INDEX 1

WARNING

Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Audi, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.

A

ABSsee Antilock brakes (ABS)

Acceleration sensorsABS 45-6

Accelerator pedal assembly20-28

Accessory belt 03-36

Air-conditioning (A/C)air distribution 87-7blower motor 87-12capacities 87-4components 87-9compressor 87-13controls and power supply 87-5dust and pollen filter 03-59evaporator housing 87-14flap motors 87-7refrigerant and refrigerant oil 87-4repairs 87-12troubleshooting 87-2

Air filter03-46

Airbags02-19, 03-58, 69-10

Alignment44-5

Alternator (generator)belt 03-36removing and installing 27-10, 27-13, 27-15, 27-17

Aluminumbody panels 55-1

Antenna91-3

Antifreeze03-27, 19-5

Antilock brakes (ABS)02-16, 45-1components

Bosch 5.7 45-6Bosch 8.0 45-9

diagnosis 45-4impulse wheel

front 45-12rear (FWD) 45-13rear (quattro) 45-16

wheel speed sensors 45-11

Anti-theft 96-29

A-pillarconnector

left 97-12right 97-11

trim 70-23

Arm rest70-15

Ashtrayfront 70-16

Automatic transmission 02-12ATF 37-3codes 37-1CVT ATF 37-5identification 03-8selector mechanism 37-15shift lock 37-16see also Continuously variable transmission (CVT)

B

Back-up lightsmanual transmission 34-15

Balance shaft02-8, 17-9

Battery27-3service 03-33

Beltaccessory 03-36timing 03-41, 13-2, 13-10, 13-17

Bi-xenon94-4, 94-10, 94-17, 94-19, 94-21, 94-25, 94-28

Bleeding brakes03-30

Blower motor87-12

Bodyaluminum panels 55-1Cabriolet AppendixA-2dimensions 02-4front fender 50-4grill 55-6overview 02-18wheel housing liner 66-1see also Trim

B-pillar trim70-25

Brake booster vacuum pump15-17

Brake fluid47-1bleeding 03-30level 03-29

Brake light switch46-21

Brakes02-16antilock 45-1bleeding 03-30booster 47-3

vacuum pressure sensor 47-8vacuum pump 47-7

caliper front 46-3, 46-6, 46-9rear 46-15, 46-17

inspection 03-51master cylinder 47-3pads and discs

checking 03-51parking brake 46-20specifications

front 46-1rear 46-2

troubleshooting 47-1vacuum pump 47-7see also Antilock brakes (ABS)see also Brake fluid

Bulbsexterior

see Headlight component and Taillight component diagrams in 95 Exterior Lights

Bumpersfront 63-1rear 63-7

Bus systems02-22, 9-2

C

Caliperfront 46-3, 46-6, 46-9rear 46-15, 46-17

Camshaft sensor 28-7, 28-12

A408_index.fm Page 1 Wednesday, October 13, 2010 9:38 AM

2 INDEX

CAN-bus02-22, 9-2

Catalytic converter26-3

CD changer91-3

Center brake light94-40

Center console70-11switches 96-21

Central lockingservice notes 57-7

Chain, timing 02-11

Child seat anchor69-1

Climate controlsee Air-conditioning (A/C)

Clutchbleeding 30-4components

5-speed 30-166-speed 30-18

hydraulics 30-2repairs 30-16self-adjusting (SAC) 30-21

Coilsee Ignition coil

Coil springfront 40-3rear 42-3

Component locations (electrical)97-3

Compression test15-2

Compressorsee Air-conditioning (A/C)

Console, center70-11

Constant velocity (CV) joint see CV joint

Continuity9-5

Continuously variable transmission (CVT)

02-13ATF

capacity 37-2level 37-5

Convertible top61-3, AppendixA-12component locations AppendixB-4emergency release AppendixB-3electrical system 61-5, AppendixA-56hydraulic system 61-11, AppendixA-30

