱✱✱ ✱ ✱✱ ✱ ✱✱
0,35 0,35 0,35 0,35 ** phased-in modification
## gn/ro gn/ge br/bl ge # up to October 2005
T17b ## up to August 2007
/16
### from September 2007
T17e T6n/4 T6n/3 T6n/1 T6n/5 T6n/2 T6n/6
117 /16
✱✱ ✱✱ ✱✱
## #
0,5 0,5 0,5 2,5 2,5
gn/ws ro gr br ro/swby copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
116
2 1/-- 3/+5V 4/S
375

ws = white
G31 Z19 G39
sw = black
G42
ro = red
6,0 br = brown
br
gn = green
bl = blue
gr = grey
44 li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
4E0-085110408
or = orange
rs = pink

Edition 04.2009
 Audi A8 Current Flow Diagram No. 85 / 12
Engine control unit, turbocharger 1 control unit, exhaust
temperature sender, electro-hydraulic engine mounting
solenoid valve, gearbox mounting valve, temperature
sender before particulate filter, exhaust gas pressure
sensor 1
G235 Exhaust gas temperature sender 1
G448 Bank 1 exhaust gas temperature sender 2
G450 Exhaust gas pressure sensor 1
F25
G506 Temperature sender before particulate filter
0,5 F25 0,5 0,5 0,5 0,5 J623 Engine control unit
ro/bl ro/bl ro/bl ro/bl ro/bl
J724 Turbocharger 1 control unit
J 724 2/+ 2 2 2 2 N144 Left electrohydraulic engine mounting solenoid valve
N145 Right electrohydraulic engine mounting solenoid valve
N144 N145 N262 N263 N262 Gearbox mounting valve 1
1/-- 3 4 1 1 1 1
N263 Gearbox mounting valve 2
IN OUT
T60b 60-pin connector, black, connector A, on engine control unit
1,0 # 0,5 #
ws/ge ws/bl T94b 94-pin connector, black, connector B, on engine control unit
0,5 1,0 0,5 0,5 1,0
br 1,0 0,5 ro/ge ro/ge ro/ws ro/ws
br/ws gr 131 Earth connection 2, in engine compartment wiring harness
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
51 T60b
/20 T94b/85 T60b/45 T94b/48 T60b/44 with T94b/29
J 623
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by AUDI AG.
D102 Connection 2, in engine compartment wiring harness

T94b/76 T94b/78 T94b/55 T94b/56 T94b T94b T94b/20

/19 /22 F25 Connection 1, in diesel direct injection system wiring harness

0,5 0,35 ✱ 0,5 ✱ 0,5 ✱ * phased from March 2005

br ge ro/ge ge ** no longer fitted, phased from March 2005
*** with particulate filter
D102 # phased-in modification

0,35 0,35 0,35 0,35 ✱ ✱ 0,35 0,35 0,5 ✱ ✱ 0,5 0,5 ✱ ✱

gn br br ro br bl gr br sw

2 1 1 2 1 2 1/+5V 2/-- 3/S

ϑ ϑ ϑ

ws = white
G235 G506 ✱ ✱ ✱ G448 ✱ ✱ ✱ G450 ✱ ✱ ✱ sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 153 154
or = orange
4E0-085121007
rs = pink

Edition 04.2009
Audi A8 Current Flow Diagram No. 85 / 13
Engine control unit, brake light switch, air filter bypass flap
valve
F Brake light switch
F47 Brake pedal switch
J104 ABS control unit
J393 Convenience system central control unit
J518 Entry and start authorisation control unit
J623 Engine control unit
17 41 N275 Air filter bypass flap valve
6,0 1,0 ✱ 0,5 ✱ ✱ B467 1,0 SB12 Fuse 12 on fuse holder B
ro ro/sw sw/gn sw/gn SB22 Fuse 22 on fuse holder B
SB38 Fuse 38 on fuse holder B
38 12 22 T6r/3 T6r 6-pin connector, black, connector B, on entry and start
SB 38 SB 12 SB 22 J 518 authorisation control unit
30A 5A 5A
T17b 17-pin connector, green, in electronics box in plenum chamber
38a 12a 22a
T17c 17-pin connector, brown, in electronics box in plenum chamber
T17e 17-pin connector, red, in electronics box in plenum chamber
0,5
✱
0,5
✱
0,5
✱✱ T32b 32-pin connector, connector B, on convenience system central
ro/ws sw/ws sw/ws control unit
T81b 81-pin connector, black, connector A, on entry and start
160 161 165 authorisation control unit
J 623 T94b 94-pin connector, black, connector B, on engine control unit

