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ELECTRICAL Electrical Equipment <meta name="InColGX" content=""> </head> <body bgcolor="white" text="black"> <h1>ELECTRICAL</h1> <h1>Electrical Equipment</h1><a name="S42401837392008020700000"></a><h2 class="clsHeadOne">27 Battery, Starter, Generator, Cruise Control</h2><a name="S12424283282008020700000"></a><h2 class="clsHeadTwo">Battery</h2><a name="S33952750452008020700000"></a><h2 class="clsHeadThree">General information</h2> <p>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.</p> <p>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.</p> <p>The automobile battery has undergone many technical changes and improvements, and development of new battery technologies continues.</p> <p>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).</p> <p>Several different types of battery may be installed. Each requires specific servicing.</p><a name="S01912186762008020700000"></a><h2 class="clsHeadThree">Warnings and safety measures for lead-acid batteries</h2> <p>When servicing batteries, Technicians must be aware of, and observe the warnings and safety measures specified in this information.</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017008" name="S34290518092008020700000">Fig. 1: Warning Symbols On Batteries</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Explanation of WARNING symbols on batteries</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>1 - Read and follow all instructions on battery, contained in Repair Information, Electrical Equipment, and in Owners Manual!<p>2 - Battery acid can cause severe burns!</p> <ul class="clsBULLET"> <li>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.</li> <li>Never tip a battery on edge. Electrolyte can spill from the ventilation openings.</li> </ul> <p>3 - Keep open flames and sparks away and DO NOT smoke near batteries! .</p> <ul class="clsBULLET"> <li>Avoid sparks when working with cables and electrical units.</li> <li>Always reinstall battery positive (B+) or negative ( - ) terminal covers if removed during servicing</li> </ul> <p>4 - Always wear eye protection when working with electrolyte!</p> <ul class="clsBULLET"> <li>If electrolyte gets into eyes, flush with large quantities of water. Seek medical attention immediately!</li> </ul> <p>5 - Keep children away from batteries!</p> <p>6 - Dispose of batteries properly!</p> <ul class="clsBULLET"> <li>Waste batteries must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to battery disposal.</li> </ul> <p>7 - Never dispose of batteries in household waste! Batteries contain lead (Pb), which is toxic.</p> <p>8 - Danger of explosion!</p> <ul class="clsBULLET"> <li>Batteries produce explosive gasses while being charged.</li> <li>Keep open flames and sparks away and DO NOT smoke near batteries.</li> <li>The battery charger MUST be turned off when connecting or disconnecting the cables at the battery.</li> <li>Battery cell caps must NOT be removed while charging.</li> </ul> <ul class="clsBULLET"> <li>Ensure that battery is charged in a well ventilated area.</li> <li>Avoid short circuits. Always reinstall battery positive (B+) or negative ( - ) terminal covers if removed during servicing.</li> </ul> </td> </tr> </table></span></p><a name="S09860850652008040900000"></a><h2 class="clsHeadFour">Smoking, naked flames, fires and sparks:</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Smoking, naked flames and fires are prohibited whilst working; flying sparks must be avoided.</li> <li>Avoid short circuits and sparks when handling cables and electrical equipment.</li> </ul> </td> </tr> </table></span></p><a name="S08608371212008040900000"></a><h2 class="clsHeadFour">Electrolyte:</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Can cause severe injury to the eyes, skin and mucous membranes.</li> <li>Inhalation can damage the respiratory system.</li> <li>Swallowing is harmful to the digestive system.</li> <li>First aid: Rinse eyes and immediately consult first aid station or inform doctor.</li> </ul> <ul class="clsBULLET"> <li>Never tilt battery. Acid can leak out of the gas vents.</li> <li>Soak up spilled electrolyte with binding agent and neutralize any residual electrolyte.</li> <li>Never allow electrolyte to come into contact with hands.</li> <li>Avoid contact with skin.</li> </ul> <ul class="clsBULLET"> <li>Never touch mouth, nose or eyes with soiled hands.</li> <li>Immediately change any clothing affected by electrolyte and place in water if necessary.</li> <li>Do not eat, drink or store foodstuffs at workplace.</li> <li>Wash thoroughly before breaks and on completion of work.</li> </ul> </td> </tr> </table></span></p><a name="S16253702432008040900000"></a><h2 class="clsHeadFour">Eye protection and protective clothing:</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Wear safety goggles and an acid-resistant apron or alternatively electrolyte-proof overalls.</li> <li>Wear electrolyte-proof gloves.</li> </ul> </td> </tr> </table></span></p><a name="S10440138082008040900000"></a><h2 class="clsHeadFour">Danger of explosion:</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>Sealing plugs must be closed when charging.</li> <li>Charging of batteries removed from the vehicle is only permitted in vented cubicles with extraction system.</li> <li>After charging, battery must be left in charging area with extraction system for an appropriate length of time.</li> </ul> <ul class="clsBULLET"> <li>Batteries must always be transported in conductive metal containers.</li> <li>Electrostatically chargeable materials are not to be used for securing purposes.</li> </ul> </td> </tr> </table></span></p><a name="S35297050642008020700000"></a><h2 class="clsHeadThree">Battery handling instructions</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Battery terminals must no longer be greased</li> <li>To avoid damaging the battery housing, do not use force when attaching battery terminals; press on by hand only.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017428" name="S37429035192008020700000">Fig. 2: Identifying Battery Terminal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Battery terminal tightening torque - <span class="clsEmphBOLD">arrow</span> - 7.5 Nm.</li> <li>Additional battery terminal tightening torque: 7.5 Nm.</li> </ul><a name="S38741429262008020700000"></a><h2 class="clsHeadThree">Battery in engine compartment, disconnecting and reconnecting</h2> <p>Should service procedures in this information specify disconnecting and reconnecting the battery, please heed the following CAUTIONS!:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before beginning repairs on the electrical system:<ul class="clsBULLET"> <li>Where applicable, obtain anti-theft radio security code.</li> <li>Switch off all electrical consumers.</li> <li>Switch the ignition off and remove ignition key.</li> <li>Disconnect negative ( - ) battery terminal.</li> </ul> <ul class="clsBULLET"> <li>On vehicles equipped with Audi Telematics by OnStar <sup>(R)</sup> , switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery --> <a class="clsExtHyperlink" id="A00278928_S09336703492008020700000">91 - COMMUNICATION</a> </li> <li>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.</li> <li>After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar <sup>(R)</sup> , switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module --> <a class="clsExtHyperlink" id="A00278928_S09336703492008020700000">91 - COMMUNICATION</a> </li> </ul> </td> </tr> </table></span></p><a name="S24175473802008040900000"></a><h2 class="clsHeadFour">Disconnecting</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S27505198382008020700000">Fig. 3: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Torque wrench VAG 1331 or (equivalent 5 - 50 Nm)</li> </ul> <ul class="clsDASH"> <li>Heed CAUTIONS listed above</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018536" name="S16952152512008020700000">Fig. 4: Pushing Cover Over Battery Toward Right And Removing It Upward</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Slide battery cover to right - <span class="clsEmphBOLD">arrow 1</span> - and lift off - <span class="clsEmphBOLD">arrow 2</span> - (where applicable).</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018537" name="S05070202612008020700000">Fig. 5: Locating Battery Ground Strap</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect negative ( - ) terminal - <span class="clsEmphBOLD">arrow</span> - from battery post.</li> </ul><a name="S33206369132008040900000"></a><h2 class="clsHeadFour">Reconnecting</h2> <ul class="clsDASH"> <li>Reconnect negative ( - ) terminal to battery post and tighten to specified torque.</li> </ul> <p>The following steps are required after reconnecting battery:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When reconnecting battery, activate vehicle equipment (radio/radio navigation system, clock, electric window lifters) in accordance with Owners Manual.</li> <li>On vehicles equipped with Audi Telematics by OnStar <sup>(R)</sup> , switch on emergency (back-up) battery --> <a class="clsExtHyperlink" id="A00278928_S09336703492008020700000">91 - COMMUNICATION</a> .</li> <li>Further measures after reconnecting the voltage supply, refer to applicable engine repair information, <ul class="clsBULLET"> <li>24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB</li> <li><a class="clsExtHyperlink" id="A00278889_S34101423592008020700000">24 - MULTIPORT FUEL INJECTION (MFI)</a> for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT</li> <li>24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN</li> <li><a class="clsExtHyperlink" id="A00278893_S37153426882008020700000">24 - FUEL INJECTION SYSTEM</a> for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH</li> <li><a class="clsExtHyperlink" id="A00278897_S07807171762008020700000">24 - MULTIPORT FUEL INJECTION (MFI)</a> for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS</li> <li><a class="clsExtHyperlink" id="A00278895_S12545223132008020700000">24 MULTIPORT FUEL INJECTION (MFI)</a> for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF</li> </ul> .</li> <li>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.</li> <li>After re-connecting battery, the ESP indicator lamp will go out only after driving a distance of several meters.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S332063691320080409000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Battery terminal to battery post - nut</td> <td align="" class="clsCellNormal">7.5</td> </tr> </tbody> </table></span></p><a name="S36611140512008020700000"></a><h2 class="clsHeadThree">Battery in luggage compartment, disconnecting and connecting</h2> <p>Should service procedures in this information specify disconnecting and reconnecting the battery, please heed the following CAUTIONS!:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before beginning repairs on the electrical system:<ul class="clsBULLET"> <li>Where applicable, obtain anti-theft radio security code.</li> <li>Switch off all electrical consumers.</li> <li>Switch the ignition off and remove ignition key.</li> <li>Disconnect negative ( - ) battery terminal.</li> </ul> <ul class="clsBULLET"> <li>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.</li> </ul> </td> </tr> </table></span></p><a name="S07481627262008040900000"></a><h2 class="clsHeadFour">Disconnecting</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S07523898192008020700000">Fig. 6: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Torque wrench VAG 1331 or (equivalent 5 - 50 Nm)</li> </ul> <ul class="clsDASH"> <li>Heed CAUTIONS listed above</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018335" name="S22782214802008020700000">Fig. 7: Disconnecting Battery Ground (GND) Strap</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Lift luggage compartment floor covering and secure.</li> <li>Disconnect battery negative ( - ) terminal - <span class="clsEmphBOLD">arrow</span> - from battery post.</li> </ul><a name="S39123246362008040900000"></a><h2 class="clsHeadFour">Connecting</h2> <ul class="clsDASH"> <li>Reconnect negative ( - ) terminal to battery post and tighten to specified torque.</li> </ul> <p>The following steps are required after reconnecting battery:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When reconnecting battery, activate vehicle equipment (radio/radio navigation system, clock, electric window lifters) in accordance with Owners Manual.</li> <li>Further measures after reconnecting the voltage supply, refer to applicable engine repair information, <ul class="clsBULLET"> <li>24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB</li> <li><a class="clsExtHyperlink" id="A00278889_S34101423592008020700000">24 - MULTIPORT FUEL INJECTION (MFI)</a> for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT</li> <li>24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN</li> <li><a class="clsExtHyperlink" id="A00278893_S37153426882008020700000">24 - FUEL INJECTION SYSTEM</a> for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH</li> <li><a class="clsExtHyperlink" id="A00278897_S07807171762008020700000">24 - MULTIPORT FUEL INJECTION (MFI)</a> for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS</li> <li><a class="clsExtHyperlink" id="A00278895_S12545223132008020700000">24 MULTIPORT FUEL INJECTION (MFI)</a> for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF</li> </ul> .</li> <li>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.</li> <li>After re-connecting battery, the ESP indicator lamp will go out only after driving a distance of several meters.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S391232463620080409000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Battery terminal to battery post - nut</td> <td align="" class="clsCellNormal">7.5</td> </tr> </tbody> </table></span></p><a name="S06641743612008020700000"></a><h2 class="clsHeadThree">Battery in engine compartment, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warning and Safety Measures for lead-acid batteries --> <a class="clsHyperlink" href="#S01912186762008020700000">Warnings and safety measures for lead-acid batteries</a></li> <li>Always wear suitable protective clothing <a class="clsHyperlink" href="#S16253702432008040900000">Eye protection and protective clothing:</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before beginning repairs on the electrical system:<ul class="clsBULLET"> <li>Where applicable, obtain anti-theft radio security code.</li> <li>Switch off all electrical consumers.</li> <li>Switch the ignition off and remove ignition key.</li> <li>Disconnect negative ( - ) battery terminal.</li> </ul> <ul class="clsBULLET"> <li>On vehicles equipped with Audi Telematics by OnStar <sup>(R)</sup> , switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery --> <a class="clsExtHyperlink" id="A00278928_S09336703492008020700000">91 - COMMUNICATION</a> </li> <li>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.</li> <li>After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar <sup>(R)</sup> , switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module --> <a class="clsExtHyperlink" id="A00278928_S09336703492008020700000">91 - COMMUNICATION</a> </li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S23537456572008020700000">Fig. 8: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Torque wrench VAG 1331 or (equivalent 5 - 50 Nm)</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014442" name="S26655523772008020700000">Fig. 9: Identifying Plenum Chamber Cover & Removing Rubber Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rubber seal from plenum chamber cover in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove plenum chamber cover - <span class="clsEmphBOLD">1</span> - from the front.</li> <li>Disconnect negative ( - ) terminal - <span class="clsEmphBOLD">1</span> - from battery</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021564" name="S00379598542008020700000">Fig. 10: Locating Battery Terminals On Battery</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Then disconnect positive ( + ) terminal - <span class="clsEmphBOLD">2</span> - from battery.</li> <li>Remove bolt - <span class="clsEmphBOLD">4</span> - from battery hold-down bracket - <span class="clsEmphBOLD">3</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>On vehicles with suspension cross-brace, hex socket bolt - <span class="clsEmphBOLD">4</span> - must be removed using an Allen key with ball head.</li> <li>Loosen bolt enough so that ball head of Allen key contacts suspension cross-brace.</li> <li>Leave bolt and securing bracket in place and swivel battery out from under hold-down bracket.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021565" name="S29943533502008020700000">Fig. 11: Identifying Angle Piece Of Central Gas Venting System</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect angled connector of central gas venting system - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Carefully lift battery out of plenum chamber.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>When disposing batteries it is absolutely necessary that the disposal procedures for batteries and sulfuric acid are observed.</td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Only maintenance-free batteries conforming to standards "TL82506" (as of December 1997) and "VW75073" (as of August 2001) may be installed.</li> <li>Batteries from the Audi parts range feature a base strip adapter for matching to different retainer flanges. The battery operating instructions give details of when and how to use the base strip adapter.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004099" name="S33051648392008020700000">Fig. 12: Battery Foot Strip Cut-Out</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Insert battery in battery carrier so that lug at rear of battery carrier - <span class="clsEmphBOLD">arrow</span> - engages in recess in battery base strip - <span class="clsEmphBOLD">1</span> -.</li> </ul> <ul class="clsBULLET"> <li>It should no longer be possible to move the battery.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004100" name="S24381422682008020700000">Fig. 13: Center Cut-Out In Battery Foot Strip Aligned With Threaded Hole In Battery Carrier</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>The battery has been properly inserted if the center recess in the battery base strip aligns with the tapped hole in the battery tray - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021564" name="S36895799522008020700000">Fig. 14: Locating Battery Terminals On Battery</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Install battery hold-down bracket - <span class="clsEmphBOLD">3</span> - and fasten with bolt - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Lug on battery retainer must engage in recess on battery base strip.</li> </ul> </td> </tr> </table></span></p> <p>Reconnect battery in the following sequence with ignition and electrical equipment switched off:</p> <ul class="clsDASH"> <li>First connect positive ( + ) terminal - <span class="clsEmphBOLD">2</span> - to battery post and torque nut to specification.</li> <li>Then connect negative ( - ) terminal - <span class="clsEmphBOLD">1</span> - to battery post and torque nut to specification.</li> <li>Connect hose for central gas venting system; see notes --> <a class="clsHyperlink" href="#S04752749752008020700000">Batteries with central gas venting</a>.</li> <li>Check firm attachment of battery following installation --> <a class="clsHyperlink" href="#S28502997252008020700000">Battery installation, checking</a>.</li> </ul> <p>The following steps are required after reconnecting battery:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When reconnecting battery, activate vehicle equipment (radio/radio navigation system, clock, electric window lifters) in accordance with Owners Manual.</li> <li>On vehicles equipped with Audi Telematics by OnStar <sup>(R)</sup> , switch on emergency (back-up) battery --> <a class="clsExtHyperlink" id="A00278928_S09336703492008020700000">91 - COMMUNICATION</a> .</li> <li>Further measures after reconnecting the voltage supply, refer to appropriate engine repair information, RG 24.</li> <li>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.</li> <li>After re-connecting battery, the ESP indicator lamp will go out only after driving a distance of several meters.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S066417436120080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Battery hold-down bracket - nut</td> <td align="" class="clsCellNormal">12</td> </tr> <tr> <td align="" class="clsCellNormal">Battery terminal to battery post - nut</td> <td align="" class="clsCellNormal">7.5</td> </tr> </tbody> </table></span></p><a name="S22449374442008020700000"></a><h2 class="clsHeadThree">Battery in luggage compartment, removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warning and Safety Measures for lead-acid batteries --> <a class="clsHyperlink" href="#S01912186762008020700000">Warnings and safety measures for lead-acid batteries</a></li> <li>Always wear suitable protective clothing <a class="clsHyperlink" href="#S16253702432008040900000">Eye protection and protective clothing:</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before beginning repairs on the electrical system:<ul class="clsBULLET"> <li>Where applicable, obtain anti-theft radio security code.</li> <li>Switch off all electrical consumers.</li> <li>Switch the ignition off and remove ignition key.</li> <li>Disconnect negative ( - ) battery terminal.</li> </ul> <ul class="clsBULLET"> <li>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.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S23730719092008020700000">Fig. 15: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Torque wrench VAG 1331 or (equivalent 5 - 50 Nm)</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021566" name="S30237318462008020700000">Fig. 16: Removing/Install Battery From Battery Console Retaining Strip</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Lift luggage compartment floor covering and secure.</li> <li>Remove formed insert behind battery - <span class="clsEmphBOLD">5</span> - upward - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Disconnect negative ( - ) terminal - <span class="clsEmphBOLD">6</span> - from battery</li> <li>Fold positive terminal cover - <span class="clsEmphBOLD">2</span> - upward.</li> </ul> <ul class="clsDASH"> <li>Then disconnect positive ( + ) terminal - <span class="clsEmphBOLD">1</span> - from battery.</li> <li>Disconnect central gas venting system hose - <span class="clsEmphBOLD">7</span> -.</li> <li>Remove bolt - <span class="clsEmphBOLD">4</span> - from battery hold-down bracket - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove battery from battery console retaining strip.</li> </ul> <ul class="clsDASH"> <li>Remove battery from luggage compartment.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>When disposing batteries it is absolutely necessary that the disposal procedures for batteries and sulfuric acid are observed.</td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Only maintenance-free batteries conforming to standards "TL82506" (as of December 1997) and "VW75073" (as of August 2001) may be installed.</li> <li>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.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021567" name="S07459612952008020700000">Fig. 17: Identifying Battery Clamping Strip And Battery Holder Mount</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Insert battery in battery holder.</li> </ul> <ul class="clsBULLET"> <li>Battery clamping strip - <span class="clsEmphBOLD">1</span> - must engage in battery holder mount - <span class="clsEmphBOLD">2</span> -.</li> <li>It should no longer be possible to move the battery.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021566" name="S31490421922008020700000">Fig. 18: Removing/Install Battery From Battery Console Retaining Strip</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Position battery hold-down bracket - <span class="clsEmphBOLD">3</span> -.</li> </ul> <ul class="clsBULLET"> <li>Lug on battery retainer must engage in recess on battery base strip.</li> </ul> <ul class="clsDASH"> <li>Hand tighten bolt - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p>Reconnect battery in the following sequence with ignition and electrical equipment switched off:</p> <ul class="clsDASH"> <li>First connect positive ( + ) terminal - <span class="clsEmphBOLD">1</span> - to battery post and torque nut to specification.</li> <li>Close positive terminal cover - <span class="clsEmphBOLD">2</span> -.</li> <li>Then connect negative ( - ) terminal - <span class="clsEmphBOLD">6</span> - to battery post and torque nut to specification.</li> <li>Connect hose for central gas venting system; see notes --> <a class="clsHyperlink" href="#S04752749752008020700000">Batteries with central gas venting</a>.</li> </ul> <ul class="clsDASH"> <li>Check firm attachment of battery following installation --> <a class="clsHyperlink" href="#S28502997252008020700000">Battery installation, checking</a>.</li> </ul> <p>The following steps are required after reconnecting battery:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When reconnecting battery, activate vehicle equipment (radio/radio navigation system, clock, electric window lifters) in accordance with Owners Manual.</li> <li>Further measures after reconnecting the voltage supply refer to applicable engine repair information, <ul class="clsBULLET"> <li>24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB</li> <li><a class="clsExtHyperlink" id="A00278889_S34101423592008020700000">24 - MULTIPORT FUEL INJECTION (MFI)</a> for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT</li> <li>24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN</li> <li><a class="clsExtHyperlink" id="A00278893_S37153426882008020700000">24 - FUEL INJECTION SYSTEM</a> for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH</li> <li><a class="clsExtHyperlink" id="A00278897_S07807171762008020700000">24 - MULTIPORT FUEL INJECTION (MFI)</a> for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS</li> <li><a class="clsExtHyperlink" id="A00278895_S12545223132008020700000">24 MULTIPORT FUEL INJECTION (MFI)</a> for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF</li> </ul> .</li> <li>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.</li> <li>After re-connecting battery, the ESP indicator lamp will go out only after driving a distance of several meters.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S224493744420080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Battery hold-down bracket - nut</td> <td align="" class="clsCellNormal">12</td> </tr> <tr> <td align="" class="clsCellNormal">Battery terminal to battery post - nut</td> <td align="" class="clsCellNormal">7.5</td> </tr> </tbody> </table></span></p><a name="S28502997252008020700000"></a><h2 class="clsHeadThree">Battery installation, checking</h2> <p>Battery must not be moveable after battery hold-down bracket and bolt is installed.</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>If battery is not secured properly, the following will result:<ul class="clsBULLET"> <li>Shortened battery service life due to vibration damage.</li> <li>Battery cell and plate damage.</li> <li>Electrolyte leakage due to battery case damage.</li> <li>Poor collision safety.</li> </ul> </td> </tr> </table></span></p><a name="S04752749752008020700000"></a><h2 class="clsHeadThree">Batteries with central gas venting</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Ensure venting system hose is always attached to battery.</li> <li>On batteries with central gas venting hose/pipe, ensure that hose does not become disconnected. Only then is the battery able to vent freely.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> </ul> </td> </tr> </table></span></p><a name="S16354695492008020700000"></a><h2 class="clsHeadThree">Battery with charge indicator (magic eye), checking</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017015" name="S33851955862008020700000">Fig. 19: Locating Magic Eye</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>The charge indicator - <span class="clsEmphBOLD">arrow</span> - provides information on the electrolyte level and charge level of the battery to be tested.</p> <p>Three different colored indications are possible:</p> <p><span class="clsArticleTable"><a name="S163546954920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">color indicator</td> <td align="CENTER" class="clsCellNormal">Battery status</td> </tr> <tr> <td align="" class="clsCellNormal">Green</td> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li>Battery adequately charged.</li> </ul> </td> </tr> <tr> <td align="" class="clsCellNormal">Black</td> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li>Not charged or inadequately charged.</li> </ul> </td> </tr> <tr> <td align="" class="clsCellNormal">Colorless or yellow</td> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li>Critical electrolyte level reached; topping up with distilled water essential.</li> </ul> </td> </tr> </tbody> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If a battery is more than 5 years old and the indicator is colorless, replace battery.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Test sequence</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When recharging the battery, and during driving, air bubbles may form under the "magic eye". They distort the color displayed by the magic eye.</li> <li>If batteries are fitted with sealing plugs for production reasons, these are covered with plastic foil.</li> <li>Prior to visual inspection, use screwdriver handle to tap gently and carefully on "magic eye" to disperse any bubbles.</li> <li>Observe color of charge indicator --> <a class="clsHyperlink" href="#S16354695492008020700000">Battery with charge indicator (magic eye), checking</a>.</li> </ul> </td> </tr> </table></span></p><a name="S05384889202008020700000"></a><h2 class="clsHeadThree">Visual inspection</h2> <p>Visually inspect battery before performing measurements, e.g. no-load voltage, specific gravity of electrolyte or battery test.</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warning and Safety Measures for lead-acid batteries --> <a class="clsHyperlink" href="#S01912186762008020700000">Warnings and safety measures for lead-acid batteries</a></li> <li>Always wear suitable protective clothing <a class="clsHyperlink" href="#S16253702432008040900000">Eye protection and protective clothing:</a>.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Check for the following:</li> </ul> <ul class="clsBULLET"> <li>Battery housing damage. Electrolyte can leak out if the housing is damaged.</li> <li>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.</li> <li>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.</li> </ul><a name="S31649395462008020700000"></a><h2 class="clsHeadThree">No-load voltage, checking</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004087" name="S23074105042008020700000">Fig. 20: Identifying Multimeter V.A.G 1526B</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Multimeter VAG 1526 B , Fluke 83 or equivalent</li> </ul> <p><span class="clsEmphBOLD">Test requirements</span> </p> <ul class="clsDASH"> <li>Always heed the following, otherwise correct measurement is not guaranteed.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If no load voltage measurement is carried out with the battery installed in vehicle, disconnect negative ( - ) battery terminal.</li> <li>The battery must not be loaded by connected power consumers for at least 2 hours before making measurements.</li> <li>The battery must not be charged for at least 2 hours before making the measurements.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>On vehicles equipped with Audi Telematics by OnStar <sup>(R)</sup> , switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery --> <a class="clsExtHyperlink" id="A00278928_S09336703492008020700000">91 - COMMUNICATION</a> </li> <li>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.</li> <li>After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar <sup>(R)</sup> , switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module --> <a class="clsExtHyperlink" id="A00278928_S09336703492008020700000">91 - COMMUNICATION</a> </li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch the ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Disconnect negative ( - ) terminal from battery post.</li> </ul> <p><span class="clsEmphBOLD">Battery in engine compartment</span> --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a></p> <p><span class="clsEmphBOLD">Battery in luggage compartment</span> --> <a class="clsHyperlink" href="#S36611140512008020700000">Battery in luggage compartment, disconnecting and connecting</a></p> <ul class="clsDASH"> <li>Measure voltage between battery posts.</li> </ul> <ul class="clsBULLET"> <li>Battery is OK if measuring instrument reading is 12.5 V or above.</li> <li>The battery no-load voltage must at no time be less than 12.5 Volts, otherwise the battery must be recharged immediately --> <a class="clsHyperlink" href="#S14200383982008020700000">Battery, charging</a>.</li> </ul> <ul class="clsDASH"> <li>Repeat voltage measurement between terminals.</li> </ul> <ul class="clsBULLET"> <li>Battery no-load voltage must not be less than 12.5 Volts.</li> </ul> <ul class="clsDASH"> <li>If no-load voltage is not OK, replace battery.</li> </ul> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Reconnect battery. Required steps:</li> </ul> <p><span class="clsEmphBOLD">Battery in engine compartment</span> <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a></p> <p><span class="clsEmphBOLD">Battery in luggage compartment</span> <a class="clsHyperlink" href="#S39123246362008040900000">Connecting</a></p><a name="S31166029312008020700000"></a><h2 class="clsHeadThree">Electrolyte level - batteries with charge indicator (magic eye), checking</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017015" name="S42357449532008020700000">Fig. 21: Locating Magic Eye</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Electrolyte level on batteries with charge indicator - <span class="clsEmphBOLD">arrow</span> - can be established from the color indication. Three different colored displays are possible:</li> </ul> <p><span class="clsArticleTable"><a name="S311660293120080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">color indicator</td> <td align="CENTER" class="clsCellNormal">Battery status</td> </tr> <tr> <td align="" class="clsCellNormal">Green</td> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li>Battery adequately charged.</li> </ul> </td> </tr> <tr> <td align="" class="clsCellNormal">Black</td> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li>Not charged or inadequately charged.</li> </ul> </td> </tr> <tr> <td align="" class="clsCellNormal">Colorless or yellow</td> <td align="" class="clsCellNormal"> <ul class="clsBULLET"> <li>Critical electrolyte level reached; topping up with distilled water essential, procedure --> <a class="clsHyperlink" href="#S22994746862008020700000">Electrolyte level - batteries with sealing plugs, checking</a></li> </ul> </td> </tr> </tbody> </table></span></p><a name="S22994746862008020700000"></a><h2 class="clsHeadThree">Electrolyte level - batteries with sealing plugs, checking</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warning and Safety Measures for lead-acid batteries <a class="clsHyperlink" href="#S09860850652008040900000">Smoking, naked flames, fires and sparks:</a>.</li> <li>Always wear suitable protective clothing <a class="clsHyperlink" href="#S16253702432008040900000">Eye protection and protective clothing:</a>.</li> <li>Only use flashlight to illuminate inside of battery casing.</li> <li>Never illuminate inside of battery casing with a naked flame.</li> </ul> <ul class="clsBULLET"> <li>Keep naked flames and burning cigarettes away from batteries.</li> <li>When disposing of batteries, always pay attention to the appropriate regulations for batteries and sulfuric acid.</li> <li>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.</li> <li>The plugs must be installed with an O-ring seal.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00007547" name="S13772274532008020700000">Fig. 22: Battery fill bottle VAS 5045</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Battery filler bottle VAS 5045</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004084" name="S01526428082008020700000">Fig. 23: Identifying Commercially Available Hydrometer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hydrometer (commercially available)</li> </ul> <p>The correct electrolyte level is an important factor in ensuring long battery service life.</p> <ul class="clsDASH"> <li>On batteries with visible min. and max marks it is sufficient to perform visual inspection from outside to check electrolyte level.</li> </ul> <ul class="clsBULLET"> <li>The electrolyte level must be above the minimum marking but not exceed the max marking.</li> </ul> <ul class="clsDASH"> <li>On batteries on which the min. and max marks are difficult to see, or on which the electrolyte level cannot be seen because of the opacity of the battery housing, remove the sealing plugs.</li> <li>Check the electrolyte level by making a visual inspection of the inside of the battery.</li> </ul> <ul class="clsBULLET"> <li>The electrolyte level must coincide with the internal level mark (plastic web). This corresponds to the max marking on the outside.</li> </ul> <p><span class="clsEmphBOLD">Electrolyte level too low</span> </p> <p>If the electrolyte level is too low, drying-out of the cell plates will reduce the capacity (power) of the battery. The cell plates must be fully covered by electrolyte (sulfuric acid/water mixture) in order to prevent corrosion of plates, plate bridges and cell connectors. Such corrosion would impair battery operation and make the battery unusable.</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004080" name="S16124066632008020700000">Fig. 24: VAS 5045 Battery Filling Bottle</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>If electrolyte level is too low, use battery filler bottle VAS 5045 to add distilled water until max mark is reached.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>Use distilled water only, this prevents contamination of the battery electrolyte and the associated increase in self discharge.</li> <li>Screw sealing plugs of battery cells back in again.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>The plugs must be equipped with an O-ring seal.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004084" name="S24199054112008020700000">Fig. 25: Identifying Commercially Available Hydrometer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Electrolyte level too high</span> </p> <p>If the electrolyte level is too high (overfilled), escaping electrolyte (sulfuric acid/water mixture) will cause damage outside the battery.</p> <ul class="clsDASH"> <li>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.</li> <li>Remove the battery cell sealing plugs.</li> <li>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.</li> <li>Screw sealing plugs of battery cells back in again.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>The plugs must be equipped with an O-ring seal.</li> </ul> </td> </tr> </table></span></p><a name="S21470658372008020700000"></a><h2 class="clsHeadThree">Electrolyte specific gravity - batteries with sealing plugs, checking</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warning and Safety Measures for lead-acid batteries <a class="clsHyperlink" href="#S09860850652008040900000">Smoking, naked flames, fires and sparks:</a>.</li> <li>Always wear suitable protective clothing <a class="clsHyperlink" href="#S16253702432008040900000">Eye protection and protective clothing:</a>.</li> <li>When disposing of batteries, always pay attention to the appropriate regulations for batteries and sulfuric acid.</li> <li>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.</li> </ul> <ul class="clsBULLET"> <li>The plugs must be installed with an O-ring seal.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004084" name="S35162779622008020700000">Fig. 26: Identifying Commercially Available Hydrometer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hydrometer (commercially available)</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The electrolyte specific gravity test in conjunction with the battery test provides specific information on battery condition.</li> <li>The temperature of the battery electrolyte must be at least 10 ° C.</li> <li>Electrolyte specific gravity can be checked immediately after charging battery.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Test sequence</span> </p> <ul class="clsDASH"> <li>Remove all battery plugs (battery cell sealing plugs).</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004086" name="S34283586212008020700000">Fig. 27: Hydrometer Specific Gravity Reading</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Immerse end of hydrometer in a cell and extract sufficient electrolyte so that float swims free in the electrolyte.</li> </ul> <ul class="clsBULLET"> <li>The greater the specific gravity of the electrolyte drawn in, the higher the float will ride.</li> <li>The specific gravity in kg/dm <sup>3</sup> (specific gravity of electrolyte) can be read off the scale - <span class="clsEmphBOLD">arrow</span> - on the hydrometer.</li> </ul> <ul class="clsDASH"> <li>Take reading on hydrometer and compare to values given in table:</li> </ul> <p><span class="clsArticleTable"><a name="S214706583720080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Charge condition in normal climatic zones</td> <td align="" class="clsCellNormal">specific gravity of electrolyte in kg/dm <sup>3</sup> </td> </tr> <tr> <td align="" class="clsCellNormal">discharged</td> <td align="" class="clsCellNormal">1.12</td> </tr> <tr> <td align="" class="clsCellNormal">half charged</td> <td align="" class="clsCellNormal">1.20</td> </tr> <tr> <td align="" class="clsCellNormal">well charged</td> <td align="" class="clsCellNormal">1.28</td> </tr> </tbody> </table></span></p> <p><span class="clsArticleTable"><a name="S214706583720080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Charge level in tropical countries</td> <td align="" class="clsCellNormal">specific gravity of electrolyte in kg/dm <sup>3</sup> </td> </tr> <tr> <td align="" class="clsCellNormal">discharged</td> <td align="" class="clsCellNormal">1.08</td> </tr> <tr> <td align="" class="clsCellNormal">half charged</td> <td align="" class="clsCellNormal">1.16</td> </tr> <tr> <td align="" class="clsCellNormal">fully charged</td> <td align="" class="clsCellNormal">1.23</td> </tr> </tbody> </table></span></p> <p>The specific gravity in normal climatic zones must be at least 1.24 kg/dm <sup>3</sup> . If specific gravity is too low in all battery cells:</p> <ul class="clsDASH"> <li>Charge battery and then repeat electrolyte specific gravity test.</li> </ul> <p><span class="clsEmphBOLD">Example 1:</span> </p> <p><span class="clsArticleTable"><a name="S214706583720080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> <col span="1" id="COL3"> <col span="1" id="COL4"> <col span="1" id="COL5"> <col span="1" id="COL6"> <col span="1" id="COL7"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Battery cell:</td> <td align="" class="clsCellNormal">1</td> <td align="" class="clsCellNormal">2</td> <td align="" class="clsCellNormal">3</td> <td align="" class="clsCellNormal">4</td> <td align="" class="clsCellNormal">5</td> <td align="" class="clsCellNormal">6</td> </tr> <tr> <td align="" class="clsCellNormal">specific gravity per cell in kg/dm <sup>3</sup> </td> <td align="" class="clsCellNormal">1.24</td> <td align="" class="clsCellNormal">1.25</td> <td align="" class="clsCellNormal">1.25</td> <td align="" class="clsCellNormal">1.10 <sup>1)</sup> </td> <td align="" class="clsCellNormal">1.24</td> <td align="" class="clsCellNormal">1.25</td> </tr> <tr> <td colspan="7" align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><sup>1)</sup> Specific gravity in cell 4 is too low (deviation is greater than 0.03 kg/dm <sup>3</sup> ).</li> </ul> </td> </tr> </tbody> </table></span></p> <p>* specific gravity in cell 4 is too low (deviation greater than 0.03 kg/dm <sup>3</sup> )</p> <p><span class="clsEmphBOLD">Example 2:</span> </p> <p><span class="clsArticleTable"><a name="S214706583720080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> <col span="1" id="COL3"> <col span="1" id="COL4"> <col span="1" id="COL5"> <col span="1" id="COL6"> <col span="1" id="COL7"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Battery cell:</td> <td align="" class="clsCellNormal">1</td> <td align="" class="clsCellNormal">2</td> <td align="" class="clsCellNormal">3</td> <td align="" class="clsCellNormal">4</td> <td align="" class="clsCellNormal">5</td> <td align="" class="clsCellNormal">6</td> </tr> <tr> <td align="" class="clsCellNormal">specific gravity per cell in kg/dm <sup>3</sup> </td> <td align="" class="clsCellNormal">1.26</td> <td align="" class="clsCellNormal">1.26</td> <td align="" class="clsCellNormal">1.25</td> <td align="" class="clsCellNormal">1.14 <sup>1)</sup> </td> <td align="" class="clsCellNormal">1.18 <sup>1)</sup> </td> <td align="" class="clsCellNormal">1.24</td> </tr> <tr> <td colspan="7" align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><sup>1)</sup> Specific gravity in cell 4 and 5 is too low (deviation is greater than 0.03 kg/dm <sup>3</sup> ).