Coolantsee Engine cooling system

Coolant pumpremoving and installing 19-7, 19-11, 19-23, 19-32

Cooling systemsee Engine cooling system

C-pillar trim70-27

Crankshaft pulley 13-4, 13-6, 13-19

Cruise control27-1stalk switch 96-16

Curb weight position40-1

CV joint boot checking 03- 52front 40-17rear 45-15

CVT02-13ATF

capacity 37-2level 37-5

Cylinder head15-4, 15-8, 15-13, 15-15

Cylinder head cover15-5, 15-10

Cylinder leak-down test15-3

D

Dashboard02-24air outlets 87-7driver storage compartment 70-9end trim 70-7

Data link connector (DLC)24-2, OBD-1

Diagnostic trouble code (DTC)access OBD-1P-codes OBD-2

Differentialoil 39-2

Dimensions02-4

Disc brakessee Brakes

DLC24-2, OBD-1

Dome light96-5

Doorcheck strap and hinge lubrication 03-59

component carrier 57-6courtesy light 96-8front 57-1handle 57-8rear 57-2trim 70-17

Door lock57-7

Door panel70-17

Door windowsee Window

D-pillar trim70-18

Drive axleboot

checking 03-52front 40-17rear 42-7

Drive belt03-36

Driver information display90-1

DTC access OBD-1P-codes OBD-2

Dust and pollen filter03-59

E

E-box (electronics box)97-11

ECM (engine control module) 24-5

EDL (electronic differential lock)45-2

Electrical systemA-pillar connector stations

left 97-12right 97-111

component locations 97-3fuses 97-11grounds 97-36troubleshooting 9-3wiring diagrams EWD-8

A408_index.fm Page 2 Wednesday, October 13, 2010 9:38 AM

INDEX 3

WARNING

Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Audi, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.

Electrolyte03-33, 27-5

Electronic braking control (EBC)45-2

Electronic differential lock (EDL)45-2

Electronic immobilizer96-29

Electronic stabilization program (ESP)

02-16, 45-2

Electronic power control (EPC) 02-11, 20-37

Electronics box (E-box)97-11

Emergency flasher switch96-21

Emergency convertible top AppendixVB-3sunroof closing 60-3

Engine02-5accessory belt 03-36applications table 02-5balance shaft 02-11compartment 03-16covers 03-18identification 03-6fluid leaks 03-20speed sensor 28-5, 28-11technical data 02-5timing belt 03-41

Engine control module (ECM) 24-5, 26-3

Engine coolant temperature (ECT) sensor

24-4, 24-5, 24-7, 24-8

Engine cooling systemantifreeze concentration 03-27,19-5bleeding 19-6, 19-9, 19-19, 19-29capacities 03-27, 19-1coolant level 03-27coolant pump 19-7, 19-11, 19-23,19-32

draining, filling 19-6, 19-9, 19-19, 19-29

hoses, inspecting 03-29pressure testing 19-4thermostat 19-4, 19-16, 19-28, 19-38radiator 19-8, 19-12, 19-24, 19-34troubleshooting 19-3

Engine lubrication components

see Lubrication system diagrams in 17 Engine–Lubrication System

oil service 03-20

Engine management02-5applications 24-2components

see Engine compartment diagrams in 24 Fuel Injection

diagnostics 24-2electronic throttle control (EPC) 20-37engine control module (ECM) 24-5engine coolant temperature (ECT) sensorsee Engine compartment diagrams in 24 Fuel Injection

evaporative control (EVAP) 20-34ME7.1.1 02-10ME7.5 02-6MED 9.1 02-7Motronic 24-1secondary air injection 26-36Siemens 02-11see also Ignition system

EPC (electronic power control)02-11, 20-27

ESP (electronic stabilization program)02-16, 45-2

Evaporative control (EVAP)20-34

Evaporatorsee Air-conditioning (A/C)