44 Earth point, lower part of left A-pillar

T94b/71 T94b/87 T94b/65
163 164 165

✱ ✱ 366 Earth connection 1, in main wiring harness

0,5 0,35 0,5 0,5 0,35 0,5 ✱ ✱ 0,35 ✱ ✱
bl/gn ro/sw ro/ws sw/ws ro/br sw/ws br

369 Earth connection 4, in main wiring harness

1 3 4 1

T17b/2 ✱ T17c/10 T17c/9 F F47 369 B467 Connection 3 in main wiring harness
F F47
4 2 2 3
T17e/2 ✱✱
B335 Connection 1 (54), in main wiring harness
✱ ✱
0,35 0,35 1,0 0,5 0,35 0,35 ✱ ✱ 0,35 ✱ ✱ 2,5
bl/gn ro/sw ro/sw ro/br ro/br ro/br ro/sw br
B336 B336 Connection 2 (54), in main wiring harness
B335 366
2 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not * up to August 2007
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ** from September 2007
✱✱✱ *** countries with cold climate only
N275 with respect to the correctness of information in this document. Copyright by AUDI AG.
ws = white
1
sw = black
ro = red
0,35 0,35 0,35 0,35 0,35 6,0 br = brown
ro/bl ro/sw ro/sw ro/sw ro/br br
gn = green
T32b T81b 32 37
bl = blue
121
/20 /34 gr = grey
J 393 J518 J 104 J 104 44 li = purple
ge = yellow
155 156 157 158 159 160 161 162 163 164 165 166 167 168
4E0-085131007
or = orange
rs = pink

Edition 04.2009
Audi A8 Current Flow Diagram No. 85 / 14
Engine control unit, radiator fan, high-pressure sender
G65 High pressure sender
J255 Climatronic control unit
J623 Engine control unit
SC9 Fuse 9 on fuse holder C
SC17 Fuse 17 on fuse holder C
T17a 17-pin connector, black, in electronics box in plenum chamber
T17b 17-pin connector, green, in electronics box in plenum chamber
T94b 94-pin connector, black, connector B, on engine control unit
38 27
V7 Radiator fan
0,5 1,0 V177 Radiator fan 2
ro/sw sw

17 9 43 Earth point, lower part of right A-pillar

SC17 SC9
5A 5A
17a 9a B279 Positive connection 3 (15a), in main wiring harness

* up to August 2007
0,5 0,5 ** from September 2007
ro/ge ro/ge

170 174
J 623

T94b/73 T94b/50 T94b/52

1,0 0,5 0,5 1,0

bl/ge bl/li br/gn sw/bl

0,5
bl/ge
T17a/14 ✱
B279

T17a/13 T17b/12 ✱ ✱ T17a/9 J 255

C8
17 170 19 171

6,0 0,5 0,5 6,0 0,5 0,5 0,5 0,35 0,35

ro/sw ro/ge bl/ge ro/ws ro/ge bl/li br/gn sw/bl gr/ro

184
1/B+ 2 3 1/B+ 2 3 3 2

M M
V7 V177 G65
4/31 4/31 1/31 ws = white
sw = black
ro = red
6,0 6,0 0,35 br = brown
br br br Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
gn = green permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
115
bl = blue with respect to the correctness of information in this document. Copyright by AUDI AG.
gr = grey
43 43 li = purple
ge = yellow
169 170 171 172 173 174 175 176 177 178 179 180 181 182
4E0-085141007
or = orange
rs = pink

Edition 04.2009
Audi A8 Current Flow Diagram No. 85 / 15
Control unit in dash panel insert, fuel pump relay
G Fuel gauge sender
G6 Fuel system pressurisation pump
G237 Fuel gauge sender 3
J17 Fuel pump relay
J285 Control unit in dash panel insert
SF2 Fuse 2 on fuse holder F
T4a 4-pin connector, under right cover on vehicle floor
T6e 6-pin connector, under right cover on vehicle floor
T32 32-pin connector, blue, on dash panel insert
Y24 Display in dash panel insert
8

361 Earth connection (fuel gauge sender), in main wiring harness

10,0
ro

390 Earth connection 25, in main wiring harness

B299
177

0,5 4,0 2,5 675 Earth point 2, on right in luggage compartment

br/gn ro ro/sw

✱✱
4/86 2/30 ✱ ✱ B299 Positive connection 3 (30), in main wiring harness
# 3/86 ✱ 1/30 ✱ 2
3 SF2 Y24 J 285 * up to August 2007
J 17 20A ** from September 2007
4/85 ✱ 2/87 ✱ 2a
6/85 8/87 ✱ ✱ # Relay and fuse carrier right in luggage compartment
✱✱