</li> </ul> </td> </tr> </tbody> </table></span></p> <p>* specific gravity in cells 4 and 5 is too low (deviation greater than 0.03 kg/dm <sup>3</sup> )</p> <p>If specifications are not obtained:</p> <ul class="clsDASH"> <li>Replace battery.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The measured values for the electrolyte specific gravity of the individual battery cells must NOT deviate by more than 0.03 kg/dm <sup>3</sup> , otherwise battery has to be replaced.</li> <li>Reinstall battery sealing plugs.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>The plugs must be equipped with an O-ring seal.</li> </ul> </td> </tr> </table></span></p><a name="S02181400982008020700000"></a><h2 class="clsHeadThree">Battery, testing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warning and Safety Measures for lead-acid batteries <a class="clsHyperlink" href="#S09860850652008040900000">Smoking, naked flames, fires and sparks:</a>.</li> <li>Always wear suitable protective clothing <a class="clsHyperlink" href="#S16253702432008040900000">Eye protection and protective clothing:</a>.</li> <li>DO NOT battery test batteries which are gassing. Otherwise there is a risk of explosion.</li> <li>The following notes and procedures must be followed to ensure correct measurements.</li> </ul> <ul class="clsBULLET"> <li>When disposing of batteries, always pay attention to the appropriate regulations for batteries and sulfuric acid.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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</li> <li>Always follow the battery tester operating instructions.</li> <li>It is not necessary to remove battery from vehicle or disconnect battery terminals.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004275" name="S36994837182008020700000">Fig. 28: Battery VAS Tester</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Battery Test Kit Midtronics MCR 340V (VAG tester illustrated here for reference only).</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Check no-load voltage --> <a class="clsHyperlink" href="#S31649395462008020700000">No-load voltage, checking</a></li> <li>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.</li> <li>Select test mode "IN-VEHICLE" or "OUT-OF-VEHICLE" (refer to MCR 340V Instruction Manual).</li> <li>Select battery type (AGR or conventional) (refer to MCR 340V Instruction Manual).</li> </ul> <ul class="clsDASH"> <li>Set tester to "Warranty Test" (refer to MCR 340V Instruction Manual).</li> <li>Perform battery test by setting load current on tester according to battery (DIN) capacity (refer to MCR 340V Instruction Manual).</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Use print function of MCR 340V where test results are required for warranty claims.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Battery test results:</span> </p> <p><span class="clsArticleTable"><a name="S021814009820080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Battery Tester Display / Printout</td> <td align="" class="clsCellNormal">Required action</td> </tr> <tr> <td align="" class="clsCellNormal">Good Battery</td> <td align="" class="clsCellNormal">None</td> </tr> <tr> <td align="" class="clsCellNormal">Good - Recharge</td> <td align="" class="clsCellNormal">Charge battery where necessary --> <a class="clsHyperlink" href="#S14200383982008020700000">Battery, charging</a></td> </tr> <tr> <td align="" class="clsCellNormal">Use inCHARGE</td> <td align="" class="clsCellNormal">Charge battery --> <a class="clsHyperlink" href="#S14200383982008020700000">Battery, charging</a></td> </tr> <tr> <td align="" class="clsCellNormal">Replace Battery</td> <td align="" class="clsCellNormal">Replace battery --> <a class="clsHyperlink" href="#S06641743612008020700000">Battery in engine compartment, removing and installing</a></td> </tr> <tr> <td align="" class="clsCellNormal">Bad Cell - Replace</td> <td align="" class="clsCellNormal">Replace battery --> <a class="clsHyperlink" href="#S06641743612008020700000">Battery in engine compartment, removing and installing</a></td> </tr> </tbody> </table></span></p><a name="S14200383982008020700000"></a><h2 class="clsHeadThree">Battery, charging</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warning and Safety Measures for lead-acid batteries <a class="clsHyperlink" href="#S09860850652008040900000">Smoking, naked flames, fires and sparks:</a>.</li> <li>Always wear suitable protective clothing <a class="clsHyperlink" href="#S16253702432008040900000">Eye protection and protective clothing:</a>.</li> </ul> <p>Danger of explosion!</p> <ul class="clsBULLET"> <li>Batteries produce explosive gasses while being charged.</li> <li>Keep open flames and sparks away and DO NOT smoke near batteries.</li> <li>The battery charger MUST be turned off when connecting or disconnecting the cables at the battery.</li> <li>Battery cell caps must NOT be removed while charging.</li> </ul> <ul class="clsBULLET"> <li>"Boosting" a sulfated battery a high charging rate can cause an explosion.</li> <li>Ensure that battery is charged in a well ventilated area.</li> <li>Precision tools must not be kept in the same room where batteries are being charged. Tools may corrode due to chemical reaction.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <ul class="clsBULLET"> <li>Battery Charging Station: Midtronics INC-940.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Before charging, battery must have a minimum temperature of 10 degrees Celsius (50 degrees Fahrenheit).</li> <li>It is not necessary to remove battery from vehicle or disconnect battery terminals.</li> <li>Charging voltage must not exceed 14.4V.</li> <li>Always follow the battery charger operating instructions.</li> <li>After charging, confirm battery no load voltage and electrolyte specific gravity before reuse in vehicle.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before beginning repairs on electrical system<ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018536" name="S03768534452008020700000">Fig. 29: Pushing Cover Over Battery Toward Right And Removing It Upward</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Slide battery cover to right - <span class="clsEmphBOLD">arrow 1</span> - and lift off - <span class="clsEmphBOLD">arrow 2</span> - where applicable.</li> </ul> <p><span class="clsEmphBOLD">Battery in engine compartment:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021568" name="S22842721362008020700000">Fig. 30: Identifying Battery Terminals, Nuts, And Terminal Clamps</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Connect battery charger to battery, positive to positive ( + ) - <span class="clsEmphBOLD">2</span> - , negative to negative ( - ) - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Battery in engine compartment:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021569" name="S04380679482008020700000">Fig. 31: Identifying Battery Charger Connected To Battery</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clamps - <span class="clsEmphBOLD">arrow</span> - and open cover - <span class="clsEmphBOLD">2</span> - over positive terminal.</li> <li>Connect positive battery charger clamp - <span class="clsEmphBOLD">3</span> - to positive ( + ) terminal - <span class="clsEmphBOLD">4</span> - and to negative battery charger clamp - <span class="clsEmphBOLD">5</span> - to negative terminal - <span class="clsEmphBOLD">1</span> - (VAS 5900 charger shown for illustration purposes only).</li> </ul> <p><span class="clsEmphBOLD">All:</span> </p> <ul class="clsDASH"> <li>Switch on battery charger.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>If battery begins gassing (boiling) violently when charging, REDUCE charging rate immediately.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Adjust charging rate according to battery capacity (refer to Midtronics INC-940 Instruction Manual).</li> </ul> <p><span class="clsEmphBOLD">Charging totally discharged batteries</span> </p> <ul class="clsBULLET"> <li>Batteries which have not been used for lengthy periods, e.g. in vehicles which have not been driven, are subject to self-discharge.</li> <li>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 --> <a class="clsHyperlink" href="#S31649395462008020700000">No-load voltage, checking</a>.</li> <li>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.</li> <li>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).</li> </ul> <ul class="clsBULLET"> <li>If totally discharged batteries are charged directly after being discharged, the sulphation dissipates.</li> <li>If this is not done, the plates become even harder and their ability to absorb charge is impaired. This results in reduced power output.</li> </ul> <p><span class="clsEmphBOLD">Procedure for charging exhausted batteries (sulphated)</span> </p> <p>Totally discharged batteries (that are also sulphated) must be charged as follows using a low charging current:</p> <ul class="clsDASH"> <li>Set charging current to approx. 5 % of battery capacity, i.e. for a 60 Ah battery the charging current is approx. 3 A.</li> <li>Charging battery --> <a class="clsHyperlink" href="#S14200383982008020700000">Battery, charging</a>.</li> </ul> <ul class="clsBULLET"> <li>The charging voltage (U <sub>max</sub> ) must not exceed 14.4 V.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>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.</td> </tr> </table></span></p><a name="S03260864182008020700000"></a><h2 class="clsHeadThree">Quick-charging</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warning and Safety Measures for lead-acid batteries <a class="clsHyperlink" href="#S09860850652008040900000">Smoking, naked flames, fires and sparks:</a>.</li> <li>Always wear suitable protective clothing <a class="clsHyperlink" href="#S16253702432008040900000">Eye protection and protective clothing:</a>.</li> </ul> <p>Danger of explosion!</p> <ul class="clsBULLET"> <li>Batteries produce explosive gasses while being charged.</li> <li>Keep open flames and sparks away and DO NOT smoke near batteries.</li> <li>The battery charger MUST be turned off when connecting or disconnecting the cables at the battery.</li> <li>Battery cell caps must NOT be removed while charging.</li> </ul> <ul class="clsBULLET"> <li>"Boosting" a sulfated battery a high charging rate can cause an explosion.</li> <li>Ensure that battery is charged in a well ventilated area.</li> <li>Precision tools must not be kept in the same room where batteries are being charged. Tools may corrode due to chemical reaction.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Battery must not be connected to vehicle electrical system when quick charging. Where applicable, disconnect battery in engine compartment --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>. Where applicable, disconnect battery in luggage compartment --> <a class="clsHyperlink" href="#S36611140512008020700000">Battery in luggage compartment, disconnecting and connecting</a>.</li> <li>Never quick-charge a totally discharged battery. Effective charging will not take place.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The battery temperature must be at least 10 ° C.</li> <li>Quick-charging of batteries should only be performed in exceptional circumstances (e.g. boost starting) as rapid charging may cause damage.</li> </ul> </td> </tr> </table></span></p><a name="S26587287732008020700000"></a><h2 class="clsHeadTwo">Battery Interrupt Igniter N253 - Audi RS4</h2><a name="S00430702722008020700000"></a><h2 class="clsHeadThree">Battery Interrupt Igniter N253 - Audi RS4, removing and installing</h2> <p>Battery Interrupt Igniter N253 must be replaced if faulty or damaged.</p> <ul class="clsDASH"> <li>Battery Interrupt Igniter N253 , replacing --> <a class="clsExtHyperlink" id="A00278922_S12872913122008020700000">69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS</a> .</li> </ul><a name="S20076978422008020700000"></a><h2 class="clsHeadTwo">Generator (GEN)</h2><a name="S33680942622008020700000"></a><h2 class="clsHeadThree">Generator (GEN) - 4-cylinder 1.8L Turbo engine, removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000757" name="S11964342402008020700000">Fig. 32: Identifying Drip Tray V.A.G 1306</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Drip tray VAG 1306 or drip tray for workshop crane VAS 6208</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000758" name="S17265799312008020700000">Fig. 33: Identifying Hose Clip Pliers Vag 1921</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hose clip pliers VAG 1921</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S16577631262008020700000">Fig. 34: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>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.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Open filler cap for coolant expansion tank.</li> <li>Remove engine cover.</li> <li>Lift vehicle.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017429" name="S32590899162008020700000">Fig. 35: Identifying Quick-Release Fasteners And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove front noise insulation.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021570" name="S00064172522008020700000">Fig. 36: Locating Retaining Clip And Engine Coolant Temperature (ECT) Sensor</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Place drip tray VAG 1306 or drip tray for workshop crane VAS 6208 below engine.</li> <li>Pull off retaining clip - <span class="clsEmphBOLD">1</span> - and pull out Engine Coolant Temperature (ECT) Sensor (on Engine) G83 - <span class="clsEmphBOLD">2</span> -.</li> <li>Drain coolant from radiator only.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021571" name="S22075449542008020700000">Fig. 37: Identifying Top Coolant Hose At Coolant Pipe</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect top coolant hose from coolant pipe - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021572" name="S38494004542008020700000">Fig. 38: Identifying Coolant Fan Control Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove radiator fan control module - <span class="clsEmphBOLD">arrow</span> - and set aside.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before removing ribbed belt, mark direction of rotation. Belt damage will result if not reinstalled in proper direction.</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021573" name="S41264082372008020700000">Fig. 39: Identifying Ribbed Belt Tensioner</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Relieve ribbed belt tension by turning tensioner in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove ribbed belt from generator pulley.</li> <li>Release pressure from the tensioner.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021574" name="S23772094752008020700000">Fig. 40: Identifying Electrical Harness Connector</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Electrical connections - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">3</span> - not applicable to US/CDN models.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021575" name="S37827165152008020700000">Fig. 41: Identifying Upper And Lower Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove top and bottom bolts - <span class="clsEmphBOLD">arrows</span> - and swing generator forward.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017018" name="S35926184972008020700000">Fig. 42: Generator Electrical Connector And Terminal B+</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove 30 ( B+ ) terminal - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove generator.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Before installing the ribbed belt, ensure that all subassemblies (generator, a/c compressor etc.) are securely mounted and turn freely.</li> <li>When installing belt, ensure correct seating in the belt pulleys!</li> <li>Reinstall all hose clamps, harness retainers and replace all removed cable ties as originally installed in production.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021576" name="S28551358322008020700000">Fig. 43: Ribbed Belt, Seated Correctly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Note running direction of ribbed belt as previously marked and route as illustrated.</li> <li>Top up coolant --> 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s) AMB - <ul class="clsBULLET"> <li>19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB</li> <li><a class="clsExtHyperlink" id="A00278881_S33573201972008020700000">19 - ENGINE - COOLING SYSTEM</a> for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT</li> <li>19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN</li> <li><a class="clsExtHyperlink" id="A00278883_S41376556702008020700000">19 - ENGINE - COOLING SYSTEM</a> for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH</li> <li><a class="clsExtHyperlink" id="A00278885_S21797592792008020700000">19 - ENGINE - COOLING SYSTEM</a> for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS</li> <li><a class="clsExtHyperlink" id="A00278884_S12212760292008020700000">19 - ENGINE - COOLING SYSTEM</a> for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF</li> </ul> .</li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> <li>Start engine and check belt running.</li> </ul><a name="S33345276562009022500000"></a><h2 class="clsHeadFour">Tightening Torques (1.8L)</h2> <p><span class="clsEmphBOLD">Tightening Torques</span> </p> <p><span class="clsArticleTable"><a name="S333452765620090225000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Generator (GEN) to engine - bolt</td> <td align="" class="clsCellNormal">23</td> </tr> <tr> <td align="" class="clsCellNormal">Terminal 30/B+ to generator - nut</td> <td align="" class="clsCellNormal">16</td> </tr> </tbody> </table></span></p><a name="S17519848972008020700000"></a><h2 class="clsHeadThree">Generator (GEN) - 4-cylinder 2.0L Turbo FSI engine, removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017484" name="S15295212312008020700000">Fig. 44: Locking Tool T40098</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Locking pin T40098 or equivalent</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S33581304302008020700000">Fig. 45: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014440" name="S16280575712008020700000">Fig. 46: Removing Engine Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove engine cover - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before removing ribbed belt, mark direction of rotation. Belt damage will result if not reinstalled in proper direction.</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017443" name="S14908041532008020700000">Fig. 47: Pivoting Belt Tensioner For Ribbed Belt To Relieve Tension On Ribbed Belt</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Relieve ribbed belt tension by turning tensioner in direction of - <span class="clsEmphBOLD">arrow</span> - and lock in place using locking pin T40098.</li> <li>Remove ribbed belt.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017448" name="S09083257892008020700000">Fig. 48: Separating Electrical Connector From Charge Air Pressure Sensor G31 & Removing Left Charge Air Hose</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove air hose - <span class="clsEmphBOLD">2</span> - at intake manifold.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Disregard - <span class="clsEmphBOLD">1</span> -.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021575" name="S01476579402008020700000">Fig. 49: Identifying Upper And Lower Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove top and bottom bolts - <span class="clsEmphBOLD">arrows</span> - and swing generator forward.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017018" name="S34190199972008020700000">Fig. 50: Generator Electrical Connector And Terminal B+</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove D+ terminal - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove generator.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Before installing the ribbed belt, ensure that all subassemblies (generator, a/c compressor etc.) are securely mounted and turn freely.</li> <li>When installing belt, ensure correct seating in the belt pulleys!</li> <li>Reinstall all hose clamps, harness retainers and replace all removed cable ties as originally installed in production.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021576" name="S12702443812008020700000">Fig. 51: Ribbed Belt, Seated Correctly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Note running direction of ribbed belt as previously marked and route as illustrated.</li> <li>Top up coolant --> 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection Ignition, Engine Code(s): BPG - <ul class="clsBULLET"> <li>19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB</li> <li><a class="clsExtHyperlink" id="A00278881_S33573201972008020700000">19 - ENGINE - COOLING SYSTEM</a> for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT</li> <li>19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN</li> <li><a class="clsExtHyperlink" id="A00278883_S41376556702008020700000">19 - ENGINE - COOLING SYSTEM</a> for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH</li> <li><a class="clsExtHyperlink" id="A00278885_S21797592792008020700000">19 - ENGINE - COOLING SYSTEM</a> for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS</li> <li><a class="clsExtHyperlink" id="A00278884_S12212760292008020700000">19 - ENGINE - COOLING SYSTEM</a> for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF</li> </ul> .</li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> <li>Start engine and check belt running.</li> </ul><a name="S38351419752009022500000"></a><h2 class="clsHeadFour">Tightening Torques (2.0L)</h2> <p><span class="clsEmphBOLD">Tightening Torques</span> </p> <p><span class="clsArticleTable"><a name="S383514197520090225000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Generator (GEN) to engine - bolt</td> <td align="" class="clsCellNormal">23</td> </tr> <tr> <td align="" class="clsCellNormal">Terminal 30/B+ to generator - nut</td> <td align="" class="clsCellNormal">16</td> </tr> </tbody> </table></span></p><a name="S05143446662008020700000"></a><h2 class="clsHeadThree">Generator (GEN) - 3.0L 6-cylinder engine, removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021577" name="S42080618762008020700000">Fig. 52: Ribbed Belt Installation Tool 3299 With Tensioner Claw 3299/1</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Ribbed Belt Installation Tool 3299 with tensioner claw 3299/1</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S18150290942008020700000">Fig. 53: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)</li> </ul><a name="S08878431472008040900000"></a><h2 class="clsHeadFour">Removing</h2> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017571" name="S20561415862008020700000">Fig. 54: Removing Front Engine Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove front engine cover - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before removing ribbed belt, mark direction of rotation. Belt damage will result if not reinstalled in proper direction.</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017606" name="S14514445722008020700000">Fig. 55: Swinging Ribbed Belt Tensioner To Release Tension On Ribbed Belt</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Relieve ribbed belt tension by turning tensioner in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove ribbed belt from power steering pump pulley.</li> <li>Lift vehicle.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017429" name="S03540488932008020700000">Fig. 56: Identifying Quick-Release Fasteners And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove front noise insulation.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004755" name="S01519885052008020700000">Fig. 57: Starter Wiring Bracket Cable Ties</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove cable ties - <span class="clsEmphBOLD">arrows</span> - , unclip cover for starter cable guide harness and remove harness from guide.</li> </ul> <p><span class="clsEmphBOLD">Vehicles with automatic transmission:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00019371" name="S24459669032008020700000">Fig. 58: Unscrewing Nut For Clamp For ATF Lines</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nuts - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove bracket for ATF lines.</li> </ul> <p><span class="clsEmphBOLD">All models:</span> </p> <ul class="clsDASH"> <li>Unclip refrigerant line from bracket at sump.</li> <li>Disconnect electrical connections at generator.</li> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017610" name="S39082401882008020700000">Fig. 59: Identifying Bolts And Generator</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove generator.</li> </ul><a name="S21360356832008040900000"></a><h2 class="clsHeadFour">Installing</h2> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Before installing the ribbed belt, ensure that all subassemblies (generator, a/c compressor etc.) are securely mounted and turn freely.</li> <li>When installing belt, ensure correct seating in the belt pulleys!</li> <li>Reinstall all hose clamps, harness retainers and replace all removed cable ties as originally installed in production.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017631" name="S25515849302008020700000">Fig. 60: Identifying Belt Path</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Note running direction of ribbed belt as previously marked and route as illustrated.</li> </ul> <ol class="clsARABICNUM"> <li>Generator (GEN)</li> <li>Ribbed belt</li> <li>Power steering pump</li> <li>Air conditioner compressor</li> <li>Crankshaft</li> <li>Tensioning roller</li> </ol> <ul class="clsDASH"> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> <li>Start engine and check belt running.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S213603568320080409000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> <col span="1" id="COL3"> </colgroup> <tbody> <tr> <td colspan="2" align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal"> </td> <td align="RIGHT" class="clsCellNormal">M8</td> <td align="" class="clsCellNormal">22</td> </tr> <tr> <td align="" class="clsCellNormal">Generator to engine bracket - bolts</td> <td align="RIGHT" class="clsCellNormal">M10</td> <td align="" class="clsCellNormal">45</td> </tr> <tr> <td colspan="2" align="" class="clsCellNormal">Terminal 30/B+ to generator - nut</td> <td align="" class="clsCellNormal">16</td> </tr> <tr> <td colspan="2" align="" class="clsCellNormal">Bracket for refrigerant line to sump - bolt</td> <td align="" class="clsCellNormal">10</td> </tr> <tr> <td colspan="2" align="" class="clsCellNormal">Bracket for starter wire to engine console - bolt</td> <td align="" class="clsCellNormal">10</td> </tr> </tbody> </table></span></p><a name="S15128135632008020700000"></a><h2 class="clsHeadThree">Generator (GEN) - 3.2L 6-cylinder FSI engine, removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S24281526182008020700000">Fig. 61: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017827" name="S09063651642008020700000">Fig. 62: Identifying Front Engine Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove front engine cover - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017848" name="S25213158152008020700000">Fig. 63: Identifying Bolts & Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove air guides - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> <li>Lift vehicle.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017429" name="S39071132672008020700000">Fig. 64: Identifying Quick-Release Fasteners And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove front noise insulation.</li> <li>Remove front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> <li>Bring lock carrier into service position --> <a class="clsExtHyperlink" id="A00278920_S31853902272008020700000">50 BODY, FRONT</a> .</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before removing ribbed belt, mark direction of rotation. Belt damage will result if not reinstalled in proper direction.</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017906" name="S07016786192008020700000">Fig. 65: Pivoting Tensioning Device To Relieve Tension On Ribbed Belt</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Relieve ribbed belt tension by turning tensioner in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove ribbed belt from generator pulley.</li> <li>Allow tensioner to return to operating position.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021578" name="S31738877102008020700000">Fig. 66: Identifying Bolts, Electrical Connections, And Generator</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Disconnect electrical connections - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - from Generator.</li> <li>Remove Generator.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Before installing the ribbed belt, ensure that all subassemblies (generator, a/c compressor etc.) are securely mounted and turn freely.</li> <li>When installing belt, ensure correct seating in the belt pulleys!</li> <li>Reinstall all hose clamps, harness retainers and replace all removed cable ties as originally installed in production.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017907" name="S05552007712008020700000">Fig. 67: Placing Ribbed Belt Over Belt Pulley</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Note running direction of ribbed belt as previously marked and route as illustrated.</li> </ul> <ol class="clsARABICNUM"> <li>Generator (GEN)</li> <li>Idler</li> <li>Coolant pump</li> <li>Power steering pump</li> <li>Air conditioning compressor</li> <li>Tensioning roller</li> <li>Crankshaft</li> </ol> <ul class="clsDASH"> <li>Reinstall lock carrier --> <a class="clsExtHyperlink" id="A00278920_S31853902272008020700000">50 BODY, FRONT</a> .</li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> <li>Start engine and check belt running.</li> <li>Reinstall front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul><a name="S37428527462009022500000"></a><h2 class="clsHeadFour">Tightening Torques (3.2L)</h2> <p><span class="clsEmphBOLD">Tightening Torques</span> </p> <p><span class="clsArticleTable"><a name="S374285274620090225000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="LEFT" class="clsCellNormal">Component - fastener</td> <td align="CENTER" class="clsCellNormal">Nm</td> </tr> <tr> <td align="LEFT" class="clsCellNormal">Generator to engine bracket - bolt</td> <td align="CENTER" class="clsCellNormal">22</td> </tr> <tr> <td align="LEFT" class="clsCellNormal">Terminal 30/B+ to generator - nut</td> <td align="CENTER" class="clsCellNormal">16</td> </tr> </tbody> </table></span></p><a name="S38944957262008020700000"></a><h2 class="clsHeadThree">Generator (GEN) - 4.2L 8-cylinder engine (Audi S4), removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000757" name="S23974085572008020700000">Fig. 68: Identifying Drip Tray V.A.G 1306</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Drip tray VAG 1306 or drip tray for workshop crane VAS 6208</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00007852" name="S06204751222008020700000">Fig. 69: Identifying Old Oil Collecting And Extracting Device V.A.G 1782</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Oil drain appliance VAG 1782 or UL approved equivalent</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000758" name="S41190114302008020700000">Fig. 70: Identifying Hose Clip Pliers Vag 1921</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hose clip pliers VAG 1921</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S39884086272008020700000">Fig. 71: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000114" name="S38444634192008020700000">Fig. 72: Identifying Torque Wrench V.A.G. 1332</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> <li>Use oil drain appliance VAG 1782 (or UL approved equivalent) to draw power steering hydraulic fluid from power steering from reservoir.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>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.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Open filler cap for coolant expansion tank.</li> <li>Lift vehicle</li> <li>Remove right front wheel.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017429" name="S23803575942008020700000">Fig. 73: Identifying Quick-Release Fasteners And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove front noise insulation.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018073" name="S21471478842008020700000">Fig. 74: Removing Right Air Guide In Front Of Auxiliary Cooler</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove air guide - <span class="clsEmphBOLD">arrow</span> - from right auxiliary radiator.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018072" name="S40595069682008020700000">Fig. 75: Removing Left Air Guide In Front Of Auxiliary Cooler</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove air guide - <span class="clsEmphBOLD">arrow</span> - from left auxiliary radiator.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018074" name="S15581660002008020700000">Fig. 76: Removing Drain Plug On Coolant Thermostat Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Place drip tray VAG 1306 or drip tray for workshop crane VAS 6208 beneath engine.</li> <li>Remove drain plug - <span class="clsEmphBOLD">arrow</span> - at thermostat housing and drain engine coolant.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017432" name="S00342111682008020700000">Fig. 77: Disconnecting Lower Coolant Hose From Radiator</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release and pull off bottom coolant hose from radiator - <span class="clsEmphBOLD">arrow</span> - and drain remaining engine coolant.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018075" name="S04633395102008020700000">Fig. 78: Disconnecting Hydraulic Lines To Cooling Coil At Left Rear Of Bumper</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Place oil drain appliance VAG 1782 underneath.</li> <li>Remove hydraulic hoses - <span class="clsEmphBOLD">arrows</span> - at rear of lock carrier to power steering cooling line.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017582" name="S15384424032008020700000">Fig. 79: Removing Cover In Engine Compartment (Right Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove right engine compartment cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S41272662002008020700000">Fig. 80: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air guide.</li> <li>Remove air guide - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018076" name="S33157282372008020700000">Fig. 81: Disconnecting Top Coolant Hose From Radiator</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove top coolant hose - <span class="clsEmphBOLD">arrow</span> - from radiator.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017583" name="S04471324632008020700000">Fig. 82: Removing Cover In Engine Compartment (Left Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left engine compartment cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017584" name="S29979265132008020700000">Fig. 83: Removing Electrical Harness Connectors And From Bracket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove electrical connections - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - from retainer and disconnect them.</li> <li>Set aside harness toward lock carrier.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017437" name="S06309055352008020700000">Fig. 84: Disconnecting Electrical Harness Connector For Headlights At Both Sides Of Vehicle</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections for left and right headlamps - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018077" name="S29648708692008020700000">Fig. 85: Disconnecting Electrical Harness Connector For Left/Right Airbag Sensors On Lock Carrier</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections for both left and right airbag sensors - <span class="clsEmphBOLD">arrow</span> - on lock carrier.</li> <li>Set aside harness toward lock carrier.</li> <li>Remove hood release cable from lock carrier --> <a class="clsExtHyperlink" id="A00278920_S06872438102008020700000">55 HOOD, LIDS</a> </li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018078" name="S32761949322008020700000">Fig. 86: Disconnecting Electrical Harness Connector For Right Fan</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">arrow</span> - for right radiator fan.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017282" name="S25712377862008020700000">Fig. 87: Removing Left/Right Air Guides At Radiator</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> - and remove right and left radiator air guides.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018294" name="S18967257932008020700000">Fig. 88: Removing Power Steering Hydraulic Oil Cooling Pipe</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unclip temperature sensor - <span class="clsEmphBOLD">1</span> - from retainer and set aside.</li> <li>Remove power steering cooling line - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018295" name="S34536186252008020700000">Fig. 89: Removing Coolant Fan Control (FC) Control Module J293 From Radiator</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screw - <span class="clsEmphBOLD">arrow</span> - and remove cooling fan control module.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>In order not to damage the condensor and refrigerant lines/hoses, ensure refrigerant lines are not excessively bent or tensioned in the following procedures.</li> <li>Do not open refrigerant circuit!</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018296" name="S31296082652008020700000">Fig. 90: Disconnecting Electrical Harness Connector At High Pressure Sensor G65</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> - at High Pressure Sensor G65.</li> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove condensor with refrigerant lines attached and lower downward.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017286" name="S00530041052008020700000">Fig. 91: Removing Bolts At Left/Right Side Of Bumper</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws at lock carrier left and right - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove front hood sealing gasket from lock carrier and fenders.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017585" name="S41624335682008020700000">Fig. 92: Removing Bolts At Impact Absorbers At Left/Right</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts at impact absorbers - <span class="clsEmphBOLD">arrows</span> - (left and right).</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Use an assistant to remove lock carrier in the following step.</li> <li>Remove lock carrier and tilt aside (secure against falling).</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018269" name="S01719833062008020700000">Fig. 93: Removing Hose Clamps And Disconnecting Coolant Hose</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release hose clamp - <span class="clsEmphBOLD">2</span> - and remove coolant hose from right coolant pipe.</li> <li>Release hose clamp - <span class="clsEmphBOLD">1</span> - and remove coolant hose from coolant pipe.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Engine shown removed in illustration for clarity.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before removing ribbed belt, mark direction of rotation. Belt damage will result if not reinstalled in proper direction.</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018135" name="S34817414222008020700000">Fig. 94: Loosening Tensioning Bolt And Ribbed Belt</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Relieve ribbed belt tension by loosening tensioner bolt - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove ribbed belt from generator pulley.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018268" name="S07077896012008020700000">Fig. 95: Removing Tensioning Roller</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> - and remove tensioner.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018271" name="S08139130822008020700000">Fig. 96: Removing Generator Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove generator from bracket and pull forwards.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018270" name="S39323129262008020700000">Fig. 97: Disconnecting Coolant Hose On Generator, Electrical Connector & Removing Electrical Wire On Generator</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release hose clamp - <span class="clsEmphBOLD">3</span> - and remove coolant hose from generator.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove nut - <span class="clsEmphBOLD">2</span> - and terminal eyelet from generator.</li> <li>Remove generator.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Before installing the ribbed belt, ensure that all subassemblies (generator, a/c compressor etc.) are securely mounted and turn freely.</li> <li>When installing belt, ensure correct seating in the belt pulleys!</li> <li>Reinstall all hose clamps, harness retainers and replace all removed cable ties as originally installed in production.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>To aid in installation, drive generator mounting bushings back into mounting flanges approx. 4mm.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Tight generator mounting bushings must be made to move freely in order to ensure sufficient clamping force at the specified bolt torque.</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018136" name="S26491835972008020700000">Fig. 98: Placing Ribbed Belt Over Belt Pulley In Sequence</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Note running direction of ribbed belt as previously marked and route as illustrated.</li> </ul> <ol class="clsARABICNUM"> <li>Generator (GEN)</li> <li>Ribbed belt</li> <li>Idler</li> <li>Vibration damper</li> <li>Tensioning roller</li> </ol> <ul class="clsDASH"> <li>Tension ribbed belt by rotating tensioner counterclockwise with torque wrench until 70 Nm is achieved.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018137" name="S01955778172008020700000">Fig. 99: Positioning Torque Wrench On Belt Tensioner Hex Bolt</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Hold and simultaneously tighten tensioner bolt - <span class="clsEmphBOLD">arrow</span> - to 22 Nm.</li> <li>Reinstall lock carrier and related assemblies --> <a class="clsExtHyperlink" id="A00278920_S31853902272008020700000">50 BODY, FRONT</a> .</li> <li>Reinstall front bumper --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> <li>Top up coolant --> 4.2 Liter V8 5V Engine Mechanical, Engine Code(s): BHF - <ul class="clsBULLET"> <li>19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB</li> <li><a class="clsExtHyperlink" id="A00278881_S33573201972008020700000">19 - ENGINE - COOLING SYSTEM</a> for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT</li> <li>19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN</li> <li><a class="clsExtHyperlink" id="A00278883_S41376556702008020700000">19 - ENGINE - COOLING SYSTEM</a> for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH</li> <li><a class="clsExtHyperlink" id="A00278885_S21797592792008020700000">19 - ENGINE - COOLING SYSTEM</a> for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS</li> <li><a class="clsExtHyperlink" id="A00278884_S12212760292008020700000">19 - ENGINE - COOLING SYSTEM</a> for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF</li> </ul> .</li> </ul> <ul class="clsDASH"> <li>Refill power steering fluid reservoir --> <a class="clsExtHyperlink" id="A00278916_S32803510402008020700000">48 - STEERING</a> </li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Power steering pump must NOT be allowed to run dry. Damage will result.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> <li>Start engine and check belt running.