Exhaust manifold21-10

Exhaust systeminstallation details 26-8, 26-12, 26-19, 26-29

see also Exhaust system diagrams in 26 Exhaust System

F

Fender, front50-4

Final driveoil 39-2

Filterair 03-46dust and pollen 03-59fuel 03-54oil 03-22

Fluid leakengine compartment 03-20

Flywheel30-16, 30-18

Foglight94-30

Footwell light96-9

Front suspension02-14codes 44-2coil spring 40-3control arms 40-5curb weight position 40-1stabilizer bar 40-16strut assembly 40-11wheel bearing 40-11

Fuel filter03-54, 20-32

Fuel flaplock 57-11, 96-27

Fuel injectionsee Engine management

Fuel injector24-4, 24-10,

Fuel level sender20-2

Fuel pressure20-21relieving system pressure 20-5residual pressure 20-24

Fuel pump20-2, 20-4high pressure 20-31power supply 20-7testing 20-4wiring 20-16

Fuel systemcomponents 20-27diagnostics 20-3delivery 20-17evaporative emissions control 20-34see also Engine management

A408_index.fm Page 3 Wednesday, October 13, 2010 9:38 AM

4 INDEX

Fuel tank20-27capacities 20-1filler flap lock 57-11, 96-27filler neck 20-30

Fuses97-11

G

Gear selectorautomatic transmission 37-15manual transmission 34-9

Generatorsee Alternator (generator)

Glasssee Window

Glove compartment70-8light 96-7

Grill55-6

Grounds97-36

H

Hand brakesee Parking brake

Headlight94-3, 94-21adjusting 03-60automatic headlight beam adjustment 94-2

suspension level sensor 40-19, 42-9switch 96-20washer 92-10xenon 94-4, 94-9, 94-15, 94-19, 94-21, 94-25, 94-28

see also Lights, exterior

Heating and ventilationdust and pollen filter 03-59heater core 87-17see also Air-conditioning (A/C)

HFC (hydraulic fading compensation)02-16

HID headlightsee Xenon headlight

High intensity headlightsee Xenon headlight

Hoodengine hood 55-2

Horn96-28

Hydraulic fading compensation (HFC)02-16

I

Ignition coil28-19

Ignition shift lock37-16

Ignition switchelectrical 96-19key cylinder 96-18

Ignition system28-2coil 28-19disabling 28-2firing order 28-2knock sensor 28-2, 28-7, 28-11

Immobilizer96-29

Instrument cluster02-24, 90-1diagnostics 90-2removing and installing 90-3

Intake manifold15-5, 15-12, 24-23see also Engine management diagrams in 24 Fuel Injection

Intercooler21-19, 21-20

Interior lightssee Lights, interior

J

Jacking vehicle03-13

K

Knock sensor28-2, 28-7, 28-11

L

Leak detection 20-34

License plate light94-42

Lid, trunk55-7

Lifting vehicle03-13

Lights, exteriorfoglights 94-30switch 96-20taillights 94-32, 94-35see also Headlightsee also Turn signal

Lights, interior96-2dome 96-5

Lock carrier, frontservice position 50-2

M

Maintenanceaccessory belt 03-36air filter 03-46ATF 03-58, 37-3battery 03-33, 27-3body and interior 03-58brake fluid 03-29brake system 03-52cooling 03-26CV joint boot 03-52diagnostic trouble codes (DTCs) access 03-64

dust and pollen filter 03-59engine covers 03-18engine oil 03-20exhaust system 03-53fuel filter 03-54headlight adjustment 03-60parking brake 46-20schedules 03-66spark plugs 03-42timing belt 03-41, 13-2, 13-10, 13-7tires and wheels 03-54transmission fluid 03-58

automatic 37-3manual 34-5

underbody sealant 03-58under car maintenance 03-58windshield wipers and washers 03-62

Manual transmission02-12gear selector 34-9identification 03-8oil 34-5removing and installing 34-16specifications 34-2

Master cylinderbrakes 47-3clutch 30-5

MCB (Multicommunication bar)91-2

Mirrorinterior 70-2outside 66-3switch 96-23

A408_index.fm Page 4 Wednesday, October 13, 2010 9:38 AM

INDEX 5

WARNING

Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Audi, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.