0,5 2,5 T32/27 T32/25

ro/sw ro/sw
2,5 0,35 0,35
sw/ws gr/bl gr/ws
42 202

T4a/1 T6e/4 T6e/1

2,5 0,35 0,35

sw/ws gr/bl gr/ws

A1/+ B2 A2

M G6 G237
202
G
A4/-- B4 A3 ws = white
4,0 2,5 2,5Protected by copyright.
0,35 sw = black
Copying0,35
for private or commercial purposes, in part or in whole, is not
br br br br/bl
permitted unless authorised by
br/bl
AUDI AG. AUDI AG does not
ro or =accept
guarantee
redany liability
361
br
with respect to the correctness of information in this document. Copyright= bybrown
AUDI AG.
T4a/3 361
gn = green
2,5
bl = blue
390 br gr = grey
675 li = purple
ge = yellow
183 184 185 186 187 188 189 190 191 192 193 194 195 196
or = orange
4E0-085151007
rs = pink

Edition 04.2009
Audi A8 Current Flow Diagram No. 85 / 16
Control unit in dash panel insert, fuel gauge, fuel pump, fuel
gauge sender, oil pressure warning lamp, oil pressure
switch
F1 Oil pressure switch
G1 Fuel gauge
G23 Fuel pump
G169 Fuel gauge sender 2
G393 Fuel gauge sender 4
185 J285 Control unit in dash panel insert
2,5
K3 Oil pressure warning lamp
ro/sw SF1 Fuse 1 on fuse holder F
T4a 4-pin connector, under right cover on vehicle floor
1
T6e 6-pin connector, under right cover on vehicle floor
SF1 T17a 17-pin connector, black, in electronics box in plenum chamber
20A
1a T32 32-pin connector, blue, on dash panel insert
Y24 Display in dash panel insert
2,5
sw/ge
361 Earth connection (fuel gauge sender), in main wiring harness
202

G1 Y24 J 285 K3

T32/22 T32/23 T32/26 T32/15

Protected by copyright. Copying202for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
0,35 0,35 0,35to the correctness
with respect 2,5 of information in this document.
0,35
Copyright by AUDI AG.
br/bl gr/ge gr/li sw/ge gr/sw

T6e/5 T6e/3 T6e/2 T4a/2 T17a/1

1,0 0,35 0,35 2,5 0,5

br/bl gr/ge gr/li sw/ge gr/sw

A2 B2 A1/+ 1

G393 G169 G 23 M
F1 ws = white
A3 B4 A4/--
0,35 0,35 2,5 sw = black
br/bl br/bl br ro = red
361 br = brown
361 T4a/4 gn = green
2,5 bl = blue
br
gr = grey
186 li = purple
ge = yellow
197 198 199 200 201 202 203 204 205 206 207 208 209 210
97-85469
or = orange
rs = pink

Edition 04.2009
Audi A8 Current Flow Diagram No. 85 / 17
Control unit in dash panel insert, coolant shortage indicator
switch, oil level and oil temperature sender
F66 Coolant shortage indicator switch
G266 Oil level and oil temperature sender
J285 Control unit in dash panel insert
K28 Coolant temperature and coolant shortage warning lamp
SB8 Fuse 8 on fuse holder B
T16 16-pin connector, black, diagnosic connetion
25 T17a 17-pin connector, black, in electronics box in plenum chamber
T17d 17-pin connector, blue, in electronics box in plenum chamber
0,5
sw T32 32-pin connector, blue, on dash panel insert
Y24 Display in dash panel insert
8

SB 8 401 Earth connection (sender earth), in interior wiring harness

5A
8a * output sender earth
# up to August 2007
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ## from September 2007
permitted unless authorised by AUDI AG. AUDI AG does0,5not guarantee or accept any liability
sw/bl
with respect to the correctness of information in this document. Copyright by AUDI AG.
15
T 16/1

K 28 Y24 J 285

T32/28 T32/21 T32/8

✱

0,35 0,35 0,35 0,5

br/gr gn/ge bl/gr sw/bl

T17a/2 T17d/14 #
T17d/8 ##
0,5 0,5
bl/gr sw/bl

3 3 1

F66 G266 ws = white

1 2/31
sw = black
ro = red
0,35 0,5 br = brown
br/gr br
gn = green
401 bl = blue
53
gr = grey
li = purple
ge = yellow
211 212 213 214 215 216 217 218 219 220 221 222 223 224
or = orange
4E0-085171007
rs = pink

Edition 04.2009