</li> <li>Check and adjust headlamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> </li> </ul><a name="S30168572412009022500000"></a><h2 class="clsHeadFour">Tightening Torques (4.2L - S4)</h2> <p><span class="clsEmphBOLD">Tightening Torques</span> </p> <p><span class="clsArticleTable"><a name="S301685724120090225000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Coolant pipes to generator - bolt</td> <td align="" class="clsCellNormal">9</td> </tr> <tr> <td align="" class="clsCellNormal">Terminal 30/B+ to generator - nut</td> <td align="" class="clsCellNormal">16</td> </tr> <tr> <td align="" class="clsCellNormal">Generator (GEN) to engine bracket - bolt</td> <td align="" class="clsCellNormal">22</td> </tr> <tr> <td align="" class="clsCellNormal">Tensioning roller to engine - bolt</td> <td align="" class="clsCellNormal">22</td> </tr> </tbody> </table></span></p><a name="S30870039652008020700000"></a><h2 class="clsHeadThree">Generator (GEN) - 4.2L 8-cylinder FSI engine (Audi RS4), removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00007852" name="S17850721552008020700000">Fig. 100: Identifying Old Oil Collecting And Extracting Device V.A.G 1782</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>oil drain appliance VAG 1782 or UL approved equivalent</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00008744" name="S34557996402008020700000">Fig. 101: Drip Tray For VAS 6100, VAS 6208</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Workshop crane drip tray VAS 6208 or drip tray VAG 1306</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S25665527002008020700000">Fig. 102: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000114" name="S03420056982008020700000">Fig. 103: Identifying Torque Wrench V.A.G. 1332</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S36611140512008020700000">Battery in luggage compartment, disconnecting and connecting</a>.</li> <li>Use oil drain appliance VAG 1782 (or UL approved equivalent) to draw power steering hydraulic fluid from power steering from reservoir.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>The cooling system is pressurized when the engine is warm. Wear gloves and other protection and carefully release system pressure if necessary, before performing repairs.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Open filler cap for coolant expansion tank.</li> <li>Lift vehicle</li> <li>Remove right front wheel.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018071" name="S08263054372008020700000">Fig. 104: Removing Quick-Release Fasteners, Screws And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove front noise insulation.</li> <li>Remove right front wheelhouse liner --> <a class="clsExtHyperlink" id="A00278920_S32431341132008020700000">66 EXTERIOR EQUIPMENT</a> .</li> <li>Remove front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> Front bumper cover, removing and installing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018073" name="S15766182392008020700000">Fig. 105: Removing Right Air Guide In Front Of Auxiliary Cooler</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove right air duct - <span class="clsEmphBOLD">arrow</span> - in front of auxiliary radiator.</li> <li>Place oil drain appliance VAG 1782 (or UL approved equivalent) under engine.</li> <li>Drain engine oil.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018337" name="S16132602662008020700000">Fig. 106: Removing Bolts On Oil Cooler Lines At Upper Part Of Oil Pan</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> - at oil cooler lines on upper part of oil pan.</li> <li>Remove oil lines from upper part of oil pan.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018072" name="S22436811312008020700000">Fig. 107: Removing Left Air Guide In Front Of Auxiliary Cooler</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left air duct - <span class="clsEmphBOLD">arrow</span> - in front of auxiliary radiator.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018336" name="S33092139702008020700000">Fig. 108: Removing Bolt On Auxiliary Cooler Upper Bracket, At Left Of Lock Carrier</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrow</span> - at upper left auxiliary radiator bracket at lock carrier.</li> <li>Place workshop crane drip tray VAS 6208 or VAG 1306 under engine.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018338" name="S08481619562008020700000">Fig. 109: Removing Drain Plug On Coolant Thermostat Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove drain plug - <span class="clsEmphBOLD">arrow</span> - at coolant regulator housing and drain coolant at engine.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018339" name="S00843220192008020700000">Fig. 110: Removing Drain Plug On Front Coolant Pipe</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Also remove drain plug - <span class="clsEmphBOLD">arrow</span> - at front coolant pipe and drain remaining coolant.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018340" name="S35100439572008020700000">Fig. 111: Removing Coolant Hose Downward From Cooler</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Loosen hose clamp - <span class="clsEmphBOLD">arrow</span> - and remove lower coolant hose from radiator.</li> <li>Place oil extractor VAG 1782 under engine.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018075" name="S13850290112008020700000">Fig. 112: Disconnecting Hydraulic Lines To Cooling Coil At Left Rear Of Bumper</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect hydraulic lines to rear left radiator coil on lock carrier - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017848" name="S39120186002008020700000">Fig. 113: Identifying Bolts & Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove air duct - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018076" name="S07428032022008020700000">Fig. 114: Disconnecting Top Coolant Hose From Radiator</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Detach upper coolant hose - <span class="clsEmphBOLD">arrow</span> - from radiator.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017583" name="S36315465272008020700000">Fig. 115: Removing Cover In Engine Compartment (Left Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove cover - <span class="clsEmphBOLD">1</span> - at left of engine compartment.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018343" name="S14043943042008020700000">Fig. 116: Removing Electrical Harness Connectors From Bracket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove electrical connections - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - from retainer and disconnect.</li> <li>Set aside harness toward lock carrier.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017437" name="S10508085302008020700000">Fig. 117: Disconnecting Electrical Harness Connector For Headlights At Both Sides Of Vehicle</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections for left and right headlamps - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018077" name="S31985076822008020700000">Fig. 118: Disconnecting Electrical Harness Connector For Left/Right Airbag Sensors On Lock Carrier</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections for left and right airbag sensors - <span class="clsEmphBOLD">arrow</span> - at lock carrier.</li> <li>Set aside harness toward lock carrier.</li> <li>Remove hood cable at lock carrier --> <a class="clsExtHyperlink" id="A00278920_S06872438102008020700000">55 HOOD, LIDS</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018078" name="S16543172662008020700000">Fig. 119: Disconnecting Electrical Harness Connector For Right Fan</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection for right radiator fan - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018497" name="S08364255922008020700000">Fig. 120: Removing Bolts On Left/Right Air Guides At Cooler</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> - at left and right air ducts on radiator.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>In order not to damage the condensor and refrigerant lines/hoses, ensure refrigerant lines are not excessively bent or tensioned in the following procedures.</li> <li>Do not open refrigerant circuit!</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018296" name="S41477991482008020700000">Fig. 121: Disconnecting Electrical Harness Connector At High Pressure Sensor G65</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> - for High Pressure Sensor G65.</li> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove condenser and swing downward with refrigerant lines connected.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018346" name="S07919951482008020700000">Fig. 122: Removing Right Coolant Hose</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove right coolant hose - <span class="clsEmphBOLD">arrow</span> - at radiator.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017286" name="S37381818772008020700000">Fig. 123: Removing Bolts At Left/Right Side Of Bumper</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> - at left and right lock carriers.</li> <li>Remove engine compartment seat at lock carrier and fender edges.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017585" name="S36541992462008020700000">Fig. 124: Removing Bolts At Impact Absorbers At Left/Right</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws on left and right shock absorbers - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Use an assistant to remove lock carrier in the following step.</li> <li>Remove lock carrier and tilt aside (secure against falling).</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before removing ribbed belt, mark direction of rotation. Belt damage will result if not reinstalled in proper direction.</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018392" name="S40229457232008020700000">Fig. 125: Releasing Ribbed Belt Tension</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Relieve ribbed belt tension by pivoting tensioner in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure lever axle is long enough so that it can be completely inserted in tensioner.</li> <li>Remove ribbed belt from generator pulley.</li> <li>Release tensioner.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018482" name="S17574806872008020700000">Fig. 126: Removing Bolts & Ribbed Belt Tensioner At Upper Part Of Oil Pan</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove tensioner - <span class="clsEmphBOLD">1</span> - at upper part of oil pan.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021579" name="S02341675122008020700000">Fig. 127: Removing Bolts And Coolant Hose From Coolant Pipe Bracket And Generator</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolt - <span class="clsEmphBOLD">2</span> - on coolant pipe bracket.</li> <li>Loosen hose clamp and remove coolant hose - <span class="clsEmphBOLD">1</span> - to generator.</li> <li>Remove bolts - <span class="clsEmphBOLD">3</span> - and - <span class="clsEmphBOLD">4</span> -.</li> <li>Remove generator from bracket and pull forward.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If generator is difficult to remove from mounting, reinstall mounting bolts loosely and carefully strike bolt heads with hammer in order to loosen mounting threaded bushings.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018483" name="S28030411792008020700000">Fig. 128: Identifying Coolant Hose, Electrical Connector, Bolt & Heat Shield</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove coolant hose - <span class="clsEmphBOLD">1</span> - from generator.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">5</span> -.</li> <li>Remove screw - <span class="clsEmphBOLD">4</span> - and remove heat shield.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Ensure coolant pipes do not slip out, otherwise O-rings on removed coolant pipes must be replaced. Re-tighten bracket - <span class="clsEmphBOLD">3</span> - after removing heat shield if necessary.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove nut - <span class="clsEmphBOLD">2</span> - and terminal 30 ( B+ ) eyelet from generator.</li> <li>Remove generator.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Before installing the ribbed belt, ensure that all subassemblies (generator, a/c compressor etc.) are securely mounted and turn freely.</li> <li>When installing belt, ensure correct seating in the belt pulleys!</li> <li>Reinstall all hose clamps, harness retainers and replace all removed cable ties as originally installed in production.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>To aid in installation, drive generator mounting bushings back into mounting flanges approx. 4mm.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Tight generator mounting bushings must be made to move freely in order to ensure sufficient clamping force at the specified bolt torque.</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018136" name="S05255398332008020700000">Fig. 129: Placing Ribbed Belt Over Belt Pulley In Sequence</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Note running direction of ribbed belt as previously marked and route as illustrated.</li> </ul> <ol class="clsARABICNUM"> <li>Generator</li> <li>Ribbed belt</li> <li>Idler pulley</li> <li>Vibration damper</li> <li>Tensioning roller</li> </ol> <ul class="clsDASH"> <li>Install lock carrier with attachments --> <a class="clsExtHyperlink" id="A00278920_S31853902272008020700000">50 BODY, FRONT</a> .</li> <li>Install front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> Front bumper cover, removing and installing.</li> <li>Before starting engine for first time, fill hydraulic oil in power steering reservoir.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Power steering pump must NOT be allowed to run dry. Damage will result.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Fill engine oil and check oil level.</li> <li>Top up coolant --> 4.2 Liter V8 5V Engine Mechanical, Engine Code(s): BNS - <ul class="clsBULLET"> <li>19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB</li> <li><a class="clsExtHyperlink" id="A00278881_S33573201972008020700000">19 - ENGINE - COOLING SYSTEM</a> for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT</li> <li>19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN</li> <li><a class="clsExtHyperlink" id="A00278883_S41376556702008020700000">19 - ENGINE - COOLING SYSTEM</a> for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH</li> <li><a class="clsExtHyperlink" id="A00278885_S21797592792008020700000">19 - ENGINE - COOLING SYSTEM</a> for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS</li> <li><a class="clsExtHyperlink" id="A00278884_S12212760292008020700000">19 - ENGINE - COOLING SYSTEM</a> for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF</li> </ul> .</li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S39123246362008040900000">Connecting</a></li> <li>Start engine and check belt routing.</li> </ul> <ul class="clsDASH"> <li>Check and adjust headlamps --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul><a name="S36588614722009022500000"></a><h2 class="clsHeadFour">Tightening Torques (4.2L - RS4)</h2> <p><span class="clsEmphBOLD">Tightening Torques</span> </p> <p><span class="clsArticleTable"><a name="S365886147220090225000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Coolant pipe bracket to generator - bolt</td> <td align="" class="clsCellNormal">9</td> </tr> <tr> <td align="" class="clsCellNormal">Terminal 30/B+ to generator - nut</td> <td align="" class="clsCellNormal">16</td> </tr> <tr> <td align="" class="clsCellNormal">Generator to engine - bolts</td> <td align="" class="clsCellNormal">22</td> </tr> <tr> <td align="" class="clsCellNormal">Tensioner to upper part of oil pan - bolts</td> <td align="" class="clsCellNormal">9</td> </tr> </tbody> </table></span></p><a name="S37729212922008020700000"></a><h2 class="clsHeadTwo">Starter</h2><a name="S41663241502008020700000"></a><h2 class="clsHeadThree">Starter - 1.8L 4-cylinder Turbo engine, removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S36499405482008020700000">Fig. 130: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000114" name="S32594925912008020700000">Fig. 131: Identifying Torque Wrench V.A.G. 1332</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> <li>Lift vehicle.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017429" name="S00863549562008020700000">Fig. 132: Identifying Quick-Release Fasteners And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove front noise insulation.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017298" name="S05840169482008020700000">Fig. 133: Identifying Line, Connector Terminal, Clamp, And Insulator</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nut at starter solenoid terminal B+ - <span class="clsEmphBOLD">2</span> - and remove connector eyelet from terminal.</li> <li>Disconnect electrical connection for terminal 50 - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove insulator from positive connection on starter where applicable.</li> <li>Remove harness clamp - <span class="clsEmphBOLD">4</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove bolt - <span class="clsEmphBOLD">3</span> - from engine block to starter bracket, and remove bracket.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021580" name="S21785533072008020700000">Fig. 134: Identifying Bolts And Starter</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove starter from below.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S416632415020080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> <col span="1" id="COL3"> </colgroup> <tbody> <tr> <td colspan="2" align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal"> </td> <td align="RIGHT" class="clsCellNormal">M10</td> <td align="" class="clsCellNormal">45</td> </tr> <tr> <td align="" class="clsCellNormal">Starter to transmission bracket - bolt</td> <td align="RIGHT" class="clsCellNormal">M12</td> <td align="" class="clsCellNormal">65</td> </tr> <tr> <td colspan="2" align="" class="clsCellNormal">Terminal B+ to starter - nut</td> <td align="" class="clsCellNormal">16</td> </tr> </tbody> </table></span></p><a name="S20939731752008020700000"></a><h2 class="clsHeadThree">Starter - 2.0L 4-cyl Turbo FSI engine, removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S39862869892008020700000">Fig. 135: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000114" name="S05959940672008020700000">Fig. 136: Identifying Torque Wrench V.A.G. 1332</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> <li>Lift vehicle.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017429" name="S24358226032008020700000">Fig. 137: Identifying Quick-Release Fasteners And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove front noise insulation.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017459" name="S20453889942008020700000">Fig. 138: Removing Left/Right Heat Shields For Drive Axles</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove heat shield - <span class="clsEmphBOLD">1</span> - for right drive shaft.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021580" name="S01694774892008020700000">Fig. 139: Identifying Bolts And Starter</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017464" name="S03825223882008020700000">Fig. 140: Identifying Starter, Electrical Connector & Nuts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove starter and swing aside.</li> <li>Disconnect electrical connection for terminal 50 - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove nut - <span class="clsEmphBOLD">1</span> - for harness clamp.</li> <li>Remove nut at starter solenoid terminal B+ - <span class="clsEmphBOLD">2</span> - and remove connector eyelet from terminal.</li> </ul> <ul class="clsDASH"> <li>Remove starter.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S209397317520080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Starter to transmission - bolt</td> <td align="" class="clsCellNormal">65</td> </tr> <tr> <td align="" class="clsCellNormal">Terminal B+ to starter - nut</td> <td align="" class="clsCellNormal">16</td> </tr> </tbody> </table></span></p><a name="S39141320372008020700000"></a><h2 class="clsHeadThree">Starter - 3.0L 6-cylinder engine, removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S13979661362008020700000">Fig. 141: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000114" name="S17772965982008020700000">Fig. 142: Identifying Torque Wrench V.A.G. 1332</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> <li>Lift vehicle.</li> <li>Remove right front wheel.</li> <li>Remove generator --> <a class="clsHyperlink" href="#S05143446662008020700000">Generator (GEN) - 3.0L 6-cylinder engine, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021581" name="S31296672702008020700000">Fig. 143: Identifying Heat Shield For Right Drive Shaft</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove heat shield for right drive shaft - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021582" name="S18472094072008020700000">Fig. 144: Identifying Cable For Terminals, Heat Shield From Solenoid Switch, And Starter</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nut at starter solenoid terminal B+ - <span class="clsEmphBOLD">2</span> - and remove connector eyelet from terminal.</li> <li>Disconnect electrical connection for terminal 50 - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove solenoid heat shield - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> - and remove starter.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install generator <a class="clsHyperlink" href="#S21360356832008040900000">Installing</a></li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S391413203720080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Starter to engine - bolt</td> <td align="" class="clsCellNormal">45</td> </tr> <tr> <td align="" class="clsCellNormal">Terminal B+ to starter - nut</td> <td align="" class="clsCellNormal">16</td> </tr> <tr> <td align="" class="clsCellNormal">Drive shaft heat shield to transmission - bolt</td> <td align="" class="clsCellNormal">23</td> </tr> </tbody> </table></span></p><a name="S34807416472008020700000"></a><h2 class="clsHeadThree">Starter - 3.2L 6-cylinder FSI engine, removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S10389756002008020700000">Fig. 145: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000114" name="S11556068632008020700000">Fig. 146: Identifying Torque Wrench V.A.G. 1332</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> <li>Lift vehicle.</li> <li>Remove right front wheel.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Secure brake disc with a wheel bolt.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017429" name="S10386413592008020700000">Fig. 147: Identifying Quick-Release Fasteners And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners - <span class="clsEmphBOLD">1 3</span> - and remove front and rear noise insulation.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018315" name="S13368792842008020700000">Fig. 148: Drive Axle Heat Shield</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove right drive shaft heat shield - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsEmphBOLD">Vehicles with automatic transmission</span> </p> <ul class="clsDASH"> <li>Remove right drive axle from transmission axle flange.</li> </ul> <p><span class="clsEmphBOLD">Continued for all:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021583" name="S14972727222008020700000">Fig. 149: Identifying Bolts, Starter Solenoid Terminal, And Connector</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nut at starter solenoid terminal B+ - <span class="clsEmphBOLD">2</span> - and connection for terminal 50 - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p><span class="clsEmphBOLD">Vehicles with automatic transmission</span> </p> <ul class="clsDASH"> <li>Remove starter towards rear of wheel housing.</li> </ul> <p><span class="clsEmphBOLD">Vehicles with standard transmission</span> </p> <ul class="clsDASH"> <li>Remove starter from between transmission and subframe.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>For clarity, subframe shown removed in illustrations.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Reinstall right drive axle from transmission axle flange. Refer to appropriate automatic transmission repair information, RG 40.</li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S348074164720080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="LEFT" class="clsCellNormal">Component - fastener</td> <td align="CENTER" class="clsCellNormal">Nm</td> </tr> <tr> <td align="LEFT" class="clsCellNormal">Stater to transmission - bolt</td> <td align="CENTER" class="clsCellNormal">65</td> </tr> <tr> <td align="" class="clsCellNormal">Terminal B+ to starter - nut</td> <td align="CENTER" class="clsCellNormal">16</td> </tr> <tr> <td align="" class="clsCellNormal">Drive shaft heat shield to transmission - bolt</td> <td align="CENTER" class="clsCellNormal">23</td> </tr> </tbody> </table></span></p><a name="S16022054192008020700000"></a><h2 class="clsHeadThree">Starter - 4.2L 8-cylinder engine (Audi S4), removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000013" name="S19058814152008020700000">Fig. 150: Identifying 10-222A Engine Support Bridge With 10-222A/8 Bracket For Engine</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Engine support bridge 10-222 A</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00002386" name="S40357445112008020700000">Fig. 151: Identifying Special Tools - Shackle 10 - 222 A/12</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Shackle (set) 10-222 A/12</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S03390462252008020700000">Fig. 152: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000114" name="S15350353562008020700000">Fig. 153: Identifying Torque Wrench V.A.G. 1332</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017835" name="S42786692882008020700000">Fig. 154: Removing/Installing Rear Engine Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unclip engine cover - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018292" name="S40184847042008020700000">Fig. 155: Securing Shackle 10-222 A/12 To Right Rear Engine Lifting Eyelet</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Attach shackle 10-222 A/12 to right rear lifting fixture on engine.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Disregard - <span class="clsEmphBOLD">1</span> -.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018293" name="S12416681992008020700000">Fig. 156: Engaging Shackle 10-222 A/12 On Spindle Of Engine Support Bridge 10-222 A</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Assemble support bracket 10-222 A and place across fenders as illustrated.</li> <li>Attach shackle to lifting spindle.</li> <li>Turn lifting spindle to apply slight lifting tension to engine.</li> <li>Lift vehicle.</li> </ul> <ul class="clsDASH"> <li>Remove right front wheel.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018071" name="S03756175852008020700000">Fig. 157: Removing Quick-Release Fasteners, Screws And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners - <span class="clsEmphBOLD">1</span> - , remove bolts - <span class="clsEmphBOLD">2</span> - and remove noise insulation.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018256" name="S37304715012008020700000">Fig. 158: Removing Nuts For Left/Right Stabilizer Mounts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove anti-roll bar bracket nuts - <span class="clsEmphBOLD">1... 4</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018117" name="S04815025132008020700000">Fig. 159: Removing Wiring Harness Bracket At Right Engine Mount Plate</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nut - <span class="clsEmphBOLD">arrow</span> - and remove harness retainer from mounting.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021584" name="S18096587552008020700000">Fig. 160: Identifying Nuts, Bolts, And Right Side Engine Mount Carrier</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nut - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove right side engine mount carrier.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018102" name="S17226714362008020700000">Fig. 161: Removing Refrigerant Line On Bracket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove right refrigerant line mounting - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018118" name="S25422072122008020700000">Fig. 162: Disconnecting Electrical Harness Connector At Right Engine Mount</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove right engine mount with bracket.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018315" name="S35570205322008020700000">Fig. 163: Drive Axle Heat Shield</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Vehicles with manual transmission:</span> </p> <ul class="clsDASH"> <li>Remove right drive shaft heat shield - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00019429" name="S00901997462008020700000">Fig. 164: Identifying Ground (GND) Wire, Wires, Nuts, Bolts & Starter</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove ground cable - <span class="clsEmphBOLD">5</span> -.</li> <li>Remove nut at starter solenoid terminal B+ - <span class="clsEmphBOLD">3</span> - and connection for terminal 50 - <span class="clsEmphBOLD">4</span> -.</li> <li>Remove nut - <span class="clsEmphBOLD">1</span> - and bolt - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove starter.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017459" name="S35066043742008020700000">Fig. 165: Removing Left/Right Heat Shields For Drive Axles</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Vehicles with automatic transmission:</span> </p> <ul class="clsDASH"> <li>Remove heat shield - <span class="clsEmphBOLD">1</span> - for drive shaft (right-side).</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018130" name="S15209633102008020700000">Fig. 166: Identifying Ground (GND) Wire, Starter Electrical Wires, Bolts & Starter</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove earth cable - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove nut at starter solenoid terminal B+ - <span class="clsEmphBOLD">3</span> - and connection for terminal 50 - <span class="clsEmphBOLD">4</span> -.</li> <li>Remove bolts - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">5</span> -.</li> <li>Remove starter.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install engine mounting and tighten subframe --> <a class="clsExtHyperlink" id="A00278916_S20573127852008020700000">40 - FRONT SUSPENSION</a> .</li> <li>Install anti-roll bar --> <a class="clsExtHyperlink" id="A00278916_S20573127852008020700000">40 - FRONT SUSPENSION</a> .</li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S160220541920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Starter to transmission - bolt</td> <td align="" class="clsCellNormal">65</td> </tr> <tr> <td align="" class="clsCellNormal">Terminal B+ to starter - nut</td> <td align="" class="clsCellNormal">16</td> </tr> <tr> <td align="" class="clsCellNormal">Ground cable to starter - bolt</td> <td align="" class="clsCellNormal">22</td> </tr> <tr> <td align="" class="clsCellNormal">Engine support to cylinder block - bolt</td> <td align="" class="clsCellNormal">42 <sup>1)</sup> </td> </tr> <tr> <td align="" class="clsCellNormal">Drive shaft heat shield to transmission - bolt</td> <td align="" class="clsCellNormal">23</td> </tr> <tr> <td colspan="2" align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><sup>1)</sup> Insert with locking compound; locking compound.</li> </ul> </td> </tr> </tbody> </table></span></p><a name="S07725832242008020700000"></a><h2 class="clsHeadThree">Starter - 4.2L 8-cylinder FSI engine (Audi RS4), removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000013" name="S37837514392008020700000">Fig. 167: Identifying 10-222A Engine Support Bridge With 10-222A/8 Bracket For Engine</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Engine Support Bridge 10-222A</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018927" name="S20565925282008020700000">Fig. 168: Insert Pad For Front Fender T40045</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Insert Pad For Front Fender T40045</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00002386" name="S40996007242008020700000">Fig. 169: Identifying Special Tools - Shackle 10 - 222 A/12</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Shackle (set) 10-222 A/12</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S09820958032008020700000">Fig. 170: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000114" name="S01977508942008020700000">Fig. 171: Identifying Torque Wrench V.A.G. 1332</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When installing, reinstall all cable ties that were loosened or cut during removal in the same locations.</li> <li>Disconnect battery --> <a class="clsHyperlink" href="#S36611140512008020700000">Battery in luggage compartment, disconnecting and connecting</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018347" name="S31948853532008020700000">Fig. 172: Pulling Rear Engine Cover Off</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rear engine cover by pulling up in direction of - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017583" name="S11517579812008020700000">Fig. 173: Removing Cover In Engine Compartment (Left Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left engine compartment cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017848" name="S34937800792008020700000">Fig. 174: Identifying Bolts & Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove air duct - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove engine compartment seal at lock carrier and fender edges.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017517" name="S28364649182008020700000">Fig. 175: Inserting Insert Pad For Front Fender T40045 On Both Sides Between Fender Mounting Flange And Body Panel Underneath</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>To avoid damaging bolted fender edges with Engine Support Bridge 10-222A , place Insert Pad For Front Fender T40045 - <span class="clsEmphBOLD">arrows</span> - on both sides between bolted fender edges and panel underneath.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021585" name="S05738783752008020700000">Fig. 176: Locating Engine Support Spindles At Rear Of Crossbar</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Place Engine Support Bridge 10-222A on bolted fender edges. Locate engine support spindles at rear of crossbar as illustrated.</li> <li>Install Shackles 10-222A/12 at engine support bridge spindles.</li> <li>Pre-tension engine slightly with engine support bridge spindles.</li> <li>Lift vehicle.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018071" name="S30180829762008020700000">Fig. 177: Removing Quick-Release Fasteners, Screws And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove right front wheel.</li> <li>Release fasteners - <span class="clsEmphBOLD">1</span> - , remove screws - <span class="clsEmphBOLD">2</span> - and remove front noise insulation.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018256" name="S08113634272008020700000">Fig. 178: Removing Nuts For Left/Right Stabilizer Mounts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left and right stabilizer bar mount nuts - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> <li>Swing stabilizer bar down.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018117" name="S28435565732008020700000">Fig. 179: Removing Wiring Harness Bracket At Right Engine Mount Plate</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove wiring harness bracket at right engine console - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021584" name="S28258051522008020700000">Fig. 180: Identifying Nuts, Bolts, And Right Side Engine Mount Carrier</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nut - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove right engine console.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018118" name="S41434817842008020700000">Fig. 181: Disconnecting Electrical Harness Connector At Right Engine Mount</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connector at right engine mount - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> - using a hex socket head wrench with ball head.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021586" name="S11931939082008020700000">Fig. 182: Identifying Engine Mount Nut</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove engine mount nut - <span class="clsEmphBOLD">1</span> - at right engine support.</li> <li>Remove engine mount and engine support.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017459" name="S36022854262008020700000">Fig. 183: Removing Left/Right Heat Shields For Drive Axles</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove right driveshaft heat shield - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021587" name="S40396440312008020700000">Fig. 184: Identifying Screws, Nuts, And Starter Heat Shield</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">4</span> - at starter heat shield.</li> <li>Remove nut - <span class="clsEmphBOLD">3</span> - and screw - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove starter forward.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021588" name="S28906260522008020700000">Fig. 185: Identifying Electrical Connection, Locking Mechanism, Nut, Ground Wire, And Cable Ties</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release electrical connection - <span class="clsEmphBOLD">2</span> - by pushing locking mechanism - <span class="clsEmphBOLD">arrow A</span> - and pressing catch down - <span class="clsEmphBOLD">arrow B</span> -.</li> <li>Remove nut - <span class="clsEmphBOLD">1</span> - and remove terminal 30 ( B+ ) eyelet.</li> <li>Remove ground wire - <span class="clsEmphBOLD">4</span> -.</li> <li>Cut through cable ties - <span class="clsEmphBOLD">3</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove starter.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When installing, install cable ties at same location.</li> <li>Install engine console and tighten subframe --> <a class="clsExtHyperlink" id="A00278916_S20573127852008020700000">40 - FRONT SUSPENSION</a> .</li> <li>Install stabilizer --> <a class="clsExtHyperlink" id="A00278916_S20573127852008020700000">40 - FRONT SUSPENSION</a> .</li> <li>Connect battery. Required steps <a class="clsHyperlink" href="#S39123246362008040900000">Connecting</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S077258322420080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Starter to transmission - bolt</td> <td align="" class="clsCellNormal">65</td> </tr> <tr> <td align="" class="clsCellNormal">Terminal B+ to starter - nut</td> <td align="" class="clsCellNormal">16</td> </tr> <tr> <td align="" class="clsCellNormal">Ground cable to starter - bolt</td> <td align="" class="clsCellNormal">22</td> </tr> <tr> <td align="" class="clsCellNormal">Engine support to cylinder block - bolt</td> <td align="" class="clsCellNormal">42 <sup>1)</sup> </td> </tr> <tr> <td align="" class="clsCellNormal">Heat shield for half-shaft to transmission - bolt</td> <td align="" class="clsCellNormal">23</td> </tr> <tr> <td colspan="2" align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><sup>1)</sup> Insert with locking compound; locking compound.</li> </ul> </td> </tr> </tbody> </table></span></p><a name="S31067607762008020700000"></a><h2 class="clsHeadOne">90 Instruments</h2><a name="S19529430472008020700000"></a><h2 class="clsHeadTwo">Instrument Cluster</h2><a name="S24888508472008020700000"></a><h2 class="clsHeadThree">General information</h2> <p>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.</p> <p>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.</p> <p>The optional Navigation system display is also included in the Drivers Information System (where applicable).</p><a name="S17028268582008020700000"></a><h2 class="clsHeadThree">Instrument cluster, disposal</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Instrument cluster LCD display contains mercury.</li> <li>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.</li> </ul> </td> </tr> </table></span></p><a name="S29158997042008020700000"></a><h2 class="clsHeadThree">On Board Diagnostic (OBD), function</h2> <p>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.</p> <p>Troubleshoot instrument cluster malfunctions and perform OBD program functions using VAS 5051/5052 tester in mode "Guided Fault Finding".</p> <p>VAS 5051/5052 connected and in mode "Guided Fault Finding":</p> <ul class="clsDASH"> <li>Enter appropriate model, equipment and model year information and press ">" to confirm.</li> </ul> <p>After the DTC memory of all control modules has been checked:</p> <ul class="clsDASH"> <li>Press "Go to" "Go to" button</li> <li>Select: "Function / Component Selection"</li> <li>Select: "Body (Repair 01; 27; 50 - 97)"</li> <li>Select: "Electrical Equipment (Repair 01; 90 - 97)"</li> </ul> <ul class="clsDASH"> <li>Select: "01 - On Board Diagnostic (OBD) capable systems"</li> <li>Select: "Instrument Cluster"</li> <li>Select appropriate option</li> <li>Follow tester prompts.</li> </ul><a name="S15407466852008020700000"></a><h2 class="clsHeadThree">Message "dEF" in trip recorder display</h2> <p>If the instrument cluster control module detects a DTC in permanent memory, letters "dEF" will appear in the trip recorder display.</p> <ul class="clsDASH"> <li>If "dEF" is displayed, Replace instrument cluster --> <a class="clsHyperlink" href="#S21852926562008020700000">Instrument cluster, removing and installing</a>.</li> </ul><a name="S21852926562008020700000"></a><h2 class="clsHeadThree">Instrument cluster, removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S34249581642008020700000">Fig. 186: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Do not disassemble instrument cluster.</li> <li>Instrument clusters contain no field serviceable components. Should malfunctions occur, replace complete instrument cluster.</li> <li>If instrument cluster is to be replaced, connect VAS 5051/5052 and initiate OBD program option "Instrument cluster, replacing" --> <a class="clsHyperlink" href="#S29158997042008020700000">On Board Diagnostic (OBD), function</a></li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Pull steering wheel with adjusting mechanism fully out and move it downward.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>For clarity, steering wheel is shown removed in the following illustrations.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021589" name="S19460345072008020700000">Fig. 187: Pulling Off Bottom Cover Towards Rear</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull off bottom cover - <span class="clsEmphBOLD">1</span> - towards rear - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021590" name="S23063386322008020700000">Fig. 188: Locating Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020819" name="S06298394322008020700000">Fig. 189: Pulling Off Left Instrument Panel Cover Using Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left instrument panel side cover - <span class="clsEmphBOLD">arrow</span> - using hook 3370.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021591" name="S19636772832008020700000">Fig. 190: Reaching Through Opening Above Fuse Panel And Pushing Out Instrument Cluster</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Reach through opening - <span class="clsEmphBOLD">arrow A</span> - above fuse panel and push out instrument cluster in direction of - <span class="clsEmphBOLD">arrow B</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017034" name="S38784135782008020700000">Fig. 191: Identifying Securing Bracket Of Connectors</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disengage lock on electrical connectors - <span class="clsEmphBOLD">arrow</span> - and disconnect.</li> <li>Remove instrument cluster from instrument panel opening.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>After installation, perform functional test of instrument cluster.</li> <li>If instrument cluster is replaced, continue to follow VAS 5051/5052 tester prompts in conjunction with OBD program option "Instrument cluster, replacing" --> <a class="clsHyperlink" href="#S29158997042008020700000">On Board Diagnostic (OBD), function</a></li> </ul><a name="S07282670722008020700000"></a><h2 class="clsHeadThree">Instrument cluster, rear view</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Do not disassemble instrument cluster.</li> <li>Instrument clusters contain no field serviceable components. All indicator warning lamps are Light Emitting Diodes (LED).</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021592" name="S36034353922008020700000">Fig. 192: Instrument Cluster, Rear View</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Should malfunctions occur, replace complete instrument cluster.