Motronicsee Engine management

Mufflersee Exhaust system diagrams in 26 Exhaust System

Multicommunication bar (MCB)91-2

Multifunction steering wheel91-7

Multitronic® transmission (CVT)02-13ATF

capacity 37-2level 37-3

identification 03-8

N

Navigation91-5

O

OBD IIOBD-1

Oil03-20capacities 17-1pan 17-5, 17-8, 17-13, 17-15pressure switch 17-3specifications 17-1see also Engine lubrication

Oil filter03-22

On-board diagnosticsOBD-1

Oxygen sensorsee Exhaust system diagrams in 26 Exhaust System

see also Fuel injection system components in 24 Fuel Injection–Gasoline

P

Parking brake46-20

P-codeOBD-2

Pollen filter03-59

Power steeringsee Steering

Power windowsee Window

R

Radiator 19-8, 19-12, 19-24, 19-34

Radiator grill55-6

Radio91-3removing and installing 91-4see also Sound systems

Raising vehicle03-13

Rear shelf70-29

Rear suspension02-15codes 44-2coil spring 42-3curb weight position 42-1overview 42-3shock absorber 42-4stabilizer bar 42-5

Rear window defoggercontrol 87-5

Refrigerantsee Air-conditioning (A/C)

Ribbed beltsee Accessory belt

Rollover protectionAppendixB-17

rpm sensor28-5, 28-11

S

SAC (self-adjusting clutch)30-21

Safetypassenger 02-19working under car 03-16

Scan toolOBD-2suppliers OBD-34

Seat belt69-5

Seatsfront 72-1memory 72-6rear 72-7

side padding 72-15switch 72-7

Secondary air injection system26-36

Self-adjusting clutch (SAC)30-21

Service positionlock carrier 50-2

Service reminder indicator 03-65

Shift lockautomatic transmission 37-16

Shock absorber42-4

Short circuit9-5

Slave cylinder, clutch30-12

Sound absorber panels03-18

Sound systemcomponents 91-3see also Radio

Spark plugs03-42

Speakersee Sound system diagrams in 91 Radio and Communication

Special tools suppliers03-4

Spiral spring 48-4, 96-13

Stabilizer barfront 40-16rear 42-5

A408_index.fm Page 5 Wednesday, October 13, 2010 9:38 AM

6 INDEX

Starter27-20removing and installing 27-20, 27-21, 27-23, 27-24

Steeringangle sensor 45-3, 96-14column 48-3column switches ignition 96-19column trim 48-4, 70-7fluid 48-1interlock 48-8lock 48-8pump 48-20rack 48-9wheel 48-4

Strut front 40-11

Sunroof60-1

Suspension02-14checking 03-53curb weight position 40-1, 42-1see also Front suspensionsee also Rear suspension

Switchesdashboard 96-21exterior lights 96-20ignition and steering lock 96-19mirror 96-23steering column switch module 96-12window 96-24

T

Tailgate55-11lock 55-16, 57-12trim 70-32

Taillight94-32, 94-35

Telematics91-7

Telephone91-5

Thermostat19-4, 19-16, 19-28, 19-38

Throttle control20-37

Tie-rod48-18

Timing belt03-41, 13-2, 13-10, 13-17

Timing chain (camshaft drive chain)02-11

Tiptronic02-12

Tires44-1pressure monitoring system 44-3

Toothed beltsee Timing belt

Towing03-11

Transfer case oil 39-5

Transmissionidentification 03-8oil 03-58see also Automatic transmissionsee also Manual transmission

Trimdashboard end 70-3door 70-17driver storage compartment 70-9pillar and side trim 70-23steering column trim 70-7tailgate trim 70-32trunk trim 70-30, 70-36

Trunk lid 55-7light 96-10lock 55-11, 57-11trim 70-30, 70-36

Turbocharger21-3, 21-10hoses 21-2, 21-5, 21-11

Turn signalfront 94-15, 94-26switch 96-16

V

Vacuum pressure sensor 47-8

Vacuum pumpbrake booster 15-17, 47-7

Vehicle identification number (VIN)01-1, 03-5

Vehicle level sensor 40-19, 42-9

Ventilationdust and pollen filter 03-59see also Air conditioning (A/C)see also Heating and ventilation