</li> </ul> <p>A - 32-pin multi-pin connector, green</p> <p>B - 32-pin multi-pin connector, blue</p><a name="S30660963432008020700000"></a><h2 class="clsHeadThree">Instrument cluster multi-pin connector assignments</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021593" name="S09350777442008020700000">Fig. 193: Identifying Multi-Pin Connector 32-Pin, Blue</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">32-pin multi-pin connector, blue</span> </p> <ol class="clsARABICNUM"> <li>Washer fluid low</li> <li>Coolant level low</li> <li>Fuel gauge sensor</li> <li>Coolant temperature</li> <li>Push button circuit 2 Navigation system</li> <li>Push button circuit 3 Navigation system</li> <li>Push button circuit x Telematics</li> <li>Menu switch</li> <li>Vacant</li> <li>Front hood switch</li> <li>Fuel gauge sensor 2</li> <li>Menu switch (Out A)</li> <li>Vacant</li> <li>Vacant</li> <li>Vacant</li> <li>FDR/TCS (= ESP)</li> <li>Convenience CAN-Bus High</li> <li>Convenience CAN-Bus Low</li> <li>Infotainment CAN-Bus Low</li> <li>Infotainment CAN-Bus High</li> <li>Ambient temp. (input)</li> <li>S contact</li> <li>Oil level / oil temperature</li> <li>Self-levelling suspension</li> <li>Menu switch (enter)</li> <li>Vacant</li> <li>Vacant</li> <li>Menu switch (Out B)</li> <li>Vacant</li> <li>Transponder 2</li> <li>Transponder 1</li> <li>Terminal 31 (sensor)</li> </ol> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021594" name="S40533197372008020700000">Fig. 194: Identifying Green 32-Pin Multi-Pin Connector</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">32-pin multi-pin connector, green</span> </p> <ol class="clsARABICNUM"> <li>Terminal 58d</li> <li>Terminal 30</li> <li>Terminal 15</li> <li>Vacant</li> <li>Speedometer (input)</li> <li>Speedometer (output 2)</li> <li>Airbag (inverted)</li> <li>Turn signal (right-side)</li> <li>Brake fluid low</li> <li>Turn signal (left-side)</li> <li>Turn signal (trailer)</li> <li>Powertrain CAN-Bus Low</li> <li>Powertrain CAN-Bus High</li> <li>Terminal 61 (generator charge warning)</li> <li>Vacant</li> <li>Oil pressure 2</li> <li>Terminal 58s</li> <li>Terminal 31 load</li> <li>Terminal 31 load</li> <li>Vacant</li> <li>Speedometer (output 1)</li> <li>ABS warning</li> <li>K wire</li> <li>CAN-Bus drive (display)</li> <li>Tank flap switch</li> <li>CAN-Bus diagnosis Low</li> <li>CAN-Bus diagnosis (display)</li> <li>CAN-Bus diagnosis High</li> <li>HRC (headlamp range control)</li> <li>Safety belt buckle</li> <li>External buzzer</li> <li>Brake pad wear</li> </ol><a name="S23585072902008020700000"></a><h2 class="clsHeadThree">Fuel Level Sensor G - front-wheel drive, multi-pin connector assignments</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Preparations</span> </p> <p>Fuel level sensor is located under the floor covering in the luggage compartment.</p> <ul class="clsDASH"> <li>Remove luggage compartment floor lining.</li> <li>If necessary, fold right backrest of rear seat bench forwards.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014433" name="S14918816152008020700000">Fig. 195: Unbolting Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> - and remove access panel.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021595" name="S40000345862008020700000">Fig. 196: Identifying Electrical 4-pin Harness Connector</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully unlock and disconnect 4-pin connector - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021596" name="S19854058502008020700000">Fig. 197: Identifying Terminal Assignment Of The 4-Pin Connector On Fuel Gauge Sender</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Pin assignment for 4-pin connector at fuel level sensor</span> </p> <ol class="clsARABICNUM"> <li>Fuel pump positive ( + )</li> <li>Sensor to fuel gauge</li> <li>Sensor Ground (GND) ( - )</li> <li>Fuel pump Ground (GND) ( - )</li> </ol><a name="S23045541392008020700000"></a><h2 class="clsHeadThree">Fuel Level Sensor G , Fuel Level Sensor 2 G169 - quattro, multi-pin connector assignments</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Preparations</span> </p> <ul class="clsDASH"> <li>Remove rear seat bench --> <a class="clsExtHyperlink" id="A00278922_S17706875992008020700000">72 - SEAT - FRAMES</a> .</li> </ul> <p><span class="clsEmphBOLD">Fuel Level Sensor G</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014428" name="S06653176002008020700000">Fig. 198: Removing Cover Bolts For Locking Flange</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> - and remove right access panel.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021597" name="S02565085022008020700000">Fig. 199: Identifying Electrical 4-pin Harness Connector</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully release and disconnect 4-pin connector - <span class="clsEmphBOLD">arrow</span> - (right-side).</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021596" name="S18781821682008020700000">Fig. 200: Identifying Terminal Assignment Of The 4-Pin Connector On Fuel Gauge Sender</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Assignment of 4-pin connector at fuel level sensor.</span> </p> <ol class="clsARABICNUM"> <li>Fuel pump positive ( + )</li> <li>Sensor to fuel gauge</li> <li>Sensor Ground (GND) ( - )</li> <li>Fuel pump Ground (GND) ( - )</li> </ol> <p><span class="clsEmphBOLD">Fuel Level Sensor 2 G169</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014428" name="S40048287392008020700000">Fig. 201: Removing Cover Bolts For Locking Flange</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> - and remove left access panel.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018600" name="S40985254522008020700000">Fig. 202: Disconnecting Electrical Harness Connector At Left Locking Flange</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully release and disconnect 4-pin connector - <span class="clsEmphBOLD">arrow</span> - (left-side).</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021596" name="S03051141022008020700000">Fig. 203: Identifying Terminal Assignment Of The 4-Pin Connector On Fuel Gauge Sender</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Assignment of 4-pin connector at fuel level sensor 2</span> </p> <ol class="clsARABICNUM"> <li>Vacant</li> <li>Sensor to fuel gauge</li> <li>Sensor Ground (GND) ( - )</li> <li>Vacant</li> </ol><a name="S41031480672008020700000"></a><h2 class="clsHeadThree">Engine Coolant Temperature (ECT) Gauge Sensor G2 - 1.8L 4-cylinder Turbo engine, multi-pin connector assignments</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Preparations</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017273" name="S18807022072008020700000">Fig. 204: Removing Engine Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners and remove engine cover - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017354" name="S00136622492008020700000">Fig. 205: Disconnecting Connector At Coolant Temperature Sensor G2/G62</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">arrow</span> - at sensor.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00015756" name="S33565070912008020700000">Fig. 206: Coolant Temperature Sensor Terminals</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Pin assignment for 4-pin connector at Engine Coolant Temperature (ECT) Gauge Sensor G2 G2</span> </p> <ol class="clsARABICNUM"> <li>Wiring from sensor to instrument cluster (temperature gauge)</li> <li>Ground (GND) ( - )</li> </ol><a name="S16599514872008020700000"></a><h2 class="clsHeadThree">Engine Coolant Temperature (ECT) Sensor G62 - 2.0L 4-cylinder Turbo FSI engine, multi-pin connector assignments</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Preparations</span> </p> <p>Location: on rear right of engine.</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014438" name="S41048856152008020700000">Fig. 207: Disconnecting Electrical Harness Connector From Engine Coolant Temperature (ECT) Sensor G62</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection at sensor - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00001018" name="S01384552882008020700000">Fig. 208: Identifying 2-Pin Electrical Harness Connector & Terminals</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Pin assignment for 2-pin connector on Engine Coolant Temperature (ECT) Sensor G62</span> </p> <ol class="clsARABICNUM"> <li>Wiring from sensor to instrument cluster (temperature gauge)</li> <li>Ground (GND) ( - )</li> </ol><a name="S30120037502008020700000"></a><h2 class="clsHeadThree">Engine Coolant Temperature (ECT) Gauge Sensor G2 - 3.0L 6-cylinder engine, multi-pin connector assignments</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Preparations</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017573" name="S11062902882008020700000">Fig. 209: Removing Rear Engine Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rear engine cover - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017586" name="S42708324242008020700000">Fig. 210: Identifying Holding Plate, Intake Air Hose, Hose & Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts for solenoid valve retaining plate - <span class="clsEmphBOLD">3</span> - - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove air intake hose - <span class="clsEmphBOLD">1</span> - at Mass Air Flow (MAF) Sensor G70.</li> <li>Remove hose - <span class="clsEmphBOLD">4</span> - at air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017587" name="S05030961212008020700000">Fig. 211: Removing Bolt And Disconnect Air Duct At Throttle Valve Control Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolt - <span class="clsEmphBOLD">arrow</span> - and pull off air duct - <span class="clsEmphBOLD">2</span> - at throttle valve control module J338.</li> <li>Where applicable, remove hose - <span class="clsEmphBOLD">1</span> - at air duct.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>For illustration purposes the air duct is shown from the rear with the engine removed.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017787" name="S10582827492008020700000">Fig. 212: Disconnecting Electrical Harness Connector At Engine Coolant Temperature (ECT) Sensor -G2-/-G62-</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> - at sensor.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Disregard - <span class="clsEmphBOLD">1</span> -.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00015756" name="S32288200142008020700000">Fig. 213: Coolant Temperature Sensor Terminals</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Pin assignment for 4-pin connector at Engine Coolant Temperature (ECT) Gauge Sensor G2</span> </p> <ol class="clsARABICNUM"> <li>Wiring from sensor to instrument cluster (temperature gauge)</li> <li>Ground (GND) ( - )</li> </ol><a name="S18182278342008020700000"></a><h2 class="clsHeadThree">Engine Coolant Temperature (ECT) Sensor G62 - 3.2L 6-cylinder FSI engine, multi-pin connector assignments</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Preparations</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017827" name="S30062090592008020700000">Fig. 214: Identifying Front Engine Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove front engine cover - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018032" name="S33693336162008020700000">Fig. 215: Disconnecting Electrical Connector, Retaining Clip And Engine Coolant Temperature (ECT) Sensor G62</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection at sensor - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Disregard - <span class="clsEmphBOLD">1</span> -.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00001018" name="S28598218212008020700000">Fig. 216: Identifying 2-Pin Electrical Harness Connector & Terminals</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Pin assignment for 2-pin connector on Engine Coolant Temperature (ECT) Sensor G62</span> </p> <ol class="clsARABICNUM"> <li>Ground (GND) ( - )</li> <li>Wiring from sensor to instrument cluster (temperature gauge)</li> </ol><a name="S31861189362008020700000"></a><h2 class="clsHeadThree">Engine Coolant Temperature (ECT) Sensor G62 - 4.2L 8-cylinder engine (Audi S4), multi-pin connector assignments</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Preparations</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017835" name="S26859511982008020700000">Fig. 217: Removing/Installing Rear Engine Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rear engine cover - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021598" name="S41201766832008020700000">Fig. 218: Identifying Electrical Connection At Sensor</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> - at sensor.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Illustration shows engine removed.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00015756" name="S33263411942008020700000">Fig. 219: Coolant Temperature Sensor Terminals</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Pin assignment for 4-pin connector at Engine Coolant Temperature (ECT) Sensor G62 - through 05.05</span> </p> <p>3 - Ground (GND) ( - )</p> <p>4 - Wiring from sensor to instrument cluster (temperature gauge)</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00001018" name="S02500648332008020700000">Fig. 220: Identifying 2-Pin Electrical Harness Connector & Terminals</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Pin assignment for 2-pin connector at Engine Coolant Temperature (ECT) Sensor G62 - from 06.05</span> </p> <ol class="clsARABICNUM"> <li>Ground (GND) ( - )</li> <li>Wiring from sensor to instrument cluster (temperature gauge)</li> </ol><a name="S07141706182008020700000"></a><h2 class="clsHeadThree">Engine Coolant Temperature (ECT) Sensor G62 - 4.2L 8-cylinder engine (Audi RS4), multi-pin connector assignments</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Preparations</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018071" name="S26295163142008020700000">Fig. 221: Removing Quick-Release Fasteners, Screws And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove front noise insulation.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018513" name="S31809352332008020700000">Fig. 222: Disconnecting Electrical Connector On Engine Coolant Temperature (ECT) Sensor G62</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> - at sensor.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Engine Coolant Temperature (ECT) Gauge Sensor G62 is accessible from lower right with engine installed.</li> <li>Engine shown removed for clarity.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00001018" name="S18853080292008020700000">Fig. 223: Identifying 2-Pin Electrical Harness Connector & Terminals</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Pin assignment for 2-pin connector at Engine Coolant Temperature (ECT) Gauge Sensor G62</span> </p> <ol class="clsARABICNUM"> <li>Wiring from sensor to instrument cluster (temperature gauge)</li> <li>Ground (GND) ( - )</li> </ol><a name="S34169455332008020700000"></a><h2 class="clsHeadThree">Radio Frequency Controlled Clock Receiver J489 , removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>J489 only where applicable.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove rear bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021599" name="S03802934522008020700000">Fig. 224: Identifying Electrical Connection, Receiver, And Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> - at receiver - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - and remove receiver.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install rear bumper cover: --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul><a name="S20032899222008020700000"></a><h2 class="clsHeadOne">92 Windshield Wiper Washer System</h2><a name="S38631306112008020700000"></a><h2 class="clsHeadTwo">Windshield Wiper System</h2><a name="S40227552382008020700000"></a><h2 class="clsHeadThree">Windshield wiper system, removing and installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003655" name="S27524229672008020700000">Fig. 225: Identifying Pry Lever 80-200</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Removal lever 80-200</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000113" name="S41224849782008020700000">Fig. 226: Identifying Torque Wrench V.A.G. 1331</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014442" name="S11777282082008020700000">Fig. 227: Identifying Plenum Chamber Cover & Removing Rubber Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rubber seal of plenum chamber cover in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove plenum chamber cover - <span class="clsEmphBOLD">1</span> - to front.</li> </ul> <p><span class="clsEmphBOLD">Wiper arms, removing</span> </p> <ul class="clsDASH"> <li>Actuate touch-wipe function and allow wiper motor to move to end position.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014443" name="S03313354732008020700000">Fig. 228: Removing Securing Clips And Cowl</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use screwdriver to pry off caps - <span class="clsEmphBOLD">3</span> -.</li> <li>Loosen nuts - <span class="clsEmphBOLD">4</span> - (do not remove).</li> <li>Loosen wiper arms - <span class="clsEmphBOLD">2</span> - from wiper shaft by tilting slightly.</li> <li>Remove nuts completely and remove wiper arms.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Should wiper arms be difficult to remove, use appropriate puller.</li> <li>Remove retaining clips - <span class="clsEmphBOLD">1</span> - and detach cowl panel grille - <span class="clsEmphBOLD">5</span> -.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Wiper assembly, removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014444" name="S07105876662008020700000">Fig. 229: Removing Screws And Cover From E-Box In Plenum Chamber</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove cover for electronics box in plenum chamber - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021600" name="S27909244982008020700000">Fig. 230: Identifying Wiper Linkage And Wiper Frame</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pry off wiper linkage - <span class="clsEmphBOLD">2</span> - from ball head using lever 80-200.</li> <li>Remove crank from wiper motor.</li> <li>Unclip pipe/hose guides at wiper frame.</li> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> - and detach entire wiper frame - <span class="clsEmphBOLD">1</span> -.</li> </ul> <ul class="clsDASH"> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Wiper motor, removing fom frame</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021601" name="S03150660612008020700000">Fig. 231: Identifying Wiper Motor And Wiper Frame</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">arrows</span> - and remove wiper motor from wiper frame.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021601" name="S29419566752008020700000">Fig. 232: Identifying Wiper Motor And Wiper Frame</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Secure wiper motor without crank to wiper frame - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Reconnect electrical connectors at wiper motor.</li> <li>Fit wiper motor with wiper frame in vehicle and loosely install bolts.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021602" name="S38939098532008020700000">Fig. 233: Pressing Wiper Linkage In To Stop And Tightening Bolts In Sequence</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press wiper linkage in to stop in direction of - <span class="clsEmphBOLD">arrow</span> - and tighten bolt - <span class="clsEmphBOLD">1</span> -.</li> <li>Then tighten bolts - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">3</span> - in sequence.</li> <li>Actuate touch-wipe function and allow wiper motor to move to end position.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021603" name="S20108252172008020700000">Fig. 234: Identifying Crank, Wiper Frame, And Nut</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Check and if necessary, align crank - <span class="clsEmphBOLD">1</span> - with wiper frame.</li> </ul> <ul class="clsBULLET"> <li>Angle α = 2 degrees</li> </ul> <ul class="clsDASH"> <li>Hold crank in position and hand-tighten nut - <span class="clsEmphBOLD">2</span> - so setting is not altered.</li> <li>Then brace crank with an open-end wrench and tighten nut fully.</li> <li>Switch on ignition.</li> <li>Actuate touch-wipe function and allow wiper motor to move to end position.</li> </ul> <ul class="clsDASH"> <li>Check that angle - <span class="clsEmphBOLD">α</span> - is attained; re-align if necessary.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Shown with wiper frame removed for illustration purposes.</li> <li>Set wiper blades to park position --> <a class="clsHyperlink" href="#S10093420522008020700000">Windshield wiper blade park position, adjusting</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S402275523820080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Wiper crank to wiper motor - nut</td> <td align="" class="clsCellNormal">18</td> </tr> <tr> <td align="" class="clsCellNormal">Wiper motor to wiper frame - bolt</td> <td align="" class="clsCellNormal">9</td> </tr> <tr> <td align="" class="clsCellNormal">Wiper frame to plenum chamber - bolt</td> <td align="" class="clsCellNormal">8</td> </tr> </tbody> </table></span></p><a name="S10093420522008020700000"></a><h2 class="clsHeadThree">Windshield wiper blade park position, adjusting</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Switch on ignition.</li> <li>Actuate touch-wipe function and allow wiper motor to move to end position.</li> <li>Switch off ignition.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00012306" name="S42044402542008020700000">Fig. 235: Checking Windshield Wiper Blade Tips Position</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Position wiper blades on windshield and align as follows:</li> </ul> <ul class="clsBULLET"> <li>Dimension - <span class="clsEmphBOLD">a</span> - = 24 mm.</li> <li>Dimension - <span class="clsEmphBOLD">b</span> - = 44 mm.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The figures given here are the distances between wiper blades and cowl panel grille of plenum chamber at bottom edge of windshield.</li> <li>Tighten nuts for wiper arms.</li> <li>Switch on ignition.</li> <li>Actuate touch-wipe function and allow wiper motor to move to end position.</li> <li>Switch off ignition.</li> <li>If necessary, re-align wiper arms and tighten nuts again.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S100934205220080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Wiper arm - nut</td> <td align="" class="clsCellNormal">21</td> </tr> </tbody> </table></span></p><a name="S29655879952008020700000"></a><h2 class="clsHeadThree">Windshield wiper blade - through 10.04, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Lift wiper arm off windshield.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021604" name="S40152756952008020700000">Fig. 236: Identifying Linkage, Wiper Blade, And Wiper Arm</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press release button at linkage - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove wiper blade - <span class="clsEmphBOLD">2</span> - from wiper arm - <span class="clsEmphBOLD">1</span> - downwards.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021605" name="S27041805112008020700000">Fig. 237: Identifying Wiper Blade And Arm</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>When installing wiper blade - <span class="clsEmphBOLD">2</span> - on drivers side, ensure blade engages in lug and retainer at spoiler engages in wiper blade.</li> <li>Lock wiper blade by pressing release button.</li> </ul><a name="S39754142322008020700000"></a><h2 class="clsHeadThree">Windshield wiper arm - through 10.04, assembly</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021606" name="S16002227342008020700000">Fig. 238: Windshield Wiper Arm - Through 10.04, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">1 - Wiper blade mount</span> </p> <ul class="clsBULLET"> <li>For drivers side (with spoiler)</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S15766681652008020700000">Windshield wiper blade mount - through 10.04, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">2 - Release button</span> </p> <p><span class="clsEmphBOLD">3 - Spacer</span> </p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S15766681652008020700000">Windshield wiper blade mount - through 10.04, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">4 - Wiper arm</span> </p><a name="S15766681652008020700000"></a><h2 class="clsHeadThree">Windshield wiper blade mount - through 10.04, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Lift wiper arm off windshield.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021604" name="S02234142332008020700000">Fig. 239: Identifying Linkage, Wiper Blade, And Wiper Arm</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press release button at linkage - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove wiper blade - <span class="clsEmphBOLD">2</span> - from wiper arm - <span class="clsEmphBOLD">1</span> - downwards.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021607" name="S42234471042008020700000">Fig. 240: Identifying Release Button, And Wiper Arm</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release the retaining lug on release button - <span class="clsEmphBOLD">arrow 1</span> -.</li> <li>Pivot the release button upwards.</li> <li>Pull release button out of wiper arm - <span class="clsEmphBOLD">arrow 2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021608" name="S26606679132008020700000">Fig. 241: Pressing Sides Of Wiper Mounting Inwards And Removing Wiper Mounting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press the sides of wiper mounting - <span class="clsEmphBOLD">1</span> - inwards - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove wiper mounting from wiper arm - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021609" name="S16547074132008020700000">Fig. 242: Identifying Retaining Lugs, And Wiper Arm</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press the spacer together at retaining lugs - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove spacer from wiper arm - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S30112448382008020700000"></a><h2 class="clsHeadThree">Windshield wiper blade - from 11.04, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021610" name="S25140000172008020700000">Fig. 243: Identifying Retaining Clip, Wiper Arm, And Wiper Blade</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Slide clip - <span class="clsEmphBOLD">2</span> - off wiper arm - <span class="clsEmphBOLD">3</span> - in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove wiper blade - <span class="clsEmphBOLD">1</span> - downwards from wiper arm.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021611" name="S33334720652008020700000">Fig. 244: Identifying Wiper Blade And Retaining Clip</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Insert joint of wiper arm in guide on wiper blade - <span class="clsEmphBOLD">arrow 1</span> -. Ensure joint is inserted fully in guide.</li> <li>Secure wiper blade by fitting retaining clip - <span class="clsEmphBOLD">arrow 2</span> -.</li> </ul><a name="S12162752992008020700000"></a><h2 class="clsHeadTwo">Windshield Washer System</h2><a name="S04526534522008020700000"></a><h2 class="clsHeadThree">Washer fluid reservoir - Audi A4 S4, removing and installing</h2> <p><span class="clsEmphBOLD">Top section of reservoir, removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017583" name="S28006281342008020700000">Fig. 245: Removing Cover In Engine Compartment (Left Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021612" name="S12105896332008020700000">Fig. 246: Identifying Nut, Bolt, Overflow Hose, And Reservoir</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Where applicable, remove overflow hose - <span class="clsEmphBOLD">2</span> - from reservoir - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove nut - <span class="clsEmphBOLD">1</span> - and bolt - <span class="clsEmphBOLD">4</span> -.</li> <li>Pull top section of reservoir upwards out of bottom section.</li> </ul> <p><span class="clsEmphBOLD">Bottom section of reservoir, removing</span> </p> <ul class="clsDASH"> <li>Remove left front wheel.</li> <li>Remove left front wheel housing liner --> <a class="clsExtHyperlink" id="A00278920_S32431341132008020700000">66 EXTERIOR EQUIPMENT</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021613" name="S33604390992008020700000">Fig. 247: Removing Bottom Section Of Reservoir</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bottom section of reservoir - <span class="clsEmphBOLD">2</span> - - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Swivel bottom section of reservoir slightly to rear.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If it is not possible to swivel bottom section of reservoir, remove bolt - <span class="clsEmphBOLD">4</span> - and detach cross member - <span class="clsEmphBOLD">1</span> -.</li> <li>Where applicable, detach overflow hose - <span class="clsEmphBOLD">3</span> - from reservoir section.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021614" name="S38089282352008020700000">Fig. 248: Identifying Electrical Connections, Hose Connector, And Fluid Pipe</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections - <span class="clsEmphBOLD">2... 4</span> -.</li> <li>Press release tab and pull off hose connector - <span class="clsEmphBOLD">1</span> -.</li> <li>Pull off washer fluid pipe - <span class="clsEmphBOLD">5</span> -.</li> <li>Remove washer fluid reservoir downwards.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Clean thread of bolts from remnants of locking fluid using wire brush. Then apply locking fluid and fit bolts. Locking fluid.</li> <li>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.</li> <li>When installing, ensure that the water hose audibly engages in the connection on the washer fluid pump.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021615" name="S31581089552008020700000">Fig. 249: Identifying Bolt Tightening Sequence</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Tighten bolts in sequence - <span class="clsEmphBOLD">1... 3</span> -.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S045265345220080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> <col span="1" id="COL3"> </colgroup> <tbody> <tr> <td colspan="2" align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal"> </td> <td align="RIGHT" class="clsCellNormal">self-locking bolt M6</td> <td align="" class="clsCellNormal">18 <sup>1) 2)</sup> </td> </tr> <tr> <td align="" class="clsCellNormal">Top section of reservoir to body</td> <td align="RIGHT" class="clsCellNormal">nut</td> <td align="" class="clsCellNormal">5.5</td> </tr> <tr> <td colspan="2" align="" class="clsCellNormal">Bottom section of reservoir to body - screw</td> <td align="" class="clsCellNormal">7</td> </tr> <tr> <td colspan="3" align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><sup>1)</sup> Replace bolt.</li> <li><sup>2)</sup> Insert with locking compound; locking compound.</li> </ul> </td> </tr> </tbody> </table></span></p><a name="S23466716982008020700000"></a><h2 class="clsHeadThree">Washer fluid reservoir - Audi RS4, removing and installing</h2> <p><span class="clsEmphBOLD">Top section of reservoir, removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017583" name="S01895892922008020700000">Fig. 250: Removing Cover In Engine Compartment (Left Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021612" name="S14771818632008020700000">Fig. 251: Identifying Nut, Bolt, Overflow Hose, And Reservoir</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Where applicable, remove overflow hose - <span class="clsEmphBOLD">2</span> - from reservoir - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove nut - <span class="clsEmphBOLD">1</span> - and bolt - <span class="clsEmphBOLD">4</span> -.</li> <li>Pull top section of reservoir upwards out of bottom section.</li> </ul> <p><span class="clsEmphBOLD">Bottom section of reservoir, removing</span> </p> <ul class="clsBULLET"> <li>Upper part of reservoir removed.</li> </ul> <ul class="clsDASH"> <li>Remove left front wheel.</li> <li>Remove left front wheel housing liner --> <a class="clsExtHyperlink" id="A00278920_S32431341132008020700000">66 EXTERIOR EQUIPMENT</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021616" name="S02767465772008020700000">Fig. 252: Identifying Screws, Crossbar, Electrical Connection, Washer Fluid Line, And Washer Fluid Reservoir</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows A</span> -.</li> <li>Remove screws - <span class="clsEmphBOLD">arrows B</span> - and remove crossbar - <span class="clsEmphBOLD">4</span> -.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> - and remove washer fluid line - <span class="clsEmphBOLD">2</span> - from retainer.</li> <li>Pivot lower part of washer fluid reservoir - <span class="clsEmphBOLD">3</span> - slightly toward rear.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021617" name="S27513771402008020700000">Fig. 253: Identifying Hose, Clamp, And Electrical Connections</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release clamp and remove hose - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove hose - <span class="clsEmphBOLD">1</span> -.</li> <li>Disconnect electrical connections - <span class="clsEmphBOLD">3</span> - and - <span class="clsEmphBOLD">4</span> -.</li> <li>Remove washer fluid reservoir downward.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, observing the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Clean screw threads installed with locking compound using a wire brush. Then insert screws with locking compound. Locking compound.</li> <li>Threaded holes that had self-locking screws or screws installed with locking compound must be cleaned (e.g. with a thread tap). Otherwise screws may shear off when reinstalled.</li> <li>When positioning hose, ensure it engages audibly in washer fluid pump connection.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021618" name="S24782447832008020700000">Fig. 254: Identifying Screw Tightening Sequence</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Tighten screws in sequence - <span class="clsEmphBOLD">1 to 5</span> -.</li> <li>Install upper part of reservoir.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S234667169820080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> <col span="1" id="COL3"> </colgroup> <tbody> <tr> <td colspan="2" align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Upper part of reservoir to</td> <td align="RIGHT" class="clsCellNormal">self-locking bolt M6</td> <td align="" class="clsCellNormal">18 <sup>1) 2)</sup> </td> </tr> <tr> <td align="" class="clsCellNormal">Body</td> <td align="RIGHT" class="clsCellNormal">Nut</td> <td align="" class="clsCellNormal">5,5</td> </tr> <tr> <td colspan="2" align="" class="clsCellNormal">Lower part of washer fluid reservoir to chassis</td> <td align="" class="clsCellNormal">5,5</td> </tr> <tr> <td colspan="3" align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><sup>1)</sup> Replace bolt.</li> <li><sup>2)</sup> Insert with locking compound; locking compound.</li> </ul> </td> </tr> </tbody> </table></span></p><a name="S16991611392008020700000"></a><h2 class="clsHeadThree">Windshield washer spray jets, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021619" name="S11186172712008020700000">Fig. 255: Unclipping Base Of Spray Jet From Bottom Of Hood</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unclip base of spray jet (bottom) from front hood - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021620" name="S00416370052008020700000">Fig. 256: Identifying Hose, And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove hose - <span class="clsEmphBOLD">1</span> - from spray jet.</li> <li>Where applicable, disconnect electrical connection - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>When positioning hose, ensure it engages audibly in spray nozzle connection.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021621" name="S28038956982008020700000">Fig. 257: Locating Oval Opening For Spray Individual Nozzles</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Place spray nozzles in hood so that oval opening - <span class="clsEmphBOLD">arrow</span> - for individual spray nozzles face windshield.</li> <li>When installing hose, ensure hose audibly engages in the connection on spray jet.</li> </ul><a name="S32496664322008020700000"></a><h2 class="clsHeadThree">Windshield washer spray jets, adjusting</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00007870" name="S18204375292008020700000">Fig. 258: Identifying Adjustment Tool T10127 Equipped With Needle 3125/ 5 A</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Adjusting tool T10127 fitted with needle 3125/5 A</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021622" name="S13282456072008020700000">Fig. 259: Identifying Windshield Dimensions</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Adjustment</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The adjustment dimensions indicate the values for a moving vehicle, i.e. the spray from the jets is slightly offset when the vehicle is stationary.</li> <li>Use water-soluble pen to mark the four points on windshield:</li> <li>Dimension - <span class="clsEmphBOLD">a</span> - = 250... 275 mm</li> <li>Dimension - <span class="clsEmphBOLD">b</span> - = 465... 490 mm</li> <li>Dimension - <span class="clsEmphBOLD">c</span> - = 270 415 mm</li> <li>Dimension - <span class="clsEmphBOLD">d</span> - = 140... 225 mm</li> <li>Align individual washer jets with these points using adjusting tool.</li> </ul> </td> </tr> </table></span></p><a name="S26075961912008020700000"></a><h2 class="clsHeadTwo">Rear Window Wiper Washer System</h2><a name="S33973078422008020700000"></a><h2 class="clsHeadThree">Rear window wiper/washer, assembly</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021623" name="S04545043792008020700000">Fig. 260: Rear Window Wiper/Washer, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">1 - Connecting pipe</span> </p> <ul class="clsBULLET"> <li>For spray jet</li> </ul> <p><span class="clsEmphBOLD">2 - Nut, 12 Nm</span> </p> <p><span class="clsEmphBOLD">3 - Spray jet</span> </p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S06191902072008020700000">Rear window washer spray jet, removing and installing</a></li> <li>Adjusting --> <a class="clsHyperlink" href="#S32852208962008020700000">Rear window washer spray jet, adjusting</a></li> </ul> <p><span class="clsEmphBOLD">4 - Cap for rear wiper</span> </p> <p><span class="clsEmphBOLD">5 - Wiper arm</span> </p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S29340812452008020700000">Rear window wiper arm, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">6 - Wiper blade</span> </p> <ul class="clsBULLET"> <li>Replacing --> <a class="clsHyperlink" href="#S12910616292008020700000">Rear window wiper blade, replacing</a></li> </ul><a name="S06191902072008020700000"></a><h2 class="clsHeadThree">Rear window washer spray jet, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021624" name="S08621570382008020700000">Fig. 261: Identifying Wiper Arm, Spray Jet, And Cap</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully pry apart ends of cap - <span class="clsEmphBOLD">3</span> - and remove from wiper arm - <span class="clsEmphBOLD">1</span> -.</li> <li>Carefully pull spray jet - <span class="clsEmphBOLD">2</span> - off connecting pipe.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsBULLET"> <li>Insert spray jet with spray opening pointing into recess on wiper arm.</li> </ul><a name="S32852208962008020700000"></a><h2 class="clsHeadThree">Rear window washer spray jet, adjusting</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00007870" name="S11840182852008020700000">Fig. 262: Identifying Adjustment Tool T10127 Equipped With Needle 3125/ 5 A</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Adjusting tool T10127 fitted with needle 3125/5 A</li> </ul> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021625" name="S34643836212008020700000">Fig. 263: Identifying Windshield Wiper Dimensions</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Adjust washer jets using adjusting tool T10127 so that water jets spray rear window at points indicated above wiper.</li> </ul> <ul class="clsBULLET"> <li>Dimension - <span class="clsEmphBOLD">a</span> - = approx. 125 mm</li> <li>Dimension - <span class="clsEmphBOLD">b</span> - = approx. 295 mm</li> <li>Dimension - <span class="clsEmphBOLD">c</span> - = approx. 5 mm</li> </ul><a name="S29340812452008020700000"></a><h2 class="clsHeadThree">Rear window wiper arm, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Switch on ignition.</li> <li>Actuate rear wiper and allow wiper arm to move to end position.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021626" name="S05583408192008020700000">Fig. 264: Identifying Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully pry cap apart slightly - <span class="clsEmphBOLD">arrows</span> - and lift off.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021627" name="S26626742732008020700000">Fig. 265: Identifying Spray Jets And Hex Head Nuts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully detach spray jet - <span class="clsEmphBOLD">2</span> -.</li> <li>Loosen nut - <span class="clsEmphBOLD">1</span> - (do not remove).</li> <li>Loosen wiper arms from wiper shaft by tilting slightly, remove nut and remove wiper arm.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Adjust wiper arm --> <a class="clsHyperlink" href="#S34971418132008020700000">Rear window wiper arm park position, adjusting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S293408124520080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Nut for wiper arm</td> <td align="" class="clsCellNormal">12</td> </tr> </tbody> </table></span></p><a name="S34971418132008020700000"></a><h2 class="clsHeadThree">Rear window wiper arm park position, adjusting</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021628" name="S06654781452008020700000">Fig. 266: Identifying Dimensions For Wiper Blade On Rear Window</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Apply wiper arm with wiper blade fitted at wiper shaft and align wiper blade on rear window as follows.</li> </ul> <ul class="clsBULLET"> <li>Dimension - <span class="clsEmphBOLD">a</span> - = 15... 20 mm</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The dimension indicates distance between tip of wiper blade and bottom edge of window.</li> <li>Switch on ignition.</li> <li>Actuate rear wiper and allow wiper arm to move to end position.</li> <li>Check setting of wiper arm again; correct as necessary.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S349714181320080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Nut for wiper arm</td> <td align="" class="clsCellNormal">12</td> </tr> </tbody> </table></span></p><a name="S12910616292008020700000"></a><h2 class="clsHeadThree">Rear window wiper blade, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Lift wiper arm off rear window.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021629" name="S11048651282008020700000">Fig. 267: Identifying Retaining Clips, Wiper Blade, And Wiper Arm</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clips - <span class="clsEmphBOLD">arrows</span> - using a screwdriver and take wiper blade - <span class="clsEmphBOLD">2</span> - out of wiper arm - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsBULLET"> <li>The wiper blade can only be fitted in one position.</li> <li>The wiper blade must engage audibly in the wiper arm.</li> </ul><a name="S35761245132008020700000"></a><h2 class="clsHeadThree">Rear window wiper motor, assembly</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021630" name="S06248833232008020700000">Fig. 268: Rear Window Wiper Motor, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">1 - Nut, 8 Nm</span> </p> <p><span class="clsEmphBOLD">2 - Wiper motor</span> </p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S25956304892008020700000">Rear window wiper motor, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">3 - Rubber grommet</span> </p> <p><span class="clsEmphBOLD">4 - Washer fluid hose</span> </p><a name="S25956304892008020700000"></a><h2 class="clsHeadThree">Rear window wiper motor, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove wiper arm --> <a class="clsHyperlink" href="#S29340812452008020700000">Rear window wiper arm, removing and installing</a>.</li> <li>Remove lower rear lid trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021631" name="S25793263682008020700000">Fig. 269: Identifying Electrical Connection, Washer Fluid Hose, And Nuts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> -.</li> <li>Disconnect washer fluid hose - <span class="clsEmphBOLD">1</span> - from connecting pipe for spray jet.</li> <li>Loosen nuts - <span class="clsEmphBOLD">arrows</span> - and detach wiper motor.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Carefully insert rubber grommet into hole in rear window.</li> </ul> <ul class="clsBULLET"> <li>Fluid hose must audibly engage in spray jet connection.</li> </ul> <ul class="clsDASH"> <li>Switch on ignition.</li> <li>Actuate rear wiper and allow wiper motor to move to end position.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Install lower rear lid trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> <li>Adjust wiper arm --> <a class="clsHyperlink" href="#S34971418132008020700000">Rear window wiper arm park position, adjusting</a>.