Vibration damper13-4, 13-6, 13-19

Voltage9-4

W

Washers92-10fluid 03-63headlight 92-14

Water pumpremoving and installing 19-7, 19-11, 19-23, 19-32

Wheel alignment44-5

Wheel bearing40-11

Wheel housing liner66-1

Wheel speed sensor45-11

Wheels03-54, 44-1alignment 44-5

Windowglass service 64-2motor reinitializing 64-1motor service 64-6switch 96-24

Wipersarms and blades 92-2blades 03-62repairs 92-2, 92-6, 92-9

Wiring diagrams EWD-8symbols EWD-7

Working under vehicle safely03-16

X

Xenon headlight94-4, 94-9, 94-15, 94-19, 94-21,94-25, 94-28

see also Headlight

A408_index.fm Page 6 Wednesday, October 13, 2010 9:38 AM

established 1950Automotive Reference™

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USATel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235http://www.bentleypublishers.com/contact-sales

Audi A4 (B6, B7)Service Manual: 2002-2008 1.8L turbo, 2.0L turbo, 3.0L, 3.2L including Avant and Cabriolet

Price: $149.95Bentley Stock Number: A408Publication Date: 2010.dec.20ISBN: 978-0-8376-1574-5Hardcover, 8 3/8 in. x 11 in.Case quantity: 11430 pages, 2610 photos, illustrations and diagrams

The Audi A4 Service Manual: 2002-2008 contains in-depth maintenance, service and repair information for Audi A4 models from 2002 to 2008 built on the B6 or B7 platforms. Service to Audi owners is of top priority to Audi and has always included the continuing development and introduction of new and expanded services. Whether you’re a professional or a do-it-yourself Audi owner, this manual will help you understand, care for and repair your Audi.

Technical features:• Covers Audi A4 Sedan, A4 Avant (station wagon) and A4 Cabriolet

models including quattro versions. (Does not cover S4 or RS4 sport models.)

• Audi A4 product familiarization section in full color, highlighting technical features, year-to-year changes and application information.

• Maintenance procedures from routine oil changes to brake pad and rotor inspection and replacement.

• Engine and cylinder head service, including timing belt and brake booster vacuum pump replacement.

• Component testing, removal and installation for engine lubrication, cooling, turbocharger and exhaust systems.

• Fuel supply system service, including fuel pump delivery volume test, EVAP system component locations and electronic power control (EPC).

• Fuel injection and ignition system component identification and technical data, including intake manifold removal and installation.

• Drivetrain maintenance, troubleshooting, adjustment and repair, including hydraulic clutch, gearshift linkage and axles.

• Repair information for ABS brake systems.• Suspension component replacement, including struts, stabilizer bar,

multi-link elements and wheel bearings.• Body adjustment and repairs, including doors, fenders, front

radiator support, dashboard, sunroof and seats.• Heating and air-conditioning repair, including A/C component

replacement such as evaporator housing.• Includes factory wiring diagrams, component locations and a

general explanation of electrical circuitry.• Audi OBD II diagnostic trouble code section, including SAE and

manufacturer defined P-codes.

Engines covered:1.8L turbo gasoline (engine code: AMB)2.0L turbo FSI gasoline (engine codes: BGP, BWT)3.0L gasoline (engine codes: AVK, BGN)3.2L gasoline (engine codes: BKH)

Transmissions covered:5-speed Manual (transmission codes: 012, 01W, 01A)6-speed Manual (transmission codes: 01E, 01X, 02X)5-speed Automatic (transmission code: 01V)6-speed Automatic (transmission code: 09L)CVT (transmission code: 01J)

BentleyPublishers.com

Preventative maintenance procedures, including brake system inspection and service03 Maintenance

bentley_a408_new.product.announcement.pdf

Wiring diagrams and component locationsEWD Electrical Wiring Diagrams

Technical model introduction information in full color02 Product Familiarization