</li> </ul> <p><span class="clsArticleTable"><a name="S259563048920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Wiper motor to rear lid - nut</td> <td align="" class="clsCellNormal">8</td> </tr> </tbody> </table></span></p><a name="S00860433972008020700000"></a><h2 class="clsHeadThree">Washer fluid reservoir, removing and installing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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 --> <a class="clsHyperlink" href="#S04526534522008020700000">Washer fluid reservoir - Audi A4 S4, removing and installing</a>. Removing and installing on RS4 --> <a class="clsHyperlink" href="#S23466716982008020700000">Washer fluid reservoir - Audi RS4, removing and installing</a></li> </ul> </td> </tr> </table></span></p><a name="S33713201642008020700000"></a><h2 class="clsHeadTwo">Headlamp Washer System - through 10.04</h2><a name="S18307621722008020700000"></a><h2 class="clsHeadThree">Headlamp washer spray jets, removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021632" name="S24379256922008020700000">Fig. 270: Pulling Up On Spray Jet Covers At Bumper And Carefully Disengaging Mounts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull cover of spray jet upwards away from bumper cover and carefully disengage retainers - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021633" name="S32627124232008020700000">Fig. 271: Identifying Washer Fluid Hose, And Spray Jet Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release clamp and remove hose - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and detach spray jet.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S183076217220080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Spray jet to bumper cover - screw</td> <td align="" class="clsCellNormal">3</td> </tr> </tbody> </table></span></p><a name="S17922007042008020700000"></a><h2 class="clsHeadThree">Headlamp washer spray jets, adjusting</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Washer jets are pre-set at the factory and do not have to be adjusted following installation.</li> </ul> </td> </tr> </table></span></p><a name="S11075084142008020700000"></a><h2 class="clsHeadThree">Washer fluid reservoir, removing and installing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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 --> <a class="clsHyperlink" href="#S04526534522008020700000">Washer fluid reservoir - Audi A4 S4, removing and installing</a>. Removing and installing on RS4 --> <a class="clsHyperlink" href="#S23466716982008020700000">Washer fluid reservoir - Audi RS4, removing and installing</a>.</li> </ul> </td> </tr> </table></span></p><a name="S34761907082008020700000"></a><h2 class="clsHeadTwo">Headlamp Washer System - from 11.04</h2><a name="S11323413972008020700000"></a><h2 class="clsHeadThree">Headlamp washer spray jets, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>To protect the bumper cover, place a cloth under pliers before taking hold of the spray jet.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021634" name="S24919714282008020700000">Fig. 272: Pulling Cover Of Spray Jet Upwards Away From Bumper Cover And Carefully Disengaging Retainers</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull cover - <span class="clsEmphBOLD">1</span> - of spray jet - <span class="clsEmphBOLD">2</span> - upwards away from bumper cover and carefully disengage retainers in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021635" name="S22618821412008020700000">Fig. 273: Identifying Hose, Spray Jet, And Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release clamp and remove hose - <span class="clsEmphBOLD">1</span> - at spray jet - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> - and detach spray jet.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S113234139720080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Spray jet to bumper cover - screw</td> <td align="" class="clsCellNormal">3</td> </tr> </tbody> </table></span></p><a name="S25980133462008020700000"></a><h2 class="clsHeadThree">Headlamp washer spray jets, adjusting</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Washer jets are pre-set at the factory and do not have to be adjusted following installation.</li> </ul> </td> </tr> </table></span></p><a name="S19311989732008020700000"></a><h2 class="clsHeadThree">Washer fluid reservoir, removing and installing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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 --> <a class="clsHyperlink" href="#S04526534522008020700000">Washer fluid reservoir - Audi A4 S4, removing and installing</a>. Removing and installing on RS4 --> <a class="clsHyperlink" href="#S23466716982008020700000">Washer fluid reservoir - Audi RS4, removing and installing</a>.</li> </ul> </td> </tr> </table></span></p><a name="S38838228742008020700000"></a><h2 class="clsHeadOne">94 Lights, Switches - Exterior</h2><a name="S01765807082008020700000"></a><h2 class="clsHeadTwo">Halogen Headlamps - through 10.04</h2><a name="S00403810422008020700000"></a><h2 class="clsHeadThree">General information</h2> <p>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.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Additional information:</li> </ul> </td> </tr> </table></span></p> <p>Owners Manual</p> <p>Self Study Program - Course Number 991103 "2002 Audi A4 Technical Features"</p> <p>Wiring Diagrams Component Locations</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before beginning repairs on electrical system<ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p><a name="S41148951512008020700000"></a><h2 class="clsHeadThree">On Board Diagnostic (OBD), functions</h2> <p>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.</p> <p>Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".</p><a name="S09479379092008020700000"></a><h2 class="clsHeadThree">Halogen headlamps, assembly</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>After performing any repairs or service that could affect headlight aim, check/adjust aim.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021636" name="S16326299002008020700000">Fig. 274: Halogen Headlamps, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">1 - Trim cover</span> </p> <p><span class="clsEmphBOLD">2 - Headlamp housing</span> </p> <p><span class="clsEmphBOLD">3 - Vent element</span> </p> <p><span class="clsEmphBOLD">4 - Turn signal/parking lamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 27/7 W</li> <li>Orange</li> <li>Replacing --> <a class="clsHyperlink" href="#S40416041152008020700000">Turn signal/parking lamp bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">5 - Bulb holder</span> </p> <ul class="clsBULLET"> <li>For turn signal/parking lamp bulb</li> </ul> <p><span class="clsEmphBOLD">6 - Housing cover</span> </p> <ul class="clsBULLET"> <li>For low beam headlamps</li> </ul> <p><span class="clsEmphBOLD">7 - Left Low Beam Headlamp M29 , Right Low Beam Headlamp M31 - bulb</span> </p> <ul class="clsBULLET"> <li>H7 - 12 V, 55 W</li> <li>Replacing --> <a class="clsHyperlink" href="#S15156373962008020700000">Low Beam Headlamp M29 / M31 - bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">8 - Housing cover</span> </p> <ul class="clsBULLET"> <li>For high beam headlamps</li> </ul> <p><span class="clsEmphBOLD">9 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb</span> </p> <ul class="clsBULLET"> <li>H7 - 12 V, 55 W</li> <li>Replacing --> <a class="clsHyperlink" href="#S38724048772008020700000">High Beam Headlamp M30 / M32 - bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">10 - Screw - 6 Nm</span> </p> <p><span class="clsEmphBOLD">11 - Vent element</span> </p> <p><span class="clsEmphBOLD">12 - Screw - 6 Nm</span> </p> <p><span class="clsEmphBOLD">13 - Stop bolt</span> </p> <ul class="clsBULLET"> <li>For aligning headlamp housing with body contour</li> <li>Must make contact with lock carrier</li> </ul><a name="S34557770512008020700000"></a><h2 class="clsHeadThree">Headlamps, removing and installing</h2><a name="S41530823982008040900000"></a><h2 class="clsHeadFour">Removing</h2> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Left headlamp</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017583" name="S42537316292008020700000">Fig. 275: Removing Cover In Engine Compartment (Left Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017582" name="S29695418602008020700000">Fig. 276: Removing Cover In Engine Compartment (Right Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove applicable right engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S34914678812008020700000">Fig. 277: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021637" name="S34461581842008020700000">Fig. 278: Locating Screws And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Both sides, continued</span> </p> <ul class="clsDASH"> <li>Use adhesive tape to mask area beneath headlamp to prevent damage to paintwork.</li> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">5</span> -.</li> <li>Loosen screws - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">4</span> - (do not remove).</li> <li>Where applicable, remove cable tie.</li> </ul> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove headlamp from body towards front.</li> </ul><a name="S14024698232008040900000"></a><h2 class="clsHeadFour">Installing</h2> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021638" name="S31019677182008020700000">Fig. 279: Locating Vent Elements On Underside Of Headlamp</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Check whether both vent elements have been inserted on underside of headlamp - <span class="clsEmphBOLD">detail</span> -.</li> <li>Slide headlamp horizontally onto lower headlamp mounting as far as it will go.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021639" name="S28464144822008020700000">Fig. 280: Locating Screws And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Position stop screw - <span class="clsEmphBOLD">1</span> - so it makes contact with lock carrier.</li> <li>Use stop screw to align headlamp with body contours (gap widths).</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Pay attention to area around fender opening when aligning headlamp.</li> <li>Tighten screws - <span class="clsEmphBOLD">2... 5</span> -.</li> <li>Following installation, check and adjust headlamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S140246982320080409000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Headlamp to lock carrier - screw</td> <td align="" class="clsCellNormal">6</td> </tr> </tbody> </table></span></p><a name="S15225486202008020700000"></a><h2 class="clsHeadThree">Headlamps, adjusting</h2> <p>Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</p><a name="S24397687232008020700000"></a><h2 class="clsHeadThree">Headlamps, service preparation</h2> <p>The following engine-dependent procedures are required in order to replace certain headlamp bulbs.</p><a name="S28320895502008020700000"></a><h2 class="clsHeadFour">Preparation - vehicles with 1.8L 4-cylinder Turbo engine</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017582" name="S41733974602008020700000">Fig. 281: Removing Cover In Engine Compartment (Right Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove right engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S29670795532008020700000">Fig. 282: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017291" name="S39301010192008020700000">Fig. 283: Disconnect Wires/Unplug Connectors</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections:</li> </ul> <ol class="clsARABICNUM"> <li>at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80</li> <li>at Mass Air Flow (MAF) Sensor G70</li> <li>at Wastegate Bypass Regulator Valve N75</li> </ol> <ul class="clsDASH"> <li>Disconnect hoses - <span class="clsEmphBOLD">4... 7</span> -.</li> <li>Disconnect hose leading to secondary air pump.</li> <li>Seat aside wiring.</li> <li>Release fasteners at air cleaner housing - <span class="clsEmphBOLD">8</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove air cleaner housing.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The vacuum line leading to combination valve for secondary air is clipped onto the underside of the air intake hose.</li> </ul> </td> </tr> </table></span></p> <p>Install in reverse order of removal.</p><a name="S32939255032008020700000"></a><h2 class="clsHeadFour">Preparation - vehicles with 3.0L 6-cylinder engine</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017582" name="S08322717202008020700000">Fig. 284: Removing Cover In Engine Compartment (Right Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove right engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S42132958822008020700000">Fig. 285: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021640" name="S25336498782008020700000">Fig. 286: Identifying Lines And Air Cleaner Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull off lines and disconnect electrical connections:</li> </ul> <ol class="clsARABICNUM"> <li>at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80</li> <li>vacuum hose at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80</li> <li>at Mass Air Flow (MAF) Sensor G70</li> </ol> <ul class="clsDASH"> <li>Pull off hose connections and set aside lines - <span class="clsEmphBOLD">4</span> - and - <span class="clsEmphBOLD">5</span> -.</li> <li>Remove air cleaner housing - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p>Install in reverse order of removal.</p><a name="S15156373962008020700000"></a><h2 class="clsHeadThree">Low Beam Headlamp M29 / M31 - bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Left headlamp:</span> </p> <ul class="clsDASH"> <li>Remove headlamp --> <a class="clsHyperlink" href="#S34557770512008020700000">Headlamps, removing and installing</a>.</li> </ul> <p>Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine:</p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 3.0L 6-cylinder engine:</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Both sides, continued</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021641" name="S30221988722008020700000">Fig. 287: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clip - <span class="clsEmphBOLD">arrow</span> - and detach housing cover for low beam from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021642" name="S07936561232008020700000">Fig. 288: Identifying Electrical Connection, Retaining Clip, And Bulb</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> - at low beam bulb.</li> <li>Disengage retaining clip - <span class="clsEmphBOLD">1</span> - and remove bulb - <span class="clsEmphBOLD">3</span> - from housing.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert bulb and secure with retaining clip.</li> <li>Secure housing cover with retaining clip.</li> </ul><a name="S38724048772008020700000"></a><h2 class="clsHeadThree">High Beam Headlamp M30 / M32 - bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Left headlamp</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017583" name="S39227344422008020700000">Fig. 289: Removing Cover In Engine Compartment (Left Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021643" name="S26672696812008020700000">Fig. 290: Disconnecting Electrical Connections From Retainer And Removing Retainer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - from retainer.</li> <li>Unclip retainer for connectors and pull off upwards - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine:</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 3.0L 6-cylinder engine:</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021644" name="S28703125162008020700000">Fig. 291: Releasing Retaining Clip And Detaching Housing Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Both sides, continued:</span> </p> <ul class="clsDASH"> <li>Release retaining clip - <span class="clsEmphBOLD">arrow</span> - and detach housing cover for high beam headlamp bulb from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021645" name="S23050138952008020700000">Fig. 292: Disconnecting Electrical Connection, Releasing Retaining Clip, And Removing Bulb</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> - at high beam headlamp bulb.</li> <li>Release retaining clip - <span class="clsEmphBOLD">2</span> - and remove bulb - <span class="clsEmphBOLD">1</span> - from housing.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Secure bulb with retaining clip.</li> <li>Secure housing cover with retaining clip.</li> </ul><a name="S40416041152008020700000"></a><h2 class="clsHeadThree">Turn signal/parking lamp bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove headlamp --> <a class="clsHyperlink" href="#S34557770512008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021646" name="S12387108882008020700000">Fig. 293: Identifying Bulb Holder</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Turn bulb holder - <span class="clsEmphBOLD">arrow</span> - counter-clockwise and remove from housing.</li> <li>Pull bulb out of bulb holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Do not touch glass portion of bulb with bare hands. Even the smallest amount of moisture and/or contaminants from fingers that evaporates on the bulb during operation can cause the glass to cloud over.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Fit new bulb in housing.</li> <li>Install headlamp <a class="clsHyperlink" href="#S14024698232008040900000">Installing</a>.</li> </ul><a name="S41313482992008020700000"></a><h2 class="clsHeadThree">Headlamp securing lugs, servicing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If headlight securing lugs break due to application of excessive force, it may still be possible to service headlight in a cost effective manner (though headlight housing must not be damaged).</li> <li>Different repair sets are available for left and right headlight.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Remove headlamp with broken retaining tab --> <a class="clsHyperlink" href="#S34557770512008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021647" name="S17353302542008020700000">Fig. 294: Exploded View Of Headlamp Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove remains of broken lug - <span class="clsEmphBOLD">3</span> - and - <span class="clsEmphBOLD">4</span> - on headlamp housing.</li> <li>Attach lug - <span class="clsEmphBOLD">2</span> - from repair kit to edge of headlight housing and secure it with two screws - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S413134829920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Headlamp to lock carrier</td> <td align="" class="clsCellNormal">6</td> </tr> </tbody> </table></span></p><a name="S22374264372008020700000"></a><h2 class="clsHeadTwo">Halogen Headlamps - from 11.04</h2><a name="S07208937072008020700000"></a><h2 class="clsHeadThree">General information</h2> <p>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.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Additional information:</li> </ul> </td> </tr> </table></span></p> <p>Owners Manual</p> <p>Self Study Program - Course Number 991503 "The 2005 Audi A4"</p> <p>Wiring Diagrams Component Locations</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before beginning repairs on electrical system<ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p><a name="S13712358022008020700000"></a><h2 class="clsHeadThree">On Board Diagnostic (OBD), functions</h2> <p>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.</p> <p>Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".</p><a name="S22243266732008020700000"></a><h2 class="clsHeadThree">Halogen headlamps, assembly</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>After performing any repairs or service that could affect headlight aim, check/adjust aim.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021648" name="S12401218212008020700000">Fig. 295: Halogen Headlamps, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">1 - Headlamp housing</span> </p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S13599339732008020700000">Headlamps, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">2 - Screw - 4.5 Nm</span> </p> <p><span class="clsEmphBOLD">3 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb</span> </p> <ul class="clsBULLET"> <li>H7 - 12 V, 55 W</li> <li>Replacing --> <a class="clsHyperlink" href="#S27795772982008020700000">High Beam Headlamp M30 / M32 - bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">4 - Housing cover</span> </p> <ul class="clsBULLET"> <li>For high beam/parking lamps</li> </ul> <p><span class="clsEmphBOLD">5 - Bulb holder</span> </p> <ul class="clsBULLET"> <li>For bulb for parking lamps</li> </ul> <p><span class="clsEmphBOLD">6 - Left Parking Lamp M1 , Right Parking Lamp M3 - bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 5 W</li> <li>W5W, Longlife - white</li> <li>Replacing --> <a class="clsHyperlink" href="#S14496990942008020700000">Parking Lamp M1 / M3 - bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">7 - Screw - 4.5 Nm</span> </p> <p><span class="clsEmphBOLD">8 - Housing cover</span> </p> <ul class="clsBULLET"> <li>For low beam headlamps</li> </ul> <p><span class="clsEmphBOLD">9 - Left Low Beam Headlamp M29 , Right Low Beam Headlamp M31 - bulb</span> </p> <ul class="clsBULLET"> <li>H7 - 12 V, 55 W</li> <li>Replacing --> <a class="clsHyperlink" href="#S41730936862008020700000">Low Beam Headlamp M29 / M31 - bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">10 - Bulb holder</span> </p> <ul class="clsBULLET"> <li>For turn signal lamp bulb</li> </ul> <p><span class="clsEmphBOLD">11 - Left Front Turn Signal Lamp M5 , Right Front Turn Signal Lamp M7 - bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 21 W</li> <li>Replacing --> <a class="clsHyperlink" href="#S24055128392008020700000">Front Turn Signal Lamp M5 / M7 - bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">12 - Trim cover</span> </p><a name="S13599339732008020700000"></a><h2 class="clsHeadThree">Headlamps, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021649" name="S03581550302008020700000">Fig. 296: Locating Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screw - <span class="clsEmphBOLD">3</span> -.</li> <li>Loosen screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - (do not remove).</li> <li>Remove headlamp from body towards front.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021650" name="S07639805562008020700000">Fig. 297: Checking Adjusting Nut Of Adjuster For Freedom Of Movement</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Check adjusting nut - <span class="clsEmphBOLD">1</span> - of adjuster for freedom of movement - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Screw in adjusting nut as far as it will go, but do not tighten.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021649" name="S32853395602008020700000">Fig. 298: Locating Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Insert headlamp and tighten screws - <span class="clsEmphBOLD">1... 3</span> - two complete turns.</li> <li>Install front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> <li>Align headlamp with body contours and front bumper cover (note gap widths).</li> <li>Tighten screws in sequence - <span class="clsEmphBOLD">2</span> - , - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">3</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When 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.</li> <li>Check gaps; if necessary, repeat procedure for installing headlamp.</li> <li>Following installation, check and adjust headlamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S135993397320080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Headlamp to lock carrier - screw</td> <td align="" class="clsCellNormal">4.5</td> </tr> </tbody> </table></span></p><a name="S25679138542008020700000"></a><h2 class="clsHeadThree">Headlamps, adjusting</h2> <p>Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</p><a name="S41730936862008020700000"></a><h2 class="clsHeadThree">Low Beam Headlamp M29 / M31 - bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S07838449472008020700000">Fig. 299: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021651" name="S09522581702008020700000">Fig. 300: Locating Retaining Tab</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining tab - <span class="clsEmphBOLD">arrow</span> - and detach housing cover from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021652" name="S18014611002008020700000">Fig. 301: Identifying Bulb, Spring Clips, And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bulb - <span class="clsEmphBOLD">2</span> - from spring clips - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> - at low beam bulb.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Do not touch glass portion of bulb with bare hands. Even the smallest amount of moisture and/or contaminants from fingers that evaporates on the bulb during operation can cause the glass to cloud over.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert bulb into housing.</li> <li>Position bulb at lower spring clip.</li> <li>Push bulb beyond resistance of upper spring clips into housing.</li> <li>Reconnect electrical connection and close housing cover.</li> </ul><a name="S27795772982008020700000"></a><h2 class="clsHeadThree">High Beam Headlamp M30 / M32 - bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S15304003842008020700000">Fig. 302: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021653" name="S17571627232008020700000">Fig. 303: Releasing Retaining Clip And Detaching Housing Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clip - <span class="clsEmphBOLD">arrow</span> - and detach housing cover for high beam/parking lamps from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021654" name="S03423046332008020700000">Fig. 304: Identifying Bulb, Spring Clips, And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bulb - <span class="clsEmphBOLD">1</span> - from spring clips - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> - at high beam headlamp bulb.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert bulb into housing.</li> <li>Position bulb at lower spring clip.</li> <li>Push bulb beyond resistance of upper spring clips into housing.</li> <li>Plug in connector and close housing cover.</li> </ul> <ul class="clsDASH"> <li>Secure housing cover with retaining clip.</li> </ul><a name="S14496990942008020700000"></a><h2 class="clsHeadThree">Parking Lamp M1 / M3 - bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S26449544942008020700000">Fig. 305: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021653" name="S12726131772008020700000">Fig. 306: Releasing Retaining Clip And Detaching Housing Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clip - <span class="clsEmphBOLD">arrow</span> - and detach housing cover for high beam/parking lamp from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021654" name="S19525375282008020700000">Fig. 307: Identifying Bulb, Spring Clips, And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove high beam headlamp bulb - <span class="clsEmphBOLD">1</span> - from spring clips - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Disregard - <span class="clsEmphBOLD">2</span> -.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021655" name="S12629098532008020700000">Fig. 308: Pulling Bulb Holder From Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull bulb holder - <span class="clsEmphBOLD">1</span> - from housing - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Pull bulb out of bulb holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert new bulb in bulb holder.</li> <li>Press parking lamp bulb holder into reflector until felt to engage.</li> <li>Position high beam headlamp bulb at lower spring clip.</li> <li>Push high beam headlamp bulb into housing (overcome resistance of upper spring clips).</li> </ul> <ul class="clsDASH"> <li>Close housing cover.</li> <li>Secure housing cover with retaining clip.</li> </ul><a name="S24055128392008020700000"></a><h2 class="clsHeadThree">Front Turn Signal Lamp M5 / M7 - bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsEmphBOLD">Left headlamp</span> </p> <ul class="clsDASH"> <li>Remove washer fluid reservoir --> <a class="clsHyperlink" href="#S04526534522008020700000">Washer fluid reservoir - Audi A4 S4, removing and installing</a>.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp</span> </p> <ul class="clsDASH"> <li>Lift vehicle.</li> <li>Remove right front wheel.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020340" name="S21722782762008020700000">Fig. 309: Loosening Left/Right Wheelhousing Liners In Front Area</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove forward portion of wheel housing liner.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021656" name="S20471591442008020700000">Fig. 310: Turning Bulb Holder Counter-Clockwise And Pulling From Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Continuation for all:</span> </p> <ul class="clsDASH"> <li>Turn bulb holder - <span class="clsEmphBOLD">3</span> - counter-clockwise - <span class="clsEmphBOLD">arrow</span> - and pull out from housing.</li> <li>Screw bulb out of holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing bulb holder, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Fit new bulb in bulb holder.</li> <li>Markings - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - must be opposite each other when inserting bulb holder into housing.</li> </ul> <p><span class="clsEmphBOLD">Left headlamp</span> </p> <ul class="clsDASH"> <li>Install washer fluid reservoir --> <a class="clsHyperlink" href="#S04526534522008020700000">Washer fluid reservoir - Audi A4 S4, removing and installing</a>.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp</span> </p> <ul class="clsDASH"> <li>Install wheel housing liner --> <a class="clsExtHyperlink" id="A00278920_S32431341132008020700000">66 EXTERIOR EQUIPMENT</a> .</li> </ul><a name="S27076760402008020700000"></a><h2 class="clsHeadThree">Headlamp securing lugs, servicing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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).</li> <li>Different repair sets are available for left and right headlight.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Remove headlamp with broken lug --> <a class="clsHyperlink" href="#S13599339732008020700000">Headlamps, removing and installing</a>.</li> <li>Remove remains of broken lugs from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021657" name="S22637527062008020700000">Fig. 311: Locating Lugs, And Screws For Headlamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Fit lugs - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">3</span> - from repair kit on headlamp housing and secure with screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S270767604020080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="LEFT" class="clsCellNormal">Component - fastener</td> <td align="CENTER" class="clsCellNormal">Nm</td> </tr> <tr> <td align="LEFT" class="clsCellNormal">Headlamp to lock carrier - screw</td> <td align="CENTER" class="clsCellNormal">4.5</td> </tr> </tbody> </table></span></p><a name="S31619767162008020700000"></a><h2 class="clsHeadTwo">Headlamps with High Intensity Gas Discharge (HID) Lamps - through 10.04</h2><a name="S35171564232008020700000"></a><h2 class="clsHeadThree">General information</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> <li>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.</li> <li>Danger of explosion and burning.</li> </ul> <ul class="clsBULLET"> <li>The control modules for HID lamps must never be operated (headlamps turned on) without an HID lamp.</li> <li>HID bulbs must only be operated (headlamps turned on) when installed in the headlamp housing.</li> <li>Always wear safety glasses and gloves when removing and installing HID bulb.</li> <li>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..</li> </ul> </td> </tr> </table></span></p> <p>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.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Additional information:</li> </ul> </td> </tr> </table></span></p> <p>Owners Manual</p> <p>Self Study Program - Course Number 991103 "2002 Audi A4 Technical Features"</p> <p>Wiring Diagrams Component Locations</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before beginning repairs on electrical system<ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p><a name="S17586665042008020700000"></a><h2 class="clsHeadThree">On Board Diagnostic (OBD), functions</h2> <p>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.</p> <p>Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".</p><a name="S31181548402008020700000"></a><h2 class="clsHeadThree">Headlamps with High Intensity Gas Discharge (HID) Lamps, assembly</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>After performing any repairs or service that could affect headlight aim, check/adjust aim.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021658" name="S23357648692008020700000">Fig. 312: Headlamps With High Intensity Gas Discharge (Hid) Lamps, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">1 - Screw - 1.5 Nm</span> </p> <p><span class="clsEmphBOLD">2 - High intensity gas discharge (HID) lamp control module</span> </p> <ul class="clsBULLET"> <li>For vehicles through approx. 09.01</li> <li>Left High Intensity Gas Discharge (HID) Lamp Control Module J343</li> <li>Right High Intensity Gas Discharge (HID) Lamp Control Module J344</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S30658091722008020700000">High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - through approx. 09.01, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">3 - Headlamp housing</span> </p> <p><span class="clsEmphBOLD">4 - Vent element</span> </p> <ul class="clsBULLET"> <li>2x</li> </ul> <p><span class="clsEmphBOLD">5 - Turn signal/parking lamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 27/7 W</li> <li>Orange</li> <li>Replacing --> <a class="clsHyperlink" href="#S23922080932008020700000">Turn signal/parking lamp bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">6 - Bulb holder</span> </p> <ul class="clsBULLET"> <li>For turn signal</li> </ul> <p><span class="clsEmphBOLD">7 - High intensity gas discharge (HID) low beam headlamp bulb</span> </p> <ul class="clsBULLET"> <li>Where applicable - vehicles through approx. 09.01</li> <li>35 W, D2S</li> <li>Replacing --> <a class="clsHyperlink" href="#S23583465262008020700000">HID low beam headlamp bulb - through approx. 09.01, replacing</a></li> </ul> <p><span class="clsEmphBOLD">8 - Housing cover</span> </p> <ul class="clsBULLET"> <li>For low beam headlamps</li> </ul> <p><span class="clsEmphBOLD">9 - High intensity gas discharge (HID) low beam headlamp lamp bulb</span> </p> <ul class="clsBULLET"> <li>Where applicable - vehicles from approx. 09.01</li> <li>35 W, D1S</li> <li>Replacing --> <a class="clsHyperlink" href="#S21430933342008020700000">HID low beam headlamp bulb - from approx. 09.01, replacing</a></li> </ul> <p><span class="clsEmphBOLD">10 - Housing cover</span> </p> <ul class="clsBULLET"> <li>For high beam headlamps</li> </ul> <p><span class="clsEmphBOLD">11 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb</span> </p> <ul class="clsBULLET"> <li>H7 - 12 V, 55 W</li> <li>Replacing --> <a class="clsHyperlink" href="#S27572507532008020700000">High Beam Headlamp M30 / M32 - bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">12 - Headlamp beam adjustment motor</span> </p> <ul class="clsBULLET"> <li>Left Headlamp Beam Adjustment Motor V48</li> <li>Right Headlamp Beam Adjustment Motor V49</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S13032527752008020700000">Headlamp Beam Adjustment Motor V48 / V49, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">13 - O-ring</span> </p> <ul class="clsBULLET"> <li>For headlamp beam adjustment motor</li> </ul> <p><span class="clsEmphBOLD">14 - 6 Nm</span> </p> <p><span class="clsEmphBOLD">15 - Stop bolt</span> </p> <ul class="clsBULLET"> <li>For aligning headlamp housing with body contour</li> <li>Must make contact with lock carrier</li> </ul> <p><span class="clsEmphBOLD">16 - Trim cover</span> </p> <p><span class="clsEmphBOLD">17 - Adapter lead</span> </p> <ul class="clsBULLET"> <li>For vehicles from approx. 09.01</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S08107815682008020700000">High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - from approx. 09.01, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">18 - High intensity gas discharge (HID) lamp control module</span> </p> <ul class="clsBULLET"> <li>For vehicles from approx. 09.01</li> <li>Left High Intensity Gas Discharge (HID) Lamp Control Module J343</li> <li>Right High Intensity Gas Discharge (HID) Lamp Control Module J344</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S08107815682008020700000">High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - from approx. 09.01, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">19 - Screw - 1.5 Nm</span> </p><a name="S25343297202008020700000"></a><h2 class="clsHeadThree">Headlamps, removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> </ul> </td> </tr> </table></span></p><a name="S27957545202008040900000"></a><h2 class="clsHeadFour">Removing</h2> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Left headlamp</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017583" name="S14838220762008020700000">Fig. 313: Removing Cover In Engine Compartment (Left Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017582" name="S18893081472008020700000">Fig. 314: Removing Cover In Engine Compartment (Right Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Right headlamp</span> </p> <ul class="clsDASH"> <li>Remove right engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S24253544362008020700000">Fig. 315: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsEmphBOLD">Both sides, continued:</span> </p> <ul class="clsDASH"> <li>Use adhesive tape to mask area beneath headlamp to prevent damage to paintwork.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021637" name="S39874405142008020700000">Fig. 316: Locating Screws And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">5</span> -.</li> <li>Loosen screws - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">4</span> - a few turns but do NOT remove completely.</li> <li>Where applicable, cut through cable tie.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove headlamp from body towards front.</li> </ul><a name="S29251685152008040900000"></a><h2 class="clsHeadFour">Installing</h2> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021638" name="S08787178602008020700000">Fig. 317: Locating Vent Elements On Underside Of Headlamp</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Check whether both vent elements have been inserted on underside of headlamp - <span class="clsEmphBOLD">detail</span> -.</li> <li>Slide headlamp horizontally onto lower headlamp mounting as far as it will go.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021639" name="S24332579482008020700000">Fig. 318: Locating Screws And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Position stop screw - <span class="clsEmphBOLD">1</span> - so that it makes contact with lock carrier.</li> <li>Use stop screw to align headlamp with body contours (gap widths).</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Pay attention to area around fender panel opening when aligning headlamp.</li> <li>Tighten screws - <span class="clsEmphBOLD">2... 5</span> -.</li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> <li>Following installation, check and adjust headlamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S292516851520080409000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Headlamp to lock carrier</td> <td align="" class="clsCellNormal">6</td> </tr> </tbody> </table></span></p><a name="S33709974082008020700000"></a><h2 class="clsHeadThree">Headlamps, adjusting</h2> <p>Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</p><a name="S11292699692008020700000"></a><h2 class="clsHeadThree">Headlamps, service preparation</h2> <p>The following engine-dependent procedures are required in order to replace certain headlamp bulbs.</p><a name="S05960942732008020700000"></a><h2 class="clsHeadFour">Preparation - vehicles with 1.8L 4-cylinder Turbo engine</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017582" name="S12219074742008020700000">Fig. 319: Removing Cover In Engine Compartment (Right Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove right engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S13506719912008020700000">Fig. 320: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017291" name="S37384693262008020700000">Fig. 321: Disconnect Wires/Unplug Connectors</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections:</li> </ul> <ol class="clsARABICNUM"> <li>at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80</li> <li>at Mass Air Flow (MAF) Sensor G70</li> <li>at Wastegate Bypass Regulator Valve N75</li> </ol> <ul class="clsDASH"> <li>Disconnect hoses - <span class="clsEmphBOLD">4... 7</span> -.</li> <li>Disconnect hose leading to secondary air pump.</li> <li>Set aside wiring.</li> <li>Release fasteners at air cleaner housing - <span class="clsEmphBOLD">8</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove air cleaner housing.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The vacuum line leading to combination valve for secondary air is clipped onto the underside of the air intake hose.</li> </ul> </td> </tr> </table></span></p> <p>Install in reverse order of removal.</p><a name="S24482594812008020700000"></a><h2 class="clsHeadFour">Preparation - vehicles with 3.0L 6-cylinder engine</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017582" name="S30588923182008020700000">Fig. 322: Removing Cover In Engine Compartment (Right Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove cover (right-side) - <span class="clsEmphBOLD">1</span> - in engine compartment.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S17592193622008020700000">Fig. 323: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021640" name="S02072233972008020700000">Fig. 324: Identifying Lines And Air Cleaner Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull off lines / disconnect electrical connections:</li> </ul> <ol class="clsARABICNUM"> <li>at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80</li> <li>vacuum hose at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80</li> <li>at Mass Air Flow (MAF) Sensor G70</li> </ol> <ul class="clsDASH"> <li>Pull off hose connections, set aside hoses and remove air cleaner housing - <span class="clsEmphBOLD">arrows</span> -</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Disregard - <span class="clsEmphBOLD">4</span> - and - <span class="clsEmphBOLD">5</span> -.</li> </ul> </td> </tr> </table></span></p> <p>Install in reverse order of removal.</p><a name="S18731552252008020700000"></a><h2 class="clsHeadFour">Preparation - 4.2L 8-cylinder engine</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017582" name="S10002462392008020700000">Fig. 325: Removing Cover In Engine Compartment (Right Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove right engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S06400688112008020700000">Fig. 326: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018094" name="S31917282122008020700000">Fig. 327: Identifying Electrical Harness Connectors, Secondary Air Injection (AIR) Pump Hose, Air Guide Hose & Mass Air Flow (MAF) Sensor</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> - at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> - at Mass Air Flow (MAF) Sensor G70.</li> <li>Disconnect hose - <span class="clsEmphBOLD">1</span> - to secondary air pump.</li> <li>Remove air intake hose - <span class="clsEmphBOLD">4</span> - at Mass Air Flow (MAF) Sensor G70.</li> </ul> <ul class="clsDASH"> <li>Set aside wiring harness at air cleaner housing.</li> <li>Release fastener - <span class="clsEmphBOLD">arrow</span> - and remove air cleaner housing together with Mass Air Flow (MAF) Sensor G70.</li> </ul> <p>Install in reverse order of removal.</p><a name="S23583465262008020700000"></a><h2 class="clsHeadThree">HID low beam headlamp bulb - through approx. 09.01, replacing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> <li>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.</li> <li>Danger of explosion and burning.</li> </ul> <ul class="clsBULLET"> <li>The control modules for HID lamps must never be operated (headlamps turned on) without an HID lamp.</li> <li>HID bulbs must only be operated (headlamps turned on) when installed in the headlamp housing.</li> <li>Always wear safety glasses and gloves when removing and installing HID bulb.</li> <li>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..</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Left headlamp</span> </p> <ul class="clsDASH"> <li>Remove headlamp --> <a class="clsHyperlink" href="#S25343297202008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine:</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 3.0L 6-cylinder engine:</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 4.2L 8-cylinder engine:</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Both sides, continued:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021641" name="S26103486142008020700000">Fig. 328: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clip - <span class="clsEmphBOLD">arrow</span> - and detach housing cover for low beam from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021659" name="S27149296442008020700000">Fig. 329: Locating Connector And Retaining Clip</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove connector - <span class="clsEmphBOLD">1</span> - at HID headlamp bulb by turning counter-clockwise.</li> <li>Release retaining clip - <span class="clsEmphBOLD">arrows</span> - and pull HID headlamp bulb from housing.</li> </ul> <p>Faulty HID headlamp bulb disposal --> <a class="clsHyperlink" href="#S29504431532008020700000">HID headlamp bulb, disposal</a></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert new HID headlamp bulb in housing.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Heed installation position: lug at top of bulb holder must engage in recess of HID headlamp bulb.</li> <li>Secure HID headlamp bulb with retaining clip.</li> <li>Secure housing cover with retaining clip.</li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> </ul> </td> </tr> </table></span></p><a name="S29504431532008020700000"></a><h2 class="clsHeadThree">HID headlamp bulb, disposal</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>HID headlamp bulbs contain mercury.</li> <li>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.</li> </ul> </td> </tr> </table></span></p><a name="S21430933342008020700000"></a><h2 class="clsHeadThree">HID low beam headlamp bulb - from approx. 09.01, replacing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> <li>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.</li> <li>Danger of explosion and burning.</li> </ul> <ul class="clsBULLET"> <li>The control modules for HID lamps must never be operated (headlamps turned on) without an HID lamp.</li> <li>HID bulbs must only be operated (headlamps turned on) when installed in the headlamp housing.</li> <li>Always wear safety glasses and gloves when removing and installing HID bulb.</li> <li>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..</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Left headlamp</span> </p> <ul class="clsDASH"> <li>Remove headlamp --> <a class="clsHyperlink" href="#S25343297202008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - 1.8L 4-cylinder Turbo engine:</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - 3.0L 6-cylinder engine:</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - 4.2L 8-cylinder engine:</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Both sides, continued:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021641" name="S22782058732008020700000">Fig. 330: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clip - <span class="clsEmphBOLD">arrow</span> - and detach housing cover for low beam from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021660" name="S02711639382008020700000">Fig. 331: Identifying Retaining Clip, HID Headlamp Bulb, And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clip - <span class="clsEmphBOLD">2</span> - and remove HID headlamp bulb - <span class="clsEmphBOLD">3</span> - from housing.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p>Faulty HID headlamp bulb disposal --> <a class="clsHyperlink" href="#S18776889782008020700000">HID headlamp bulb, disposal</a></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert new HID headlamp bulb in housing.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Heed installation position: lug at top of bulb holder must engage in recess of HID headlamp bulb.</li> <li>Secure HID headlamp bulb with retaining clip.</li> <li>Secure housing cover with retaining clip.</li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> </ul> </td> </tr> </table></span></p><a name="S18776889782008020700000"></a><h2 class="clsHeadThree">HID headlamp bulb, disposal</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>HID headlamp bulbs contain mercury.</li> <li>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.</li> </ul> </td> </tr> </table></span></p><a name="S27572507532008020700000"></a><h2 class="clsHeadThree">High Beam Headlamp M30 / M32 - bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Left headlamp</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017583" name="S12895138382008020700000">Fig. 332: Removing Cover In Engine Compartment (Left Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021643" name="S22499761012008020700000">Fig. 333: Disconnecting Electrical Connections From Retainer And Removing Retainer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connectors - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - from retainer.</li> <li>Unclip retainer for connectors and pull off upwards - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p>Additional preparation:</p> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine:</span> </p> <ul class="clsDASH"> <li>Remove air cleaner housing.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 3.0L 6-cylinder engine:</span> </p> <ul class="clsDASH"> <li>Remove air cleaner housing.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 4.2L 8-cylinder petrol engine:</span> </p> <ul class="clsDASH"> <li>Remove air cleaner housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021644" name="S08658046622008020700000">Fig. 334: Releasing Retaining Clip And Detaching Housing Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Both sides, continued:</span> </p> <ul class="clsDASH"> <li>Release retaining clip - <span class="clsEmphBOLD">arrow</span> - and detach housing cover for high beam from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021661" name="S09924059342008020700000">Fig. 335: Identifying Electrical Connection, Retaining Clip, And Bulb</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> - at high beam headlamp bulb.</li> <li>Release retaining clip - <span class="clsEmphBOLD">2</span> - and remove bulb - <span class="clsEmphBOLD">1</span> - from housing.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Do not touch glass portion of bulb with bare hands. Even the smallest amount of moisture and/or contaminants from fingers that evaporates on the bulb during operation can cause the glass to cloud over.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Fit new bulb in housing.</li> <li>Secure bulb with retaining clip.</li> <li>Secure housing cover with retaining clip.</li> </ul><a name="S23922080932008020700000"></a><h2 class="clsHeadThree">Turn signal/parking lamp bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove headlamp --> <a class="clsHyperlink" href="#S25343297202008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021646" name="S37667003132008020700000">Fig. 336: Identifying Bulb Holder</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Turn bulb holder - <span class="clsEmphBOLD">arrow</span> - counter-clockwise and pull it from housing.</li> <li>Pull bulb out of bulb holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing bulb holder, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Fit new bulb in housing.</li> <li>Install headlamp <a class="clsHyperlink" href="#S29251685152008040900000">Installing</a>.</li> </ul><a name="S13032527752008020700000"></a><h2 class="clsHeadThree">Headlamp Beam Adjustment Motor V48 / V49, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Left headlamp</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017583" name="S20337524102008020700000">Fig. 337: Removing Cover In Engine Compartment (Left Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021643" name="S28187415092008020700000">Fig. 338: Disconnecting Electrical Connections From Retainer And Removing Retainer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - from retainer.</li> <li>Unclip retainer for connectors and pull off upwards - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p>Additional preparation:</p> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine:</span> </p> <ul class="clsDASH"> <li>Remove air cleaner housing.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 3.0L 6-cylinder engine</span> </p> <ul class="clsDASH"> <li>Remove air cleaner housing.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 4.2L 8-cylinder engine</span> </p> <ul class="clsDASH"> <li>Remove air cleaner housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021644" name="S24588580312008020700000">Fig. 339: Releasing Retaining Clip And Detaching Housing Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Both sides, continued:</span> </p> <ul class="clsDASH"> <li>Release retaining clip - <span class="clsEmphBOLD">arrow</span> - and detach housing cover for high beam from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021662" name="S39944246422008020700000">Fig. 340: Releasing Headlamp Range Control Motor</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release headlamp range control motor: at right-side headlamp by turning counter-clockwise - <span class="clsEmphBOLD">arrow</span> - ; at left-side headlamp by turning clockwise.</li> <li>Press ball head of actuator shaft downwards out of its mounting by tilting control motor.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Start by inserting ball head of actuator shaft in mounting on reflector from below; to do so, pull reflector to rear.</li> <li>Secure housing cover with retaining clip.</li> <li>Following installation, check and adjust headlamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Headlamps must always be adjusted if the control motors are removed and installed or replaced.</li> </ul> </td> </tr> </table></span></p><a name="S30658091722008020700000"></a><h2 class="clsHeadThree">High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - through approx. 09.01, removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove headlamp --> <a class="clsHyperlink" href="#S25343297202008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021641" name="S28951531112008020700000">Fig. 341: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clip - <span class="clsEmphBOLD">arrow</span> - and detach housing cover for low beam from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021659" name="S15343547892008020700000">Fig. 342: Locating Connector And Retaining Clip</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove connector - <span class="clsEmphBOLD">1</span> - at HID headlamp bulb by turning counter-clockwise.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Leave retaining clip - <span class="clsEmphBOLD">arrows</span> - for HID headlamp bulb in position.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021663" name="S41850738282008020700000">Fig. 343: Identifying Control Module Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove control module from headlamp housing.</li> <li>Connector at HID headlamp bulb can then be passed through headlamp housing.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Secure housing cover with retaining clip.</li> <li>Install headlamp <a class="clsHyperlink" href="#S29251685152008040900000">Installing</a>.</li> </ul><a name="S08107815682008020700000"></a><h2 class="clsHeadThree">High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - from approx. 09.01, removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove headlamp --> <a class="clsHyperlink" href="#S25343297202008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021641" name="S40969472692008020700000">Fig. 344: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clip - <span class="clsEmphBOLD">arrow</span> - and detach housing cover for low beam from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021660" name="S16274124412008020700000">Fig. 345: Identifying Retaining Clip, HID Headlamp Bulb, And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clip - <span class="clsEmphBOLD">2</span> - and remove HID headlamp bulb - <span class="clsEmphBOLD">3</span> - from housing.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021663" name="S28000039822008020700000">Fig. 346: Identifying Control Module Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove control module from headlamp housing.</li> <li>Disconnect electrical connections.</li> <li>Remove adapter lead for HID headlamp bulb.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert HID headlamp bulb in housing.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Heed installation position: lug at top of bulb holder must engage in recess of HID headlamp bulb.</li> <li>Secure HID headlamp bulb with retaining clip.</li> <li>Secure housing cover with retaining clip.</li> <li>Install headlamp <a class="clsHyperlink" href="#S29251685152008040900000">Installing</a>.</li> </ul> </td> </tr> </table></span></p><a name="S18071777412008020700000"></a><h2 class="clsHeadThree">Headlamp securing lugs, servicing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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).</li> <li>Different repair sets are available for left and right headlight.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Remove headlamp with broken lug --> <a class="clsHyperlink" href="#S25343297202008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021647" name="S38673274712008020700000">Fig. 347: Exploded View Of Headlamp Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove remains of broken lug - <span class="clsEmphBOLD">3</span> - and - <span class="clsEmphBOLD">4</span> - at headlamp housing.</li> <li>Position retaining tab - <span class="clsEmphBOLD">2</span> - from repair kit at edge of headlamp housing and secure from rear with the two screws - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S180717774120080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Headlamp to lock carrier</td> <td align="" class="clsCellNormal">6</td> </tr> </tbody> </table></span></p><a name="S02509288662008020700000"></a><h2 class="clsHeadTwo">Headlamps with High Intensity Gas Discharge HID Lamps - through 10.04</h2><a name="S08896161182008020700000"></a><h2 class="clsHeadThree">General information</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> <li>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.</li> <li>Danger of explosion and burning.</li> </ul> <ul class="clsBULLET"> <li>The control modules for HID lamps must never be operated (headlamps turned on) without an HID lamp.</li> <li>HID bulbs must only be operated (headlamps turned on) when installed in the headlamp housing.</li> <li>Always wear safety glasses and gloves when removing and installing HID bulb.</li> <li>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..</li> </ul> </td> </tr> </table></span></p> <p>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.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Additional information:</li> </ul> </td> </tr> </table></span></p> <p>Owners Manual</p> <p>Self Study Program - Course Number 991103 "2002 Audi A4 Technical Features"</p> <p>Wiring Diagrams Component Locations</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before beginning repairs on electrical system<ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p><a name="S04870154692008020700000"></a><h2 class="clsHeadThree">On Board Diagnostic (OBD), functions</h2> <p>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.</p> <p>Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".</p><a name="S29300107402008020700000"></a><h2 class="clsHeadThree">Headlamps with High Intensity Gas Discharge (HID) "Bi-Xenon" Lamps, assembly</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>After performing any repairs or service that could affect headlight aim, check/adjust aim.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021664" name="S17743702252008020700000">Fig. 348: Headlamps With High Intensity Gas Discharge (HID) "Bi-Xenon" Lamps, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">1 - Trim cover</span> </p> <p><span class="clsEmphBOLD">2 - Headlamp housing</span> </p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S12098580432008020700000">Headlamps, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">3 - Turn signal/parking lamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 28/7 W</li> <li>Orange</li> <li>Replacing --> <a class="clsHyperlink" href="#S13099006172008020700000">Turn signal/parking lamp bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">4 - Bulb holder</span> </p> <ul class="clsBULLET"> <li>For turn signal</li> </ul> <p><span class="clsEmphBOLD">5 - Headlamp beam adjustment motor</span> </p> <ul class="clsBULLET"> <li>Left Headlamp Beam Adjustment Motor V48</li> <li>Right Headlamp Beam Adjustment Motor V49</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S29053330252008020700000">Headlamp Beam Adjustment Motor V48 / V49, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">6 - High intensity gas discharge (HID) low beam headlamp bulb</span> </p> <ul class="clsBULLET"> <li>35 W, D1S</li> <li>Replacing --> <a class="clsHyperlink" href="#S26921400062008020700000">HID low beam headlamp bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">7 - Screw - 1.5 Nm</span> </p> <p><span class="clsEmphBOLD">8 - Adapter lead</span> </p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S09586994772008020700000">Adapter cable for HID headlamp bulb control module, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">9 - High intensity gas discharge (HID) lamp control module</span> </p> <ul class="clsBULLET"> <li>Left High-intensity Gas Discharge (HID) Lamp Control Module J343</li> <li>Right High-intensity Gas Discharge (HID) Lamp Control Module J344</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S35224281122008020700000">High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">10 - Screw - 1.5 Nm</span> </p> <p><span class="clsEmphBOLD">11 - Housing cover</span> </p> <p><span class="clsEmphBOLD">12 - Cover cap with adjuster wheel</span> </p> <p><span class="clsEmphBOLD">13 - Screw - 1.5 Nm</span> </p> <p><span class="clsEmphBOLD">14 - Adjuster rod</span> </p> <p><span class="clsEmphBOLD">15 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb</span> </p> <ul class="clsBULLET"> <li>H10 - 12 V, 42 W</li> <li>Replacing --> <a class="clsHyperlink" href="#S12019138312008020700000">High Beam Headlamp bulb M30 / M32, replacing</a></li> </ul> <p><span class="clsEmphBOLD">16 - Vent element</span> </p> <ul class="clsBULLET"> <li>1x</li> </ul> <p><span class="clsEmphBOLD">17 - Screw - 6 Nm</span> </p> <p><span class="clsEmphBOLD">18 - Stop bolt</span> </p> <ul class="clsBULLET"> <li>For aligning headlamp housing with body contour</li> <li>Must make contact with lock carrier</li> </ul><a name="S12098580432008020700000"></a><h2 class="clsHeadThree">Headlamps, removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> </ul> </td> </tr> </table></span></p><a name="S30444719922008040900000"></a><h2 class="clsHeadFour">Removing</h2> <p><span class="clsEmphBOLD">Left headlamp</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017583" name="S18437487542008020700000">Fig. 349: Removing Cover In Engine Compartment (Left Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove left engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017582" name="S00418803872008020700000">Fig. 350: Removing Cover In Engine Compartment (Right Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove right engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S06014716082008020700000">Fig. 351: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsEmphBOLD">Both sides, continued:</span> </p> <ul class="clsDASH"> <li>Use adhesive tape to mask area beneath headlamp to prevent damage to paintwork.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021637" name="S06865632192008020700000">Fig. 352: Locating Screws And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">5</span> -.</li> <li>Loosen screws - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">4</span> - (do not remove).</li> <li>Where applicable, remove cable tie.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove headlamp from body towards front.</li> </ul><a name="S14371063172008040900000"></a><h2 class="clsHeadFour">Installing</h2> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021665" name="S30312097112008020700000">Fig. 353: Checking Whether Vent Element Has Been Inserted On Underside Of Headlamp</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Check whether vent element has been inserted on underside of headlamp - <span class="clsEmphBOLD">detail</span> -.</li> <li>Slide headlamp horizontally onto lower headlamp mounting as far as it will go.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021639" name="S40534917362008020700000">Fig. 354: Locating Screws And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Position stop screw - <span class="clsEmphBOLD">1</span> - so that it makes contact with lock carrier.</li> <li>Use stop screw to align headlamp with body contours (gap widths).</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Pay attention to area around fender opening when aligning headlamp.</li> <li>Tighten screws - <span class="clsEmphBOLD">2... 5</span> -.</li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> <li>Following installation, check and adjust headlamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S143710631720080409000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Headlamp to lock carrier</td> <td align="" class="clsCellNormal">6</td> </tr> </tbody> </table></span></p><a name="S13007968742008020700000"></a><h2 class="clsHeadThree">Headlamps, adjusting</h2> <p>Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</p><a name="S26921400062008020700000"></a><h2 class="clsHeadThree">HID low beam headlamp bulb, replacing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> <li>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.</li> <li>Danger of explosion and burning.</li> </ul> <ul class="clsBULLET"> <li>The control modules for HID lamps must never be operated (headlamps turned on) without an HID lamp.</li> <li>HID bulbs must only be operated (headlamps turned on) when installed in the headlamp housing.</li> <li>Always wear safety glasses and gloves when removing and installing HID bulb.</li> <li>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..</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove headlamp --> <a class="clsHyperlink" href="#S12098580432008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021666" name="S11832192822008020700000">Fig. 355: Removing Screws And Retaining Clip</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> <li>Release retaining clip - <span class="clsEmphBOLD">3</span> - in direction of - <span class="clsEmphBOLD">arrow</span> - and detach housing cover from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021667" name="S15512753252008020700000">Fig. 356: Identifying Electrical Connection, Retaining Clip, And HID Headlamp Bulb</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> -.</li> <li>Release retaining clip - <span class="clsEmphBOLD">1</span> - and remove HID headlamp bulb - <span class="clsEmphBOLD">2</span> - from housing.</li> </ul> <p>Faulty HID headlamp bulb disposal --> <a class="clsHyperlink" href="#S01574480182008020700000">HID headlamp bulb, disposal</a></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert new HID headlamp bulb in housing.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Heed installation position: lug at top of bulb holder must engage in recess of HID headlamp bulb.</li> <li>Secure HID headlamp bulb with retaining clip.</li> <li>Secure housing cover with screws and retaining clip.</li> <li>Install headlamp <a class="clsHyperlink" href="#S14371063172008040900000">Installing</a>.</li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> </ul> </td> </tr> </table></span></p><a name="S01574480182008020700000"></a><h2 class="clsHeadThree">HID headlamp bulb, disposal</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>HID headlamp bulbs contain mercury.</li> <li>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.</li> </ul> </td> </tr> </table></span></p><a name="S12019138312008020700000"></a><h2 class="clsHeadThree">High Beam Headlamp bulb M30 / M32, replacing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove headlamp --> <a class="clsHyperlink" href="#S12098580432008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021666" name="S03293442782008020700000">Fig. 357: Removing Screws And Retaining Clip</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> <li>Release retaining clip - <span class="clsEmphBOLD">3</span> - in direction of - <span class="clsEmphBOLD">arrow</span> - and detach housing cover from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021668" name="S10802748672008020700000">Fig. 358: Turning Bulb Clockwise And Removing From Housing/Disconnecting Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Turn bulb - <span class="clsEmphBOLD">1</span> - clockwise - <span class="clsEmphBOLD">arrow</span> - and remove from housing.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Fit new bulb in housing.</li> <li>Secure bulb by turning in counter-clockwise direction.</li> <li>Secure housing cover with screws and retaining clip.</li> <li>Install headlamp <a class="clsHyperlink" href="#S14371063172008040900000">Installing</a>.</li> </ul> <ul class="clsDASH"> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> </ul><a name="S11422758442008020700000"></a><h2 class="clsHeadThree">High/Low Beam Switch-Over Solenoid N347 / N348, removing and installing</h2> <p>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.</p> <ul class="clsDASH"> <li>Replace headlamp --> <a class="clsHyperlink" href="#S12098580432008020700000">Headlamps, removing and installing</a>.</li> </ul><a name="S13099006172008020700000"></a><h2 class="clsHeadThree">Turn signal/parking lamp bulb, replacing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove headlamp --> <a class="clsHyperlink" href="#S12098580432008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021646" name="S14373094072008020700000">Fig. 359: Identifying Bulb Holder</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Turn bulb holder - <span class="clsEmphBOLD">arrow</span> - counter-clockwise and pull it from housing.</li> <li>Pull bulb out of bulb holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Do not touch glass portion of bulb with bare hands. Even the smallest amount of moisture and/or contaminants from fingers that evaporates on the bulb during operation can cause the glass to cloud over.</li> <li>When installing bulb holder, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Fit new bulb in housing.</li> <li>Install headlamp <a class="clsHyperlink" href="#S14371063172008040900000">Installing</a>.</li> </ul><a name="S29053330252008020700000"></a><h2 class="clsHeadThree">Headlamp Beam Adjustment Motor V48 / V49, removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove headlamp --> <a class="clsHyperlink" href="#S12098580432008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021666" name="S15115678922008020700000">Fig. 360: Removing Screws And Retaining Clip</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> <li>Release retaining clip - <span class="clsEmphBOLD">3</span> - in direction of - <span class="clsEmphBOLD">arrow</span> - and detach housing cover from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021669" name="S18364401812008020700000">Fig. 361: Locating Screw And Cover Cap</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screw - <span class="clsEmphBOLD">2</span> -.</li> <li>Lift off cover cap - <span class="clsEmphBOLD">1</span> - with adjuster wheel.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021670" name="S15438192922008020700000">Fig. 362: Identifying Adjuster Rod, Electrical Connection, Control Motor, Swivel Ball Head, And Mounting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove adjuster rod - <span class="clsEmphBOLD">3</span> - upwards out of headlamp housing.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">4</span> -.</li> <li>Turn control motor - <span class="clsEmphBOLD">5</span> - for left-side headlamp in a clockwise direction, for right-side headlamp in counter-clockwise direction - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Swivel ball head - <span class="clsEmphBOLD">2</span> - of actuator shaft downwards out of mounting - <span class="clsEmphBOLD">1</span> - on reflector.</li> </ul> <ul class="clsDASH"> <li>Remove headlamp range control motor from headlamp housing.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Push ball head of actuator shaft into mounting on reflector and turn control motor to limit stop in installation position.</li> <li>Insert adjuster rod into headlamp housing.</li> <li>Secure housing cover with screws and retaining clip.</li> <li>Install headlamp <a class="clsHyperlink" href="#S14371063172008040900000">Installing</a>.</li> </ul> <ul class="clsDASH"> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> <li>Following installation, check and adjust headlamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Headlamps must always be adjusted if the control motors are removed and installed or replaced.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S290533302520080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="LEFT" class="clsCellNormal">Component</td> <td align="CENTER" class="clsCellNormal">Nm</td> </tr> <tr> <td align="LEFT" class="clsCellNormal">Cover cap with adjuster wheel to headlamp housing</td> <td align="CENTER" class="clsCellNormal">1.5</td> </tr> </tbody> </table></span></p><a name="S35224281122008020700000"></a><h2 class="clsHeadThree">High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344, removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove headlamp --> <a class="clsHyperlink" href="#S12098580432008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021671" name="S22760493332008020700000">Fig. 363: Identifying Screws And Control Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove control module - <span class="clsEmphBOLD">1</span> - from housing cover for headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021672" name="S39910533222008020700000">Fig. 364: Identifying Electrical Connections</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Check gasket between control module for HID headlamp bulb and headlamp housing.</li> <li>Install headlamp <a class="clsHyperlink" href="#S14371063172008040900000">Installing</a>.</li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S352242811220080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="LEFT" class="clsCellNormal">Component - fastener</td> <td align="CENTER" class="clsCellNormal">Nm</td> </tr> <tr> <td align="LEFT" class="clsCellNormal">Control module to headlamp - screw</td> <td align="CENTER" class="clsCellNormal">1</td> </tr> </tbody> </table></span></p><a name="S09586994772008020700000"></a><h2 class="clsHeadThree">Adapter cable for HID headlamp bulb control module, removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove headlamp --> <a class="clsHyperlink" href="#S12098580432008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021666" name="S39155588072008020700000">Fig. 365: Removing Screws And Retaining Clip</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> <li>Release retaining clip - <span class="clsEmphBOLD">3</span> - in direction of - <span class="clsEmphBOLD">arrow</span> - and detach housing cover from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021671" name="S37917352162008020700000">Fig. 366: Identifying Screws And Control Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove control module - <span class="clsEmphBOLD">1</span> - from housing cover for headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021672" name="S00541425642008020700000">Fig. 367: Identifying Electrical Connections</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Disregard - <span class="clsEmphBOLD">2</span> -.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021673" name="S11875382782008020700000">Fig. 368: Identifying Electrical Connection, Wiring, Adapter Cable, Retainer, And Housing Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">4</span> - at HID headlamp bulb.</li> <li>Remove wiring - <span class="clsEmphBOLD">1</span> - and adapter cable - <span class="clsEmphBOLD">3</span> - from retainer - <span class="clsEmphBOLD">2</span> -.</li> <li>Guide adapter cable out of housing cover - <span class="clsEmphBOLD">5</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Insert adapter cable and electrical wiring in retainer.</li> <li>Check gasket between control module for gas discharge lamp and headlamp housing.</li> <li>Install headlamp <a class="clsHyperlink" href="#S14371063172008040900000">Installing</a>.</li> <li>Reconnect battery. Required steps <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S095869947720080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="LEFT" class="clsCellNormal">Component - fastener</td> <td align="CENTER" class="clsCellNormal">Nm</td> </tr> <tr> <td align="LEFT" class="clsCellNormal">Control module to headlamp - screw</td> <td align="CENTER" class="clsCellNormal">1</td> </tr> </tbody> </table></span></p><a name="S20832722962008020700000"></a><h2 class="clsHeadThree">Headlamp securing lugs, servicing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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).</li> <li>Different repair sets are available for left and right headlight.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Remove headlamp with broken lug --> <a class="clsHyperlink" href="#S12098580432008020700000">Headlamps, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021647" name="S01216019452008020700000">Fig. 369: Exploded View Of Headlamp Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove remains of broken-off lug - <span class="clsEmphBOLD">3</span> - and - <span class="clsEmphBOLD">4</span> - at headlamp housing.</li> <li>Position retaining tab - <span class="clsEmphBOLD">2</span> - from repair kit at edge of headlamp housing and secure from rear with the two screws - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S208327229620080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Headlamp to lock carrier</td> <td align="" class="clsCellNormal">6</td> </tr> </tbody> </table></span></p><a name="S31876980562008020700000"></a><h2 class="clsHeadTwo">Headlamps with High Intensity Gas Discharge HID Bi-Xenon Lamps - through 10.04</h2><a name="S07963682512008020700000"></a><h2 class="clsHeadThree">General information</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> <li>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.</li> <li>Danger of explosion and burning.</li> </ul> <ul class="clsBULLET"> <li>The control modules for HID lamps must never be operated (headlamps turned on) without an HID lamp.</li> <li>HID bulbs must only be operated (headlamps turned on) when installed in the headlamp housing.</li> <li>Always wear safety glasses and gloves when removing and installing HID bulb.</li> <li>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..</li> </ul> </td> </tr> </table></span></p> <p>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.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Additional information:</li> </ul> </td> </tr> </table></span></p> <p>Owners Manual</p> <p>Self Study Program - Course Number 991503 "The 2005 Audi A4"</p> <p>Wiring Diagrams Component Locations</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before beginning repairs on electrical system<ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p><a name="S11200713382008020700000"></a><h2 class="clsHeadThree">On Board Diagnostic (OBD), functions</h2> <p>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.</p> <p>Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnosis, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding".</p><a name="S09253623162008020700000"></a><h2 class="clsHeadThree">Headlamps with High Intensity Gas Discharge (HID) "Bi-Xenon" Lamps, assembly</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>After performing any repairs or service that could affect headlight aim, check/adjust aim.</li> <li>Headlamp without adaptive light function (cornering lights) is illustrated.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021674" name="S39119813132008020700000">Fig. 370: Headlamps With High Intensity Gas Discharge (HID) "Bi-Xenon" Lamps, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">1 - Screw - 1.5 Nm</span> </p> <p><span class="clsEmphBOLD">2 - High intensity gas discharge (HID) lamp control module</span> </p> <ul class="clsBULLET"> <li>Left High-intensity Gas Discharge (HID) Lamp Control Module J343</li> <li>Right High-intensity Gas Discharge (HID) Lamp Control Module J344</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S09671359742008020700000">High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">3 - Headlamp housing</span> </p> <p><span class="clsEmphBOLD">4 - Screw - 4.5 Nm</span> </p> <p><span class="clsEmphBOLD">5 - Housing cover</span> </p> <ul class="clsBULLET"> <li>For parking/daytime running lamps</li> </ul> <p><span class="clsEmphBOLD">6 - Daytime running lamp (DRL) bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 21 W</li> <li>Replacing --> <a class="clsHyperlink" href="#S18913532482008020700000">Daytime Running Lamp (DRL) bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">7 - Bulb holder</span> </p> <ul class="clsBULLET"> <li>For daytime running lamp (DRL) bulb</li> </ul> <p><span class="clsEmphBOLD">8 - Bulb holder</span> </p> <ul class="clsBULLET"> <li>For parking lamps</li> </ul> <p><span class="clsEmphBOLD">9 - Left Parking Lamp M1 , Right Parking Lamp M3 - bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 5 W</li> <li>Replacing --> <a class="clsHyperlink" href="#S00555908532008020700000">Parking Lamp M1 / M3 - bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">10 - Screw - 4.5 Nm</span> </p> <p><span class="clsEmphBOLD">11 - Housing cover</span> </p> <ul class="clsBULLET"> <li>For low beam headlamps</li> </ul> <p><span class="clsEmphBOLD">12 - Screw - 1.5 Nm</span> </p> <p><span class="clsEmphBOLD">13 - High intensity gas discharge (HID) lamp</span> </p> <ul class="clsBULLET"> <li>35 W, D1S</li> <li>Replacing --> <a class="clsHyperlink" href="#S00638938522008020700000">HID headlamp bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">14 - Bulb holder</span> </p> <ul class="clsBULLET"> <li>For turn signal bulb</li> </ul> <p><span class="clsEmphBOLD">15 - Left Front Turn Signal Lamp M5 , Right Front Turn Signal Lamp M7 - bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 21 W</li> <li>Orange</li> <li>Replacing --> <a class="clsHyperlink" href="#S22992063712008020700000">Front Turn Signal Lamp M5 / M7 - bulb, replacing</a></li> </ul> <p><span class="clsEmphBOLD">16 - Trim cover</span> </p><a name="S38123747392008020700000"></a><h2 class="clsHeadThree">Headlamps, removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> </ul> </td> </tr> </table></span></p><a name="S19401666902008040900000"></a><h2 class="clsHeadFour">Removing</h2> <ul class="clsDASH"> <li>Remove front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> <li>Disconnect battery. Audi A4 S4 --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>. Audi RS4 --> <a class="clsHyperlink" href="#S36611140512008020700000">Battery in luggage compartment, disconnecting and connecting</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021649" name="S39341777162008020700000">Fig. 371: Locating Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screw - <span class="clsEmphBOLD">3</span> -.</li> <li>Loosen screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - (do not remove).</li> <li>Remove headlamp from body towards front.</li> <li>Disconnect electrical connection.</li> </ul><a name="S27474171482008040900000"></a><h2 class="clsHeadFour">Installing</h2> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021650" name="S11095986112008020700000">Fig. 372: Checking Adjusting Nut Of Adjuster For Freedom Of Movement</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Check adjusting nut - <span class="clsEmphBOLD">1</span> - of adjuster for freedom of movement - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Screw adjusting nut as far as it will go, but do not tighten.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021649" name="S12782141542008020700000">Fig. 373: Locating Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Insert headlamp and screw in screws - <span class="clsEmphBOLD">1... 3</span> - two complete turns.</li> <li>Install front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> <li>Align headlamp with body contours and front bumper cover (note gap widths).</li> <li>Tighten screws in sequence - <span class="clsEmphBOLD">2</span> - , - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">3</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>Check gaps; if necessary, repeat procedure for installing headlamp.</li> <li>Reconnect battery. Required steps Audi A4 S4 <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>. Required steps Audi RS4 <a class="clsHyperlink" href="#S39123246362008040900000">Connecting</a></li> <li>Following installation, check and adjust headlamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S274741714820080409000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Headlamp to lock carrier - screw</td> <td align="" class="clsCellNormal">4.5</td> </tr> </tbody> </table></span></p><a name="S20731063022008020700000"></a><h2 class="clsHeadThree">Headlamps, adjusting</h2> <p>Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</p><a name="S26941625502008020700000"></a><h2 class="clsHeadThree">Headlamps, service preparation</h2> <p>The following equipment and engine-dependent procedures are required in order to replace certain headlamp bulbs.</p><a name="S00547326112008020700000"></a><h2 class="clsHeadFour">Upper washer fluid reservoir and power steering fluid reservoir, removing and installing</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021675" name="S22587514962008020700000">Fig. 374: Identifying Nut, Bolts, Breather Hose, And Washer Fluid Reservoir</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nut - <span class="clsEmphBOLD">1</span> - and bolts - <span class="clsEmphBOLD">4</span> - and - <span class="clsEmphBOLD">5</span> -.</li> <li>Remove breather hose - <span class="clsEmphBOLD">2</span> - from top section of washer fluid reservoir - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove top section of washer fluid reservoir and move power steering reservoir - <span class="clsEmphBOLD">6</span> - to side with hydraulic hoses still attached.</li> </ul> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Clean remnants of locking fluid from bolts using wire brush. Then apply locking fluid and fit bolts. Locking fluid.</li> <li>Clean remnants of locking fluid from inside thread using a thread tap. Otherwise, bolts may break should they need to be removed again later.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S005473261120080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Top section of reservoir to body</td> <td align="" class="clsCellNormal">5.5</td> </tr> <tr> <td align="" class="clsCellNormal">Top section of reservoir and power steering reservoir to body</td> <td align="" class="clsCellNormal">18 <sup>1) 2)</sup> </td> </tr> <tr> <td colspan="2" align="" class="clsCellNormal"> <ul class="clsBULLET"> <li><sup>1)</sup> Replace bolt.</li> <li><sup>2)</sup> Insert with locking compound; locking compound.</li> </ul> </td> </tr> </tbody> </table></span></p><a name="S17570667452008020700000"></a><h2 class="clsHeadFour">Preparation - vehicles with 1.8L 4-cylinder Turbo engine</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S26991578202008020700000">Fig. 375: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017291" name="S32233562312008020700000">Fig. 376: Disconnect Wires/Unplug Connectors</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections:</li> </ul> <ol class="clsARABICNUM"> <li>at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80</li> <li>at Mass Air Flow (MAF) Sensor G70</li> <li>at Wastegate Bypass Regulator Valve N75</li> </ol> <ul class="clsDASH"> <li>Disconnect hoses - <span class="clsEmphBOLD">4... 7</span> -.</li> <li>Disconnect hose to secondary air pump.</li> <li>Set aside wiring.</li> <li>Release fastener - <span class="clsEmphBOLD">8</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove air cleaner housing.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The vacuum line leading to combination valve for secondary air is clipped onto the underside of the air intake hose.</li> </ul> </td> </tr> </table></span></p> <p>Install in reverse order of removal.</p><a name="S37058415132008020700000"></a><h2 class="clsHeadFour">Preparation - vehicles with 2.0L 4-cylinder Turbo FSI engine</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S41925152632008020700000">Fig. 377: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017565" name="S31400648952008020700000">Fig. 378: Identifying Intake, Mass Air Flow (MAF) Sensor G70 Electrical Harness Connector & Air Filter Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove air intake hose - <span class="clsEmphBOLD">1</span> - between turbocharger and air cleaner housing.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> - at Mass Air Flow (MAF) Sensor G70.</li> <li>Pull off clip - <span class="clsEmphBOLD">3</span> - and remove air cleaner housing together with Mass Air Flow (MAF) Sensor G70.</li> </ul> <p>Install in reverse order of removal.</p><a name="S15435133842008020700000"></a><h2 class="clsHeadFour">Preparation - vehicles with 3.0L 6-cylinder engine</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S29303477252008020700000">Fig. 379: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021640" name="S25703860962008020700000">Fig. 380: Identifying Lines And Air Cleaner Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull off lines and disconnect electrical connections:</li> </ul> <ol class="clsARABICNUM"> <li>at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80</li> <li>vacuum hose at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80</li> <li>at Mass Air Flow (MAF) Sensor G70</li> </ol> <ul class="clsDASH"> <li>Pull off hose connections, set aside hoses and remove air cleaner housing - <span class="clsEmphBOLD">arrows</span> -</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Disregard - <span class="clsEmphBOLD">4</span> - and - <span class="clsEmphBOLD">5</span> -.</li> </ul> </td> </tr> </table></span></p> <p>Install in reverse order of removal.</p><a name="S16445326472008020700000"></a><h2 class="clsHeadFour">Preparation - vehicles with 3.2L 6-cylinder FSI engine</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017848" name="S35980734412008020700000">Fig. 381: Identifying Bolts & Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove air duct - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017851" name="S03035635422008020700000">Fig. 382: Locating Fastener</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fastener - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove air cleaner housing.</li> </ul> <p>Install in reverse order of removal.</p><a name="S33683868432008020700000"></a><h2 class="clsHeadFour">Preparation - vehicles with 4.2L 8-cylinder engine (Audi S4)</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017582" name="S01787009362008020700000">Fig. 383: Removing Cover In Engine Compartment (Right Side)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove right engine cover - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004732" name="S15886484892008020700000">Fig. 384: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - <span class="clsEmphBOLD">1</span> - at air duct.</li> <li>Remove air duct - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018094" name="S09158863992008020700000">Fig. 385: Identifying Electrical Harness Connectors, Secondary Air Injection (AIR) Pump Hose, Air Guide Hose & Mass Air Flow (MAF) Sensor</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> - at Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> - at Mass Air Low (MAF) Sensor G70.</li> <li>Disconnect hose - <span class="clsEmphBOLD">1</span> - to secondary air pump.</li> <li>Remove air intake hose - <span class="clsEmphBOLD">4</span> - at Mass Air Low (MAF) Sensor G70.</li> </ul> <ul class="clsDASH"> <li>Set aside wiring harness at air cleaner housing.</li> <li>Remove clip - <span class="clsEmphBOLD">arrow</span> - and remove air cleaner housing together with Mass Air Low (MAF) Sensor G70.</li> </ul> <p>Install in reverse order of removal.</p><a name="S34534044832008020700000"></a><h2 class="clsHeadFour">Preparation - vehicles with 4.2L 8-cylinder FSI engine (Audi RS4)</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018347" name="S37005760752008020700000">Fig. 386: Pulling Rear Engine Cover Off</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rear engine cover in direction of - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017848" name="S30747734052008020700000">Fig. 387: Identifying Bolts & Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove air duct - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018356" name="S34539863982008020700000">Fig. 388: Identifying Mass Air Flow (MAF) Sensor G70 Electrical Harness Connector, Secondary Air Injection (Air) Pump Hose, Vacuum Lines & Air Guide Hose</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">4</span> - for Mass Air Flow (MAF) Sensor G70.</li> <li>Remove hose - <span class="clsEmphBOLD">5</span> - to Secondary Air Injection (AIR) pump.</li> <li>Remove vacuum hoses - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove air guide hose - <span class="clsEmphBOLD">3</span> - at Mass Air Flow (MAF) Sensor.</li> </ul> <ul class="clsDASH"> <li>Free up wiring harness at air filter housing.</li> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> - and remove upper part of air filter housing.</li> <li>Disengage electrical wiring harness bracket at body.</li> <li>Remove clip - <span class="clsEmphBOLD">arrow</span> - and remove air filter housing with Mass Air Flow (MAF) sensor.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Disregard - <span class="clsEmphBOLD">6</span> -.</li> </ul> </td> </tr> </table></span></p> <p>Install in reverse order of removal.</p><a name="S00638938522008020700000"></a><h2 class="clsHeadThree">HID headlamp bulb, replacing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> <li>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.</li> <li>Danger of explosion and burning.</li> </ul> <ul class="clsBULLET"> <li>The control modules for HID lamps must never be operated (headlamps turned on) without an HID lamp.</li> <li>HID bulbs must only be operated (headlamps turned on) when installed in the headlamp housing.</li> <li>Always wear safety glasses and gloves when removing and installing HID bulb.</li> <li>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..</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery. Audi A4 S4 --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>. Audi RS4 --> <a class="clsHyperlink" href="#S36611140512008020700000">Battery in luggage compartment, disconnecting and connecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Left headlamp</span> </p> <ul class="clsDASH"> <li>Remove top section of washer fluid reservoir and power steering reservoir.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine:</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 2.0L 4-cylinder Turbo FSI engine:</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 3.0L 6-cylinder engine</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 3.2L 6-cylinder FSI engine</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 4.2L 8-cylinder engine (Audi S4)</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp - vehicles with 4.2L 8-cylinder FSI engine (Audi RS4)</span> </p> <ul class="clsDASH"> <li>Preparation.</li> </ul> <p><span class="clsEmphBOLD">Both sides, continued:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021676" name="S39631763392008020700000">Fig. 389: Removing Screws And Cover For Low Beam From Headlamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove cover for low beam from headlamp housing - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021677" name="S24726875652008020700000">Fig. 390: Identifying Retainers, Electrical Connection, Retaining Clips, And HID Headlamp Bulb</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove electrical wire from retainers - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">4</span> -.</li> <li>Release retaining clips - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">3</span> - and remove HID headlamp bulb - <span class="clsEmphBOLD">2</span> - from housing.</li> </ul> <p>Faulty HID headlamp bulb disposal --> <a class="clsHyperlink" href="#S21832763342008020700000">HID headlamp bulb, disposal</a></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert new HID headlamp bulb in housing.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Note installation position: the electrical connection must always point downwards.</li> <li>Secure HID headlamp bulb with retaining clips.</li> <li>Reconnect battery. Required steps Audi A4 S4 <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>. Required steps Audi RS4</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S006389385220080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Housing cover for low beam to headlamp housing</td> <td align="" class="clsCellNormal">1.5</td> </tr> </tbody> </table></span></p><a name="S21832763342008020700000"></a><h2 class="clsHeadThree">HID headlamp bulb, disposal</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>HID headlamp bulbs contain mercury.</li> <li>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.</li> </ul> </td> </tr> </table></span></p><a name="S18913532482008020700000"></a><h2 class="clsHeadThree">Daytime Running Lamp (DRL) bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Right headlamp</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017405" name="S38669109582008020700000">Fig. 391: Removing Bolts & Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove air ducts - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021678" name="S14134275982008020700000">Fig. 392: Releasing Retaining Tab And Detaching Housing Cover For Side Lights From Headlamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Both sides, continued:</span> </p> <ul class="clsDASH"> <li>Release retaining tab - <span class="clsEmphBOLD">arrow</span> - and detach housing cover for side lights from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021679" name="S13934935432008020700000">Fig. 393: Turning Bulb Holder Counter-Clockwise And Removing From Headlamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Turn bulb holder - <span class="clsEmphBOLD">1</span> - counter-clockwise - <span class="clsEmphBOLD">arrow</span> - and remove from headlamp housing.</li> <li>Screw bulb out of bulb holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Do not touch glass portion of bulb with bare hands. Even the smallest amount of moisture and/or contaminants from fingers that evaporates on the bulb during operation can cause the glass to cloud over.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Fit new bulb in housing.</li> <li>Secure bulb holder by turning clockwise.</li> <li>Close housing cover.</li> </ul><a name="S00555908532008020700000"></a><h2 class="clsHeadThree">Parking Lamp M1 / M3 - bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Right headlamp</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017405" name="S36445543512008020700000">Fig. 394: Removing Bolts & Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove air ducts - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021678" name="S28350707162008020700000">Fig. 395: Releasing Retaining Tab And Detaching Housing Cover For Side Lights From Headlamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Both sides, continued:</span> </p> <ul class="clsDASH"> <li>Release retaining tab - <span class="clsEmphBOLD">arrow</span> - and detach housing cover for side lights from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021680" name="S10951239132008020700000">Fig. 396: Releasing Two Retainer Tabs And Pulling Bulb Holder Out Of Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release the two retainer tabs and pull bulb holder - <span class="clsEmphBOLD">1</span> - out of housing - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Pull bulb for side lights out of bulb holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert new bulb in bulb holder.</li> <li>Close housing cover.</li> </ul><a name="S26796753412008020700000"></a><h2 class="clsHeadThree">High/Low Beam Switch-Over Solenoid N347 / N348 and Dynamic Cornering Light Motor V318 / V319, removing and installing</h2> <p>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.</p> <ul class="clsDASH"> <li>Replace headlamp --> <a class="clsHyperlink" href="#S38123747392008020700000">Headlamps, removing and installing</a>.</li> </ul><a name="S22992063712008020700000"></a><h2 class="clsHeadThree">Front Turn Signal Lamp M5 / M7 - bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Left headlamp</span> </p> <ul class="clsDASH"> <li>Remove washer fluid reservoir --> <a class="clsHyperlink" href="#S04526534522008020700000">Washer fluid reservoir - Audi A4 S4, removing and installing</a>.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp</span> </p> <ul class="clsDASH"> <li>Lift vehicle.</li> <li>Remove right front wheel.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020340" name="S05356393662008020700000">Fig. 397: Loosening Left/Right Wheelhousing Liners In Front Area</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove forward portion of wheel housing liner.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021656" name="S00772069602008020700000">Fig. 398: Turning Bulb Holder Counter-Clockwise And Pulling From Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">All models:</span> </p> <ul class="clsDASH"> <li>Turn bulb holder - <span class="clsEmphBOLD">3</span> - counter-clockwise - <span class="clsEmphBOLD">arrow</span> - and pull from housing.</li> <li>Screw bulb out of holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Fit new bulb in housing.</li> <li>Markings - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - must be opposite each other when inserting bulb holder into housing.</li> </ul> <p><span class="clsEmphBOLD">Left headlamp</span> </p> <ul class="clsDASH"> <li>Install washer fluid reservoir --> <a class="clsHyperlink" href="#S04526534522008020700000">Washer fluid reservoir - Audi A4 S4, removing and installing</a>.</li> </ul> <p><span class="clsEmphBOLD">Right headlamp</span> </p> <ul class="clsDASH"> <li>Install wheel housing liner --> <a class="clsExtHyperlink" id="A00278920_S32431341132008020700000">66 EXTERIOR EQUIPMENT</a> .</li> </ul><a name="S09671359742008020700000"></a><h2 class="clsHeadThree">High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344, removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>HIGH VOLTAGE!</li> <li>Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove headlamp.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021681" name="S04045022682008020700000">Fig. 399: Identifying Screws, And Control Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove control module - <span class="clsEmphBOLD">1</span> - from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021682" name="S41434677652008020700000">Fig. 400: Disconnecting Adapter Cable For HID Headlamp Bulb At Control Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect adapter cable - <span class="clsEmphBOLD">2</span> - for HID headlamp bulb at control module - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Check gasket between control module for HID headlamp bulb and headlamp housing.</li> <li>Install headlamp <a class="clsHyperlink" href="#S27474171482008040900000">Installing</a>.</li> </ul><a name="S20786567792008020700000"></a><h2 class="clsHeadThree">Headlamp securing lugs, servicing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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).</li> <li>Different repair sets are available for left and right headlight.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Remove headlamp with broken lugs --> <a class="clsHyperlink" href="#S13599339732008020700000">Headlamps, removing and installing</a>.</li> <li>Remove remains of broken lugs from headlamp housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021657" name="S18226569882008020700000">Fig. 401: Locating Lugs, And Screws For Headlamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Fit lugs - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">3</span> - from repair kit on headlamp housing and secure with screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S207865677920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Headlamp to lock carrier</td> <td align="" class="clsCellNormal">6</td> </tr> </tbody> </table></span></p><a name="S21681615182008020700000"></a><h2 class="clsHeadTwo">Fog Lamps - through 10.04</h2><a name="S26556068122008020700000"></a><h2 class="clsHeadThree">Fog lamp housing, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Audi A4:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020342" name="S37421072152008020700000">Fig. 402: Releasing Catches Using Screwdriver And Removing Air Intake Grille On Left/Right On Bottom Part Of Bumper</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining hooks - <span class="clsEmphBOLD">1... 4</span> - using a screwdriver - <span class="clsEmphBOLD">arrow</span> - and pull off air intake grille in bottom section of bumper.</li> </ul> <p><span class="clsEmphBOLD">Audi S4:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021683" name="S12921324672008020700000">Fig. 403: Identifying Screw, Air Intake Grille, And Retaining Clip</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Turn screw - <span class="clsEmphBOLD">1</span> - 90 ° (1/4 turn).</li> <li>Remove air intake grille from fog lamp housing in direction of - <span class="clsEmphBOLD">arrow A</span> -.</li> <li>Then push air intake grille in direction of - <span class="clsEmphBOLD">arrow B</span> - and simultaneously disengage retaining clip - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove air intake grille.</li> </ul> <p><span class="clsEmphBOLD">All models:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021684" name="S35572998482008020700000">Fig. 404: Identifying Screws For Fog Lamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Disengage fog lamp housing and remove.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Engage fog lamp housing.</li> <li>Check and adjust fog lamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S265560681220080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Fog lamp housing to bumper - screw</td> <td align="" class="clsCellNormal">5</td> </tr> </tbody> </table></span></p><a name="S31045559572008020700000"></a><h2 class="clsHeadThree">Fog lamp bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove fog lamp assembly --> <a class="clsHyperlink" href="#S26556068122008020700000">Fog lamp housing, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021685" name="S16565676962008020700000">Fig. 405: Disconnecting Electrical Connection At Bulb And Turning Bulb Counter-Clockwise To Remove From Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> - at bulb.</li> <li>Turn bulb counter-clockwise - <span class="clsEmphBOLD">arrow</span> - and remove from housing.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert bulb and secure by turning in clockwise direction.</li> <li>Check and adjust fog lamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul><a name="S27133766292008020700000"></a><h2 class="clsHeadThree">Fog lamps, adjusting</h2> <p>Fog lamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</p><a name="S16931140712008020700000"></a><h2 class="clsHeadTwo">Fog Lamps - from 11.04</h2><a name="S40056764392008020700000"></a><h2 class="clsHeadThree">Fog lamp housing - Audi A4, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Vehicles without charge air cooler:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017429" name="S07041877212008020700000">Fig. 406: Identifying Quick-Release Fasteners And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove front noise insulation.</li> </ul> <p><span class="clsEmphBOLD">Vehicles with charge air cooler:</span> </p> <ul class="clsDASH"> <li>Remove front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p><span class="clsEmphBOLD">All models:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021686" name="S15459910802008020700000">Fig. 407: Identifying Screws, Electrical Connection, And Fog Lamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove fog lamp housing - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsEmphBOLD">Vehicles with charge air cooler:</span> </p> <ul class="clsDASH"> <li>Install front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p><span class="clsEmphBOLD">All models:</span> </p> <ul class="clsDASH"> <li>Check and adjust fog lamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S400567643920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Fog lamp housing to bumper cover - screw</td> <td align="" class="clsCellNormal">6</td> </tr> </tbody> </table></span></p><a name="S33920583242008020700000"></a><h2 class="clsHeadThree">Fog lamp housing - Audi A4 with "S-line" equipment Audi S4, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021687" name="S38855455502008020700000">Fig. 408: Removing Air Intake Grille From Fog Lamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove air intake grille from fog lamp housing in direction of - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021688" name="S17084140972008020700000">Fig. 409: Locating Screws For Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Disconnect electrical connection.</li> <li>Remove housing from opening.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Check and adjust fog lamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S339205832420080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Fog lamp housing to bumper cover - screw</td> <td align="" class="clsCellNormal">6</td> </tr> </tbody> </table></span></p><a name="S37036714492008020700000"></a><h2 class="clsHeadThree">Fog lamp housing - Audi RS4, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021689" name="S24636161312008020700000">Fig. 410: Pulling Off Air Inlet Grille In Lower Section Of Bumper Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull off air inlet grille in lower section of bumper cover - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021684" name="S20465041742008020700000">Fig. 411: Identifying Screws For Fog Lamp Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Disengage housing and remove from opening.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>First engage fog lamp housing on inner side of bumper cover.</li> <li>Check and adjust fog lamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S370367144920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Fog lamp housing to bumper cover - screw</td> <td align="" class="clsCellNormal">6</td> </tr> </tbody> </table></span></p><a name="S09934779312008020700000"></a><h2 class="clsHeadThree">Fog lamp bulb - Audi A4, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Vehicles with charge air cooler:</span> </p> <ul class="clsDASH"> <li>Remove front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p><span class="clsEmphBOLD">Vehicles without charge air cooler:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017429" name="S31264114982008020700000">Fig. 412: Identifying Quick-Release Fasteners And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove front noise insulation.</li> </ul> <p><span class="clsEmphBOLD">All models:</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021690" name="S30172080602008020700000">Fig. 413: Disconnecting Electrical Connection And Turning Bulb Counter Clockwise To Remove</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> -.</li> <li>Turn bulb - <span class="clsEmphBOLD">1</span> - counter-clockwise - <span class="clsEmphBOLD">arrow</span> - and remove from housing.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert bulb and secure by turning in clockwise direction.</li> </ul> <p><span class="clsEmphBOLD">Vehicles with charge air cooler:</span> </p> <ul class="clsDASH"> <li>Install front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p><span class="clsEmphBOLD">All models:</span> </p> <ul class="clsDASH"> <li>Check and adjust fog lamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul><a name="S26743778452008020700000"></a><h2 class="clsHeadThree">Fog lamp bulb - Audi A4 with "S-line" equipment Audi S4, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove fog lamp housing --> <a class="clsHyperlink" href="#S33920583242008020700000">Fog lamp housing - Audi A4 with "S-line" equipment Audi S4, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021685" name="S30773261432008020700000">Fig. 414: Disconnecting Electrical Connection At Bulb And Turning Bulb Counter-Clockwise To Remove From Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> -.</li> <li>Rotate bulb counter-clockwise - <span class="clsEmphBOLD">arrow</span> - and remove from housing.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert bulb and secure by turning in clockwise direction.</li> <li>Check and adjust fog lamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul><a name="S25348277332008020700000"></a><h2 class="clsHeadThree">Fog lamp bulb - Audi RS4, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove housing --> <a class="clsHyperlink" href="#S37036714492008020700000">Fog lamp housing - Audi RS4, removing and installing</a></li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021685" name="S42905850502008020700000">Fig. 415: Disconnecting Electrical Connection At Bulb And Turning Bulb Counter-Clockwise To Remove From Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> - at bulb.</li> <li>Rotate bulb holder counterclockwise - <span class="clsEmphBOLD">arrow</span> - and remove from housing.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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.</li> <li>When installing housing cover, ensure proper seating. Water intrusion will damage headlamp.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Insert bulb and secure by turning in clockwise direction.</li> <li>Check and adjust fog lamps if necessary --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</li> </ul><a name="S07399627722008020700000"></a><h2 class="clsHeadThree">Fog lamps, adjusting</h2> <p>Fog lamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications --> <a class="clsExtHyperlink" id="A00278918_S08498934582008020700000">00 - TECHNICAL DATA</a> .</p><a name="S22166948252008020700000"></a><h2 class="clsHeadTwo">Side Mounted Turn Signals</h2><a name="S30652292142008020700000"></a><h2 class="clsHeadThree">Side mounted turn signals, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017073" name="S35645177042008020700000">Fig. 416: Pushing Turn Signal Light/Housing Against Retainer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press turn signal housing towards front of vehicle against retainer tab - <span class="clsEmphBOLD">arrow</span> - and remove carefully from fender opening.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S36027622592008020700000"></a><h2 class="clsHeadTwo">Rear Lights - through 10.04</h2><a name="S39705180182008020700000"></a><h2 class="clsHeadThree">Rear lights - Sedan, assembly</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021691" name="S09181932912008020700000">Fig. 417: Rear Lights - Sedan, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">1 - Taillamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 5 W</li> </ul> <p><span class="clsEmphBOLD">2 - Brake/taillamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 21/5 W</li> </ul> <p><span class="clsEmphBOLD">3 - Clip nut</span> </p> <ul class="clsBULLET"> <li>2x</li> </ul> <p><span class="clsEmphBOLD">4 - Electrical connector</span> </p> <p><span class="clsEmphBOLD">5 - Retainer</span> </p> <ul class="clsBULLET"> <li>Replace if seal is damaged</li> </ul> <p><span class="clsEmphBOLD">6 - Nut - 12 Nm</span> </p> <p><span class="clsEmphBOLD">7 - O-ring</span> </p> <ul class="clsBULLET"> <li>Replace if damaged</li> </ul> <p><span class="clsEmphBOLD">8 - Bolt - 6 Nm</span> </p> <p><span class="clsEmphBOLD">9 - Turn signal lamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 21 W</li> <li>Orange</li> </ul> <p><span class="clsEmphBOLD">10 - Backup lamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p><span class="clsEmphBOLD">11 - Bulb holder</span> </p> <p><span class="clsEmphBOLD">12 - Rear fog lamp bulb (where applicable)</span> </p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p><span class="clsEmphBOLD">13 - Housing</span> </p><a name="S00197122262008020700000"></a><h2 class="clsHeadThree">Rear light/bulb carrier - Sedan, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021692" name="S42942813282008020700000">Fig. 418: Folding Pre-Punched Area Of Luggage Compartment And Removing Screw</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Fold pre-punched area - <span class="clsEmphBOLD">1</span> - of luggage compartment lining forwards.</li> <li>Remove screw - <span class="clsEmphBOLD">3</span> -.</li> <li>Swivel rear light outwards, and at the same time disengage retaining pins from body.</li> <li>Disconnect electrical connection at bulb carrier.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021693" name="S13341689612008020700000">Fig. 419: Pressing Retaining Clips Together To Take Bulb Carrier Out Of Rear Light</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press retaining clips together - <span class="clsEmphBOLD">arrows</span> - and take bulb carrier out of rear light.</li> <li>Turn bulbs to remove them from their holders.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure seal between body and rear light housing seals completely.</li> <li>Fit rear light in position on body and press retaining pins into holes.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021692" name="S05405402642008020700000">Fig. 420: Folding Pre-Punched Area Of Luggage Compartment And Removing Screw</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Tighten screw - <span class="clsEmphBOLD">3</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>After loosening nut - <span class="clsEmphBOLD">2</span> - , rear light can be aligned with body contours (uniform gap widths).</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S001971222620080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Rear light to body - nut</td> <td align="" class="clsCellNormal">12</td> </tr> <tr> <td align="" class="clsCellNormal">Rear light to body - screw</td> <td align="" class="clsCellNormal">6</td> </tr> </tbody> </table></span></p><a name="S18549842222008020700000"></a><h2 class="clsHeadThree">Rear lights - Avant, assembly</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021694" name="S11291178102008020700000">Fig. 421: Rear Lights - Avant, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">1 - Bulb holder</span> </p> <p><span class="clsEmphBOLD">2 - Clip nut</span> </p> <ul class="clsBULLET"> <li>2x</li> </ul> <p><span class="clsEmphBOLD">3 - Electrical connector</span> </p> <p><span class="clsEmphBOLD">4 - Retainer</span> </p> <ul class="clsBULLET"> <li>Replace if seal is damaged</li> </ul> <p><span class="clsEmphBOLD">5 - Nut - 12 Nm</span> </p> <p><span class="clsEmphBOLD">6 - O-ring</span> </p> <ul class="clsBULLET"> <li>Replace if damaged</li> </ul> <p><span class="clsEmphBOLD">7 - Bolt - 6 Nm</span> </p> <p><span class="clsEmphBOLD">8 - Rear fog lamp bulb (where applicable)</span> </p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p><span class="clsEmphBOLD">9 - Turn signal lamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 21 W</li> <li>Orange</li> </ul> <p><span class="clsEmphBOLD">10 - Backup lamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p><span class="clsEmphBOLD">11 - Brake/taillamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 21/5 W</li> </ul> <p><span class="clsEmphBOLD">12 - Housing</span> </p><a name="S25852273412008020700000"></a><h2 class="clsHeadThree">Rear light/bulb carrier - Avant, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021695" name="S24992130992008020700000">Fig. 422: Removing Plug From Luggage Compartment Lining</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove plug - <span class="clsEmphBOLD">arrow</span> - from luggage compartment lining.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021696" name="S34277854072008020700000">Fig. 423: Locating Screw</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screw - <span class="clsEmphBOLD">1</span> -.</li> <li>Swivel rear light outwards, and at the same time disengage retaining pins from body.</li> <li>Disconnect electrical connection at bulb carrier.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021697" name="S19982679002008020700000">Fig. 424: Pressing Apart Retaining Clips And Taking Bulb Carrier Out Of Rear Light</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press apart retaining clips - <span class="clsEmphBOLD">arrows</span> - and take bulb carrier out of rear light.</li> <li>Turn bulbs to remove them from their holders.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure seal between body and rear light housing seals completely.</li> <li>Fit rear light in position on body and press retaining pins into holes.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021696" name="S12462370862008020700000">Fig. 425: Locating Screw</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Tighten screw - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>After loosening nut - <span class="clsEmphBOLD">2</span> - , rear light can be aligned with body contours (uniform gap widths).</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S258522734120080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Rear light to body - nut</td> <td align="" class="clsCellNormal">12</td> </tr> <tr> <td align="" class="clsCellNormal">Rear light to body - screw</td> <td align="" class="clsCellNormal">6</td> </tr> </tbody> </table></span></p><a name="S31951723562008020700000"></a><h2 class="clsHeadTwo">Rear Lights - from 11.04</h2><a name="S17573134842008020700000"></a><h2 class="clsHeadThree">Rear lights in rear fender - Sedan, assembly</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021698" name="S23380945072008020700000">Fig. 426: Rear Lights In Rear Fender - Sedan, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">1 - Turn signal lamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p><span class="clsEmphBOLD">2 - Brake/taillamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p><span class="clsEmphBOLD">3 - Clip nut</span> </p> <ul class="clsBULLET"> <li>2x</li> </ul> <p><span class="clsEmphBOLD">4 - Electrical connector</span> </p> <p><span class="clsEmphBOLD">5 - Bolt - 3.5 Nm</span> </p> <ul class="clsBULLET"> <li>With hex socket (17 mm)</li> </ul> <p><span class="clsEmphBOLD">6 - Bulb holder</span> </p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S15698553112008020700000">Rear light/bulb carrier in rear fender - Sedan, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">7 - Taillamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p><span class="clsEmphBOLD">8 - Backup lamp bulb</span> </p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p><span class="clsEmphBOLD">9 - Housing</span> </p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S15698553112008020700000">Rear light/bulb carrier in rear fender - Sedan, removing and installing</a></li> </ul><a name="S15698553112008020700000"></a><h2 class="clsHeadThree">Rear light/bulb carrier in rear fender - Sedan, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021699" name="S25515462522008020700000">Fig. 427: Identifying Pre-punched Area Of Luggage Compartment Lining, Fastener, And Rear Light</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Fold pre-punched area - <span class="clsEmphBOLD">2</span> - of luggage compartment lining forwards.</li> <li>Remove fastener - <span class="clsEmphBOLD">1</span> - (17 mm hex socket ).</li> <li>Swivel rear light outwards - <span class="clsEmphBOLD">arrow</span> - , and at the same time disengage retaining pins from body.</li> <li>Disconnect electrical connection at bulb carrier.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021700" name="S36340204562008020700000">Fig. 428: Pressing Together Retaining Tabs And Removing Bulb Carrier From Rear Light</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press together retaining tabs - <span class="clsEmphBOLD">arrows</span> - and remove bulb carrier - <span class="clsEmphBOLD">1</span> - from rear light.</li> <li>Turn bulbs to remove them from their holders.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure seal between body and rear light housing seals completely.</li> <li>Fit rear light in position on body and press retaining pins into holes.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S156985531120080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Rear light to body - screw</td> <td align="" class="clsCellNormal">3.5</td> </tr> </tbody> </table></span></p><a name="S17918931672008020700000"></a><h2 class="clsHeadThree">Rear lights in rear lid - Sedan, assembly</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021701" name="S08430793582008020700000">Fig. 429: Rear Lights In Rear Lid - Sedan, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Housing</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S24797524452008020700000">Rear light/bulb carrier in rear lid - Sedan, removing and installing</a></li> </ul> <p>2 - Taillamp/rear fog lamp bulb</p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p>3 - Bulb holder</p> <ul class="clsBULLET"> <li>For taillamp/rear fog lamp bulb</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S21597691812008020700000">Taillamp/rear fog lamp bulb, replacing</a></li> </ul> <p>4 - Electrical connector</p> <p>5 - Nut - 3.5 Nm</p> <p>6 - Retainer</p> <ul class="clsBULLET"> <li>For securing housing to rear lid</li> </ul><a name="S24797524452008020700000"></a><h2 class="clsHeadThree">Rear light/bulb carrier in rear lid - Sedan, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021702" name="S23347172072008020700000">Fig. 430: Unclipping Plug From Luggage Compartment Trim Using A Small Screwdriver</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unclip plug - <span class="clsEmphBOLD">1</span> - from luggage compartment trim - <span class="clsEmphBOLD">arrow</span> - using a small screwdriver.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021703" name="S09055386032008020700000">Fig. 431: Identifying Nut, Retainer, And Inner Rear Light</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nut - <span class="clsEmphBOLD">3</span> - and remove retainer - <span class="clsEmphBOLD">2</span> -.</li> <li>Press inner rear light - <span class="clsEmphBOLD">1</span> - towards - <span class="clsEmphBOLD">arrow</span> - (working from inside of rear lid) until light can be removed from the outside.</li> <li>Disconnect electrical connection at bulb carrier.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure seal between body and rear light housing seals completely.</li> <li>Position inner rear light at outer edge of rear lid.</li> <li>Push on retainer at stud for inner rear light and tighten nut.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>As the nut is tightened the retainer becomes wedged at the inner rear light and the rear lid.</li> <li>Clip plug into luggage compartment lining.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S247975244520080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Inner rear light to body - nut</td> <td align="" class="clsCellNormal">3.5</td> </tr> </tbody> </table></span></p><a name="S21597691812008020700000"></a><h2 class="clsHeadThree">Taillamp/rear fog lamp bulb, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021702" name="S13047375412008020700000">Fig. 432: Unclipping Plug From Luggage Compartment Trim Using A Small Screwdriver</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unclip plug - <span class="clsEmphBOLD">1</span> - from luggage compartment trim - <span class="clsEmphBOLD">arrow</span> - using a small screwdriver.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021704" name="S10225228202008020700000">Fig. 433: Releasing Retaining Tab To Remove Bulb Holder</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining tab - <span class="clsEmphBOLD">arrow</span> - and remove bulb holder - <span class="clsEmphBOLD">1</span> -.</li> <li>Twist and remove bulb from bulb holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S15526455092008020700000"></a><h2 class="clsHeadThree">Rear lights in rear fender - Avant, assembly</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021705" name="S35612264872008020700000">Fig. 434: Rear Lights In Rear Fender - Avant, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Turn signal lamp bulb</p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p>2 - Electrical connector</p> <p>3 - Clip nut</p> <ul class="clsBULLET"> <li>2x</li> </ul> <p>4 - Bolt - 3.5 Nm</p> <ul class="clsBULLET"> <li>With hex socket (17 mm)</li> </ul> <p>5 - Bulb holder</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S04022826632008020700000">Rear light/bulb carrier in rear fender - Avant, removing and installing</a></li> </ul> <p>6 - Brake/taillamp bulb</p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p>7 - Backup lamp bulb</p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p>8 - Housing</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S04022826632008020700000">Rear light/bulb carrier in rear fender - Avant, removing and installing</a></li> </ul><a name="S04022826632008020700000"></a><h2 class="clsHeadThree">Rear light/bulb carrier in rear fender - Avant, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021706" name="S14958748912008020700000">Fig. 435: Unclipping Plug From Luggage Compartment Trim Using A Screwdriver</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unclip plug - <span class="clsEmphBOLD">1</span> - from luggage compartment trim - <span class="clsEmphBOLD">arrow</span> - using a screwdriver.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021707" name="S21919856222008020700000">Fig. 436: Identifying Screw And Rear Light</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screw - <span class="clsEmphBOLD">2</span> -.</li> <li>Swivel rear light - <span class="clsEmphBOLD">1</span> - outwards - <span class="clsEmphBOLD">arrow</span> - , and at the same time disengage retaining pins from body.</li> <li>Disconnect electrical connection at bulb carrier.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021708" name="S30365557822008020700000">Fig. 437: Pressing Apart Retaining Tabs And Removing Bulb Carrier From Rear Light</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press apart retaining tabs - <span class="clsEmphBOLD">arrows</span> - and remove bulb carrier - <span class="clsEmphBOLD">1</span> - from rear light.</li> <li>Turn bulbs to remove them from their holders.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure seal between body and rear light housing seals completely.</li> <li>Fit rear light in position on body and press retaining pins into holes.</li> <li>Tighten screw.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S040228266320080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Rear light to body - nut</td> <td align="" class="clsCellNormal">3.5</td> </tr> </tbody> </table></span></p><a name="S25336200282008020700000"></a><h2 class="clsHeadThree">Rear lights in rear lid - Avant, assembly</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021709" name="S39836417142008020700000">Fig. 438: Rear Lights In Rear Lid - Avant, Assembly</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Housing</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S08849920112008020700000">Rear light/bulb carrier in rear lid - Avant, removing and installing</a></li> </ul> <p>2 - Taillamp bulb</p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p>3 - Electrical connector</p> <p>4 - Nut - 3.5 Nm</p> <p>5 - Retainer</p> <ul class="clsBULLET"> <li>For securing housing to rear lid</li> </ul> <p>6 - Bulb holder</p> <ul class="clsBULLET"> <li>For tail light/rear Fog lamp bulb</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S35343812282008020700000">Taillamp/rear fog lamp bulb, removing and installing</a></li> </ul> <p>7 - Taillamp/rear fog lamp bulb</p> <ul class="clsBULLET"> <li>12 V, 21 W</li> </ul> <p>8 - Nut - 3.5 Nm</p> <p>9 - Retainer bracket</p> <ul class="clsBULLET"> <li>For securing bulb holder and housing to rear lid</li> </ul><a name="S08849920112008020700000"></a><h2 class="clsHeadThree">Rear light/bulb carrier in rear lid - Avant, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021710" name="S16196968542008020700000">Fig. 439: Unclipping Plug From Luggage Compartment Trim</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unclip plug - <span class="clsEmphBOLD">1</span> - from luggage compartment trim - <span class="clsEmphBOLD">arrow</span> - using a small screwdriver.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021711" name="S07723453332008020700000">Fig. 440: Identifying Nuts, Bulb Holder, And Rear Light</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nut - <span class="clsEmphBOLD">2</span> - and remove retainer bracket and bulb holder - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove nut - <span class="clsEmphBOLD">4</span> - and remove inner rear light - <span class="clsEmphBOLD">1</span> - from outside in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Pull the retainer - <span class="clsEmphBOLD">5</span> - out of body opening.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S088499201120080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Retainer to housing - nut</td> <td align="" class="clsCellNormal">3.5</td> </tr> <tr> <td align="" class="clsCellNormal">Retainer bracket to housing - nut</td> <td align="" class="clsCellNormal">3.5</td> </tr> </tbody> </table></span></p><a name="S35343812282008020700000"></a><h2 class="clsHeadThree">Taillamp/rear fog lamp bulb, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021710" name="S01055933552008020700000">Fig. 441: Unclipping Plug From Luggage Compartment Trim</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unclip plug - <span class="clsEmphBOLD">1</span> - from luggage compartment trim - <span class="clsEmphBOLD">arrow</span> - using a small screwdriver.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021712" name="S11226392012008020700000">Fig. 442: Identifying Nut, Bulb Holder, And Retaining Tabs</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nut - <span class="clsEmphBOLD">1</span> - and detach retainer bracket.</li> <li>Remove bulb holder - <span class="clsEmphBOLD">2</span> - from housing (press apart retaining tabs - <span class="clsEmphBOLD">arrows</span> - ).</li> <li>Screw bulb out of bulb holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Insert new bulb in bulb holder.</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S353438122820080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Retainer bracket to housing - nut</td> <td align="" class="clsCellNormal">3.5</td> </tr> </tbody> </table></span></p><a name="S21887188742008020700000"></a><h2 class="clsHeadTwo">High-Mount Brake Lamp - through 10.04</h2><a name="S09948455382008020700000"></a><h2 class="clsHeadThree">High-mount brake lamp - Sedan, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>High-mount brake lamp is accessible from luggage compartment via panel opening below rear shelf.</li> <li>Complete high-mount brake lamp must be replaced if LEDs are inoperative.</li> <li>Do not press brake pedal.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021713" name="S23692007952008020700000">Fig. 443: Identifying Electrical Connection, High-Mount Brake Lamp, And Retaining Clips</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> - at high-mount brake lamp - <span class="clsEmphBOLD">2</span> -.</li> <li>Pry off retaining clips in direction of - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Pull high-mount brake lamp downwards out of opening.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S09999387542008020700000"></a><h2 class="clsHeadThree">High-mount brake lamp - Avant, removing and installing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Complete high-mount brake lamp must be replaced if LEDs are inoperative.</li> </ul> </td> </tr> </table></span></p> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S03475525592008020700000">Fig. 444: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Do not press brake pedal.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021714" name="S32985057442008020700000">Fig. 445: Releasing Retaining Rail Of Spring Tabs Towards Right By Pressing Screwdriver Handle Left</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove upper rear lid trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> <li>Insert screwdriver - <span class="clsEmphBOLD">1</span> - into hole in rear lid through which wire is routed to high-mount brake lamp.</li> <li>Release retaining rail - <span class="clsEmphBOLD">2</span> - of spring tabs towards right - <span class="clsEmphBOLD">arrow in detail view</span> - by pressing screwdriver handle firmly to left - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021715" name="S25008644022008020700000">Fig. 446: Identifying High-Mount Brake Lamp And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Starting on the right, use hook 3370 to pull high-mount brake lamp - <span class="clsEmphBOLD">2</span> - out of rear lid opening - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove fastening elements for high-mount brake lamp (5x) out of rear lid.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021716" name="S38476674342008020700000">Fig. 447: Identifying Lug, Spring Clip, Catches, Housing Guides, And Retaining Rail</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Position spring clips on high-mount brake lamp housing such that lug - <span class="clsEmphBOLD">2</span> - faces recess on spring clip - <span class="clsEmphBOLD">3</span> -.</li> <li>Ensure spring clip catches - <span class="clsEmphBOLD">4</span> - engage in guides - <span class="clsEmphBOLD">5</span> - on housing.</li> <li>Position retaining rail - <span class="clsEmphBOLD">1</span> - onto housing and lock in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsBULLET"> <li>The spring clips are locked in place by the retaining rail.</li> </ul> <ul class="clsDASH"> <li>Connect electrical connector and push high-mount brake lamp into rear lid opening until it engages audibly.</li> </ul><a name="S30698800912008020700000"></a><h2 class="clsHeadTwo">High-Mount Brake Lamp - from 11.04</h2><a name="S33783750522008020700000"></a><h2 class="clsHeadThree">High-mount brake lamp - Sedan, removing and installing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>High-mount brake lamp is accessible from luggage compartment via panel opening below rear shelf.</li> <li>Complete high-mount brake lamp must be replaced if LEDs are inoperative.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Do not press brake pedal.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021717" name="S28949059682008020700000">Fig. 448: Identifying Electrical Connection, High-Mount Brake Lamp, And Retaining Clips</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> - at high-mount brake lamp - <span class="clsEmphBOLD">2</span> -.</li> <li>Release retaining clips - <span class="clsEmphBOLD">3</span> - in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Pull high-mount brake lamp downwards out of opening.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S13226759282008020700000"></a><h2 class="clsHeadThree">High-mount brake lamp - Avant, removing and installing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Complete high-mount brake lamp must be replaced if LEDs are inoperative.</li> </ul> </td> </tr> </table></span></p> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S14144855522008020700000">Fig. 449: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Do not press brake pedal.</li> <li>Remove upper rear lid trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021714" name="S28093179622008020700000">Fig. 450: Releasing Retaining Rail Of Spring Tabs Towards Right By Pressing Screwdriver Handle Left</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Insert screwdriver - <span class="clsEmphBOLD">1</span> - into hole in rear lid through which wire is routed to high-mount brake lamp.</li> <li>Release retaining rail - <span class="clsEmphBOLD">2</span> - of spring tabs towards right - <span class="clsEmphBOLD">arrow in detail view</span> - by pressing screwdriver handle firmly to left - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021715" name="S31647054422008020700000">Fig. 451: Identifying High-Mount Brake Lamp And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Starting on the right, use hook 3370 to pull high-mount brake lamp - <span class="clsEmphBOLD">2</span> - out of rear lid opening - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove fastening elements for high-mount brake lamp (4x) out of rear lid.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021716" name="S07755467802008020700000">Fig. 452: Identifying Lug, Spring Clip, Catches, Housing Guides, And Retaining Rail</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Position spring clips on high-mount brake lamp housing such that lug - <span class="clsEmphBOLD">2</span> - faces recess on spring clip - <span class="clsEmphBOLD">3</span> -.</li> <li>Ensure spring clip catches - <span class="clsEmphBOLD">4</span> - engage in the guides - <span class="clsEmphBOLD">5</span> - on the housing.</li> <li>Position retaining rail - <span class="clsEmphBOLD">1</span> - onto housing and lock in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsBULLET"> <li>The spring clips are locked in place by the retaining rail.</li> </ul> <ul class="clsDASH"> <li>Connect electrical connector and push high-mount brake lamp into rear lid opening until it engages audibly.</li> </ul><a name="S39717075322008020700000"></a><h2 class="clsHeadTwo">License Plate Lamp</h2><a name="S33123090092008020700000"></a><h2 class="clsHeadThree">License plate lamp, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021718" name="S33879919862008020700000">Fig. 453: Identifying Bolt In Handle Recess</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screw - <span class="clsEmphBOLD">arrow</span> - in handle trim.</li> <li>Lever bulb holder out of handle trim.</li> <li>Remove bulb (12 V, 5 W) from bulb holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S18863838642008020700000"></a><h2 class="clsHeadTwo">Steering Column Switch Module</h2><a name="S40539501892008020700000"></a><h2 class="clsHeadThree">General information</h2> <p>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.</p> <p>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.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Additional information:</li> </ul> </td> </tr> </table></span></p> <p>Owners Manual</p> <p>Self Study Program - Course Number 991103 "2002 Audi A4 Technical Features"</p> <p>Self Study Program - Course Number 991503 "The 2005 Audi A4"</p> <p>Wiring Diagrams Component Locations</p><a name="S26188615562008020700000"></a><h2 class="clsHeadThree">On Board Diagnostic (OBD), function</h2> <p>The Steering Column Electronic Systems Control Module J527 is controlled by an internal microprocessor with On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory.</p> <p>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.</p><a name="S28973430962008020700000"></a><h2 class="clsHeadThree">Steering column switch module, assembly</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021719" name="S38282977112008020700000">Fig. 454: Steering Column Switch Module (SCSM), Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Spiral spring</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Position of spiral spring must not be changed once removed.</td> </tr> </table></span></p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S16388206232008020700000">Spiral spring, removing and installing</a></li> </ul> <p>2 - Steering Angle Sensor G85</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S40078717482008020700000">Steering Angle Sensor G85 , removing and installing</a></li> </ul> <p>3 - Socket head bolt</p> <p>4 - Cruise Control Switch E45</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S19633625472008020700000">Cruise Control Switch E45 , removing and installing</a></li> </ul> <p>5 - Socket head bolt</p> <p>6 - Turn Signal Switch E2</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S35199634942008020700000">Turn Signal Switch E2 , removing and installing</a></li> </ul> <p>7 - Retaining clip</p> <p>8 - Steering Column Electronic Systems Control Module J527</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S32822962892008020700000">Steering Column Electronics Systems Control Module J527 , removing and installing</a></li> <li>Multi-pin connector assignments --> <a class="clsHyperlink" href="#S11833126752008020700000">Steering Column Electronics Systems Control Module J527 , front multi-pin connector assignments</a></li> </ul> <p>9 - Clamping bolt - 3 Nm</p> <p>10 - Windshield Wiper/Washer Switch E22</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S16007958242008020700000">Windshield Wiper/Washer Switch E22 , removing and installing</a></li> </ul> <p>11 - Socket head bolt</p><a name="S21991854192008020700000"></a><h2 class="clsHeadThree">Steering column switch module, removing and installing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020763" name="S27563572612008020700000">Fig. 455: Torx Screwdriver T8 T 40056</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Special screwdriver T8 T40056 or equivalent "Torx - 8"</li> </ul><a name="S38000176152008040900000"></a><h2 class="clsHeadFour">Removing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Should any steering column switches require replacement, follow applicable component "Replacement" procedure using VAS 5051/5051 in operating mode "Guided Fault Finding".</li> <li>Move steering wheel down and to rear as far as possible; make use of the full range of the steering column adjuster.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Special safety precautions apply to vehicles equipped with airbags. Heed all WARNINGS pertaining to airbag servicing --> <a class="clsExtHyperlink" id="A00278922_S12872913122008020700000">69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS</a> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove airbag and steering wheel --> <a class="clsExtHyperlink" id="A00278922_S12872913122008020700000">69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021720" name="S15539437082008020700000">Fig. 456: Identifying Ground Down Torx Screwdriver T8 T40056 Shoulder</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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 - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021721" name="S15144225452008020700000">Fig. 457: Identifying Screws, Hex Socket Head Bolt, Trim Cover, And Upper Steering Column Trim</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use Special Screwdriver T8 T40056 to remove screws - <span class="clsEmphBOLD">4</span> - and - <span class="clsEmphBOLD">5</span> -.</li> <li>Remove hex socket head bolt - <span class="clsEmphBOLD">6</span> -.</li> <li>Release trim cover - <span class="clsEmphBOLD">1</span> - on upper steering column trim - <span class="clsEmphBOLD">2</span> - using a small screwdriver - <span class="clsEmphBOLD">arrows A and B</span> -.</li> <li></li> </ul> <ul class="clsDASH"> <li>Separate upper trim - <span class="clsEmphBOLD">2</span> - from lower trim - <span class="clsEmphBOLD">3</span> - and remove upper trim.</li> <li>Remove release lever for steering column adjustment - <span class="clsEmphBOLD">7</span> - and guide out lower trim.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021722" name="S26300827742008020700000">Fig. 458: Identifying Screw And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screw - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before disconnecting electrical connections at module, discharge any static electricity by briefly grasping hold of door striker plate or similar, grounded article on vehicle.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">3</span> -.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021723" name="S34638848872008020700000">Fig. 459: Disengage Connector Lock To Release Connector</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disengage connector lock - <span class="clsEmphBOLD">1</span> - in direction of - <span class="clsEmphBOLD">arrow</span> - in order to release connector - <span class="clsEmphBOLD">2</span> -.</li> <li>Carefully remove steering column switch module.</li> </ul><a name="S31996687132008040900000"></a><h2 class="clsHeadFour">Installing</h2> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Ensure all fasteners and electrical connectors are properly connected and locked into place.</li> <li>Insert upper steering column trim in hooks for bottom trim, press both sections together and tighten screws.</li> <li>Install steering wheel and drivers airbag --> <a class="clsExtHyperlink" id="A00278922_S12872913122008020700000">69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S319966871320080409000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Steering column switch module - bolt</td> <td align="" class="clsCellNormal">3</td> </tr> <tr> <td align="" class="clsCellNormal">Trim for steering column switch - screw</td> <td align="" class="clsCellNormal">1</td> </tr> </tbody> </table></span></p><a name="S16388206232008020700000"></a><h2 class="clsHeadThree">Spiral spring, removing and installing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020763" name="S08446081602008020700000">Fig. 460: Torx Screwdriver T8 T 40056</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Special Screwdriver T8 T40056 or equivalent "Torx - 8"</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Ensure steering is in straight ahead and centered prior to removing spiral spring.</li> <li>Position of spiral spring must not be changed once removed.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Move steering wheel down and to rear as far as possible; make use of the full range of the steering column adjuster.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Special safety precautions apply to vehicles equipped with airbags. Heed all WARNINGS pertaining to airbag servicing --> <a class="clsExtHyperlink" id="A00278922_S12872913122008020700000">69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS</a> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove airbag and steering wheel --> <a class="clsExtHyperlink" id="A00278922_S12872913122008020700000">69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021720" name="S07783849082008020700000">Fig. 461: Identifying Ground Down Torx Screwdriver T8 T40056 Shoulder</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Due to manufacturing tolerances, it may not be possible to insert Special Screwdriver T8 T40056 all the way into access hole in switch module. In these cases, grind down shoulder of screwdriver in areas indicated - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021721" name="S11420670642008020700000">Fig. 462: Identifying Screws, Hex Socket Head Bolt, Trim Cover, And Upper Steering Column Trim</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use Special Screwdriver T8 T40056 to remove screws - <span class="clsEmphBOLD">4</span> - and - <span class="clsEmphBOLD">5</span> -.</li> <li>Remove hex socket head bolt - <span class="clsEmphBOLD">6</span> -.</li> <li>Release trim cover - <span class="clsEmphBOLD">1</span> - on upper steering column trim - <span class="clsEmphBOLD">2</span> - using a small screwdriver - <span class="clsEmphBOLD">arrows A and B</span> -.</li> <li></li> </ul> <ul class="clsDASH"> <li>Separate upper trim - <span class="clsEmphBOLD">2</span> - from lower trim - <span class="clsEmphBOLD">3</span> - and remove upper trim.</li> <li>Remove release lever for steering column adjustment - <span class="clsEmphBOLD">7</span> - and guide out lower trim.</li> <li>Disconnect upper electrical connection at spiral spring.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021724" name="S41629984182008020700000">Fig. 463: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully release clip fasteners - <span class="clsEmphBOLD">arrows</span> - and remove spiral spring - <span class="clsEmphBOLD">1</span> - from steering column switch module.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Steering column switch module shown removed for illustration purposes.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Ensure all fasteners and electrical connectors are properly connected and locked into place.</li> <li>Insert upper steering column trim into bottom trim, press both sections together and tighten screws.</li> <li>Install steering wheel and airbag --> <a class="clsExtHyperlink" id="A00278922_S12872913122008020700000">69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S163882062320080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Steering column switch module - bolt</td> <td align="" class="clsCellNormal">3</td> </tr> <tr> <td align="" class="clsCellNormal">Trim for steering column switch - screw</td> <td align="" class="clsCellNormal">1</td> </tr> </tbody> </table></span></p><a name="S40078717482008020700000"></a><h2 class="clsHeadThree">Steering Angle Sensor G85 , removing and installing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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".</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove spiral spring --> <a class="clsHyperlink" href="#S16388206232008020700000">Spiral spring, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021725" name="S23100726912008020700000">Fig. 464: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control Module J527</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove Steering Angle Sensor G85 - <span class="clsEmphBOLD">1</span> - from Steering Column Electronic Systems Control Module J527 in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Perform "zero - calibrate" procedure using VAS 505/5052 in operating mode "Guided Fault Finding".</li> </ul><a name="S32822962892008020700000"></a><h2 class="clsHeadThree">Steering Column Electronics Systems Control Module J527 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>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".</li> <li>Remove steering column switch module --> <a class="clsHyperlink" href="#S21991854192008020700000">Steering column switch module, removing and installing</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Ensure steering is in straight ahead and centered prior to removing spiral spring.</li> <li>Position of spiral spring must not be changed once removed.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021724" name="S34375406832008020700000">Fig. 465: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully release clip fasteners - <span class="clsEmphBOLD">arrows</span> - and remove spiral spring - <span class="clsEmphBOLD">1</span> - from steering column switch module.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021725" name="S31542199182008020700000">Fig. 466: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control Module J527</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove Steering Angle Sensor G85 - <span class="clsEmphBOLD">1</span> - from Steering Column Electronic Systems Control Module J527 in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021726" name="S37409809172008020700000">Fig. 467: Removing Screws, And Steering Column Electronics Systems Control Module J527 From Steering Column Switch Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Steering Column Electronics Systems Control Module J527 - <span class="clsEmphBOLD">1</span> - from steering column switch module.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Ensure all fasteners and electrical connectors are properly connected and locked into place.</li> <li>Install steering column switch module <a class="clsHyperlink" href="#S31996687132008040900000">Installing</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S328229628920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Steering column switch module to Steering Column Electronics Systems Control Module J527</td> <td align="" class="clsCellNormal">0.6</td> </tr> <tr> <td align="" class="clsCellNormal">Intermittent wiper switch E22 to Steering Column Electronics Systems Control Module J527</td> <td align="" class="clsCellNormal">0.6</td> </tr> <tr> <td align="" class="clsCellNormal">Cruise Control Switch E45 to Steering Column Electronic Systems Control Module J527</td> <td align="" class="clsCellNormal">0.6</td> </tr> </tbody> </table></span></p><a name="S11833126752008020700000"></a><h2 class="clsHeadThree">Steering Column Electronics Systems Control Module J527 , front multi-pin connector assignments</h2> <p>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.</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021727" name="S23152373952008020700000">Fig. 468: Steering Column Electronics Systems Control Module J527 , Front Multi-Pin Connector Assignments</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>A - Cruise control system multi-pin connector</p> <p>1 - Ground (GND) ( - )</p> <p>2 - Set</p> <p>3 - Distance</p> <p>4 - 12 V voltage supply</p> <p>5 - Activation/touch function "Off"</p> <p>6 - Acceleration/deceleration</p> <p>7 - Locked "Off"</p> <p>B - Turn signal switch multi-pin connector</p> <p>1 - Ground (GND) ( - )</p> <p>2 - Radio telephone (special-purpose vehicles)</p> <p>3 - Alarm (special-purpose vehicles)</p> <p>4 - Vacant</p> <p>5 - Headlamp flasher/light control</p> <p>6 - Turn signal indicators</p> <p>C - Multi-function steering wheel / Tiptronic / heated steering wheel multi-pin connector</p> <p>7 Tiptronic ""</p> <p>8 - Multi-function steering wheel "+" voltage supply</p> <p>9 - Multi-function steering wheel data</p> <p>10 - Tiptronic "+"</p> <p>11 - Multi-function steering wheel dimmer</p> <p>12 - Tiptronic earth</p> <p>13 - Heated steering wheel "+"</p> <p>14 - Heated steering wheel ""</p> <p>D - Steering angle sensor multi-pin connector</p> <p>1 - Light barrier 5</p> <p>2 - Light barrier 3</p> <p>3 - Light barrier 1</p> <p>4 - 12 V voltage supply</p> <p>5 -5 V voltage supply</p> <p>6 - Light barrier 6</p> <p>7 - Light barrier 4</p> <p>8 - Light barrier 2</p> <p>9 - Steering angle sensor Ground (GND) ( - )</p> <p>10 - Light barrier 7</p> <p>E - Horn switch multi-pin connector</p> <p>1 - Horn Ground (GND) ( - )</p> <p>2 - Horn</p> <p>F - Wiper switch multi-pin connector</p> <p>1 - Ground (GND) ( - )</p> <p>2 - Intermittent wipe potentiometer</p> <p>3 - Multi-function Indicator (On-board computer)</p> <p>4 - Vacant</p> <p>5 - Wash</p> <p>6 - Wipe</p><a name="S05494373112008020700000"></a><h2 class="clsHeadThree">Steering Column Electronics Systems Control Module J527 , rear multi-pin connector assignments</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021561" name="S24354005692008020700000">Fig. 469: Steering Column Electronic Systems Control Module (Rear) Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Multi-pin connector, 16-pin</p> <ol class="clsARABICNUM"> <li>Ground (GND) ( - )</li> <li>Terminal 30 (B+)</li> <li>CAN-Bus Powertrain (shielding)</li> <li>Vacant</li> <li>Cruise control locked Off</li> <li>Alarm (special-purpose vehicles)</li> <li>Radio telephone (special-purpose vehicles)</li> <li>CAN-Bus Low (convenience)</li> <li>CAN-Bus High (convenience)</li> <li>CAN-Bus High - Powertrain (shielding</li> <li>CAN- Bus Low - Powertrain (shielding</li> <li>Ignition lock terminal 75</li> <li>Ignition lock terminal 15</li> <li>Ignition lock S contact</li> <li>Ignition lock terminal 50</li> <li>Ignition lock terminal P</li> </ol><a name="S35199634942008020700000"></a><h2 class="clsHeadThree">Turn Signal Switch E2 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove steering column switch module --> <a class="clsHyperlink" href="#S21991854192008020700000">Steering column switch module, removing and installing</a>.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Ensure steering is in straight ahead and centered prior to removing spiral spring.</li> <li>Position of spiral spring must not be changed once removed.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021724" name="S20083850842008020700000">Fig. 470: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully release clip fasteners - <span class="clsEmphBOLD">arrows</span> - and remove spiral spring - <span class="clsEmphBOLD">1</span> - from steering column switch module.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021725" name="S17369652882008020700000">Fig. 471: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control Module J527</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove Steering Angle Sensor G85 - <span class="clsEmphBOLD">1</span> - from Steering Column Electronic Systems Control Module J527 in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021728" name="S40182722832008020700000">Fig. 472: Identifying Screws, Steering Column Electronics Systems Control Module, Windshield Wiper/Washer Switch, And Retaining Clip</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove the Steering Column Electronics Systems Control Module J527 - <span class="clsEmphBOLD">2</span> - and Windshield Wiper/Washer Switch E22 - <span class="clsEmphBOLD">3</span> - from steering column switch module.</li> <li>Remove Cruise Control Switch E45 - <span class="clsEmphBOLD">1</span> - from steering column switch module.</li> <li>Remove screw - <span class="clsEmphBOLD">5</span> - and remove retaining clip - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Further Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Ensure all fasteners and electrical connectors are properly connected and locked into place.</li> <li>Install steering column switch module <a class="clsHyperlink" href="#S31996687132008040900000">Installing</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S351996349420080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Steering column switch module to Steering Column Electronics Systems Control Module J527</td> <td align="" class="clsCellNormal">0.6</td> </tr> <tr> <td align="" class="clsCellNormal">Intermittent wiper switch E22 to Steering Column Electronics Systems Control Module J527</td> <td align="" class="clsCellNormal">0.6</td> </tr> <tr> <td align="" class="clsCellNormal">Cruise Control Switch E45 to Steering Column Electronic Systems Control Module J527</td> <td align="" class="clsCellNormal">0.6</td> </tr> </tbody> </table></span></p><a name="S19633625472008020700000"></a><h2 class="clsHeadThree">Cruise Control Switch E45 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove steering column switch module --> <a class="clsHyperlink" href="#S21991854192008020700000">Steering column switch module, removing and installing</a>.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Ensure steering is in straight ahead and centered prior to removing spiral spring.</li> <li>Position of spiral spring must not be changed once removed.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021724" name="S42176981792008020700000">Fig. 473: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully release clip fasteners - <span class="clsEmphBOLD">arrows</span> - and remove spiral spring - <span class="clsEmphBOLD">1</span> - from steering column switch module.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021725" name="S03892677332008020700000">Fig. 474: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control Module J527</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove Steering Angle Sensor G85 - <span class="clsEmphBOLD">1</span> - from Steering Column Electronic Systems Control Module J527 in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021729" name="S06230376352008020700000">Fig. 475: Identifying Screws, Steering Column Electronics Systems Control Module, And Cruise Control Switch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Steering Column Electronics Systems Control Module J527 - <span class="clsEmphBOLD">2</span> - from steering column switch module.</li> <li>Remove Cruise Control Switch E45 - <span class="clsEmphBOLD">1</span> - from steering column switch module.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Further Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Ensure all fasteners and electrical connectors are properly connected and locked into place.</li> <li>Install steering column switch module <a class="clsHyperlink" href="#S31996687132008040900000">Installing</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S196336254720080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Steering column switch module to Steering Column Electronics Systems Control Module J527</td> <td align="" class="clsCellNormal">0.6</td> </tr> <tr> <td align="" class="clsCellNormal">Intermittent wiper switch E22 to Steering Column Electronics Systems Control Module J527</td> <td align="" class="clsCellNormal">0.6</td> </tr> <tr> <td align="" class="clsCellNormal">Cruise Control Switch E45 to Steering Column Electronic Systems Control Module J527</td> <td align="" class="clsCellNormal">0.6</td> </tr> </tbody> </table></span></p><a name="S16007958242008020700000"></a><h2 class="clsHeadThree">Windshield Wiper/Washer Switch E22 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove steering column switch module --> <a class="clsHyperlink" href="#S21991854192008020700000">Steering column switch module, removing and installing</a>.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Ensure steering is in straight ahead and centered prior to removing spiral spring.</li> <li>Position of spiral spring must not be changed once removed.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021724" name="S26673682962008020700000">Fig. 476: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully release clip fasteners - <span class="clsEmphBOLD">arrows</span> - and remove spiral spring - <span class="clsEmphBOLD">1</span> - from steering column switch module.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021725" name="S21520025842008020700000">Fig. 477: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control Module J527</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove Steering Angle Sensor G85 - <span class="clsEmphBOLD">1</span> - from Steering Column Electronic Systems Control Module J527 in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021730" name="S19410652022008020700000">Fig. 478: Identifying Screws And Windshield Wiper/Washer Switch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove Windshield Wiper/Washer Switch E22 - <span class="clsEmphBOLD">3</span> - from steering column switch module - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Further Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Ensure all fasteners and electrical connectors are properly connected and locked into place.</li> <li>Install steering column switch module <a class="clsHyperlink" href="#S31996687132008040900000">Installing</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S160079582420080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Windshield Wiper/Washer Switch E22 to Steering Column Electronics Systems Control Module J527</td> <td align="" class="clsCellNormal">0.6</td> </tr> </tbody> </table></span></p><a name="S01100779472008020700000"></a><h2 class="clsHeadTwo">Ignition/Starter Switch and Lock Cylinder</h2><a name="S17582230242008020700000"></a><h2 class="clsHeadThree">Lock cylinder, removing and installing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The immobilizer reading coil is integrated with the lock cylinder and cannot be serviced or replaced individually.</li> <li>Should the reading coil malfunction, replace complete lock cylinder. .</li> <li>Observe reading coil specifications when replacing lock cylinders --> <a class="clsHyperlink" href="#S00317162112008020700000">Reader coil, replacing</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove steering column switch module --> <a class="clsHyperlink" href="#S21991854192008020700000">Steering column switch module, removing and installing</a></li> <li>Disconnect electrical connection at reader coil.</li> </ul> <p>Vehicles with automatic transmission:</p> <ul class="clsDASH"> <li>Move selector lever to "P".</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017092" name="S02105374822008020700000">Fig. 479: Turn Ignition Key To "Ignition On" Position</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Turn ignition key to "Ignition ON" position - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Then lift interlock lever - <span class="clsEmphBOLD">1</span> - slightly and pull locking cable - <span class="clsEmphBOLD">2</span> - out of ignition lock housing.</li> </ul> <p>All models:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The spare key is necessary for removing the lock cylinder, because the following sequence can only be performed using an ignition key with flat key grip, i.e. without illumination and without remote control.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017093" name="S24754867932008020700000">Fig. 480: Aligning Recess In Trim</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Turn spare key to ignition "ON" position, thus aligning recess in trim - <span class="clsEmphBOLD">arrow</span> - with hole in ignition lock.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The illustration shows the correct lock position without the ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017094" name="S12557417442008020700000">Fig. 481: Identifying Steel Wire In Hole, Lock Cylinder And Reader Coil Out Of Steering Lock Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Insert a steel wire or pin ( approx. 1.5 mm) in hole - <span class="clsEmphBOLD">1</span> - as far as it will go, at the same time pulling lock cylinder - <span class="clsEmphBOLD">2</span> - with reader coil out of steering lock housing - <span class="clsEmphBOLD">3</span> -.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Steering lock must not be operated without the lock cylinder, otherwise it will lock completely. The entire steering lock must then be replaced.</td> </tr> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When replacing lock cylinder, note immobilizer reader coil specifications --> <a class="clsHyperlink" href="#S00317162112008020700000">Reader coil, replacing</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Insert spare ignition key into lock cylinder and turn to ignition "on" position.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017094" name="S27101276242008020700000">Fig. 482: Identifying Steel Wire In Hole, Lock Cylinder And Reader Coil Out Of Steering Lock Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Re-insert steel wire/pin - <span class="clsEmphBOLD">1</span> - in hole on end face as far as it will go.</li> <li>Insert lock cylinder - <span class="clsEmphBOLD">2</span> - with reader coil in steering lock housing - <span class="clsEmphBOLD">3</span> -.</li> <li>Then pull out steel wire and press in lock cylinder firmly until catch engages audibly.</li> <li>Connect electrical connector on immobilizer reader coil.</li> </ul> <p>Vehicles with automatic transmission:</p> <ul class="clsDASH"> <li>Turn ignition key to "Ignition ON" position.</li> <li>Slide locking cable - <span class="clsEmphBOLD">2</span> - into ignition lock housing until it engages audibly.</li> </ul><a name="S15355356842008020700000"></a><h2 class="clsHeadThree">Ignition/starter switch, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove steering column switch module --> <a class="clsHyperlink" href="#S21991854192008020700000">Steering column switch module, removing and installing</a>.</li> <li>Disconnect electrical connection at immobilizer reader coil.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017095" name="S26510933142008020700000">Fig. 483: Locating Screws , Ignition/Starter Switch And Steering Lock Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> - at ignition/starter switch.</li> <li>Remove sealing paint from both securing screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Loosen bolts - <span class="clsEmphBOLD">arrows</span> - (do not remove) and pull ignition/starter switch out of steering lock housing - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure that the ignition/starter switch and lock cylinder are in the same position, e.g. "Ignition ON" , when installing.</li> <li>Apply sealing paint to bolts - <span class="clsEmphBOLD">arrows</span> - at steering lock housing - <span class="clsEmphBOLD">2</span> -.</li> <li>Install steering column switch module <a class="clsHyperlink" href="#S31996687132008040900000">Installing</a>.</li> </ul> </td> </tr> </table></span></p><a name="S35040927422008020700000"></a><h2 class="clsHeadThree">Ignition/starter switch, multi-pin connector assignments</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017096" name="S42447655612008020700000">Fig. 484: Connection Assignment At Ignition/Starter Switch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>15 - Terminal 15</p> <p>30 - Terminal 30 (B+)</p> <p>50 - Terminal 50</p> <p>50b - Terminal 50b</p> <p>75 - Terminal 75</p> <p>86s - Terminal 86s</p> <p>P - Park position</p><a name="S37350634452008020700000"></a><h2 class="clsHeadTwo">Parking Aid System</h2><a name="S24008880942008020700000"></a><h2 class="clsHeadThree">General information</h2> <p>At time of publication, the optional parking aid system (also know as "Acoustic park assist" or " Parktronic <sup>(R)</sup> " ) is only available as a 4-channel system that monitors the area to the rear of the vehicle.</p> <p>The system is activated automatically whenever the vehicle is shifted into reverse.</p> <p>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.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Additional information:</li> </ul> </td> </tr> </table></span></p> <p>Owners Manual</p> <p>Wiring Diagrams Component Locations</p><a name="S28955319352008020700000"></a><h2 class="clsHeadThree">On Board Diagnostic (OBD), functions</h2> <p>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.</p> <p>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".</p><a name="S36805651342008020700000"></a><h2 class="clsHeadThree">Parking aid system, component overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021731" name="S13818103292008020700000">Fig. 485: Parking Aid System, Component Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Front sensors not applicable to USA/Canada</p> <p>2 - Not applicable to USA/Canada</p> <p>3 - Not applicable to USA/Canada</p> <p>4 - Rear Parking Aid Warning Buzzer H15</p> <p>Sedan:</p> <ul class="clsBULLET"> <li>Under rear parcel shelf</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S31834893362008020700000">Rear Parking Aid Warning Buzzer H15 - Sedan, removing and installing</a></li> </ul> <p>Avant:</p> <ul class="clsBULLET"> <li>In luggage compartment rear left under side trim</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S05812038122008020700000">Rear Parking Aid Warning Buzzer H15 - Avant, removing and installing</a></li> </ul> <p>5 - Rear Parking Aid Sensors</p> <ul class="clsBULLET"> <li>In rear bumper</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S08834330362008020700000">Rear parking aid sensors, removing and installing</a></li> </ul> <p>6 - Parking Aid Control Module J446</p> <ul class="clsBULLET"> <li>in left rear luggage compartment under side trim</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S32113581532008020700000">Parking Aid Control Module J446 , removing and installing</a></li> </ul><a name="S32113581532008020700000"></a><h2 class="clsHeadThree">Parking Aid Control Module J446 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsBULLET"> <li>Location: At left rear or luggage compartment below side trim/taillamp.</li> </ul> <ul class="clsDASH"> <li>Remove left luggage compartment side trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul> <p>Sedan:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021489" name="S40639711782008020700000">Fig. 486: Removing Screws And Base Mount</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> - and remove base mount - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021490" name="S10192677602008020700000">Fig. 487: Disconnecting Electrical Connections And Antenna Wiring At Rear Of Navigation Interface</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Where applicable, disconnect electrical connections and antenna wiring at rear of Navigation Interface R94 - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Disregard - <span class="clsEmphBOLD">2</span> -.</li> </ul> </td> </tr> </table></span></p> <p>Avant:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021491" name="S33413134412008020700000">Fig. 488: Removing Screws And Base Mount</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> - and remove base mount - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p>All:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021732" name="S15862771352008020700000">Fig. 489: Identifying Electrical Connections, Screws, And Parking Aid Control Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove Parking Aid Control Module J446 - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Sedan installation is illustrated.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S321135815320080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Parking Aid Control Module J446 to body - screw</td> <td align="" class="clsCellNormal">1.8</td> </tr> </tbody> </table></span></p><a name="S31834893362008020700000"></a><h2 class="clsHeadThree">Rear Parking Aid Warning Buzzer H15 - Sedan, removing and installing</h2> <ul class="clsBULLET"> <li>Location: At right rear under rear parcel shelf</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove rear parcel shelf --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> <li>Disconnect electrical connection.</li> <li>Remove expander clip threaded pin using a TORX screwdriver.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021733" name="S30169131522008020700000">Fig. 490: Removing Warning Buzzer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove warning buzzer - <span class="clsEmphBOLD">arrow</span> - upward out of lower luggage compartment partition.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Press threaded pins into expander clips.</li> <li>Install rear parcel shelf --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul><a name="S05812038122008020700000"></a><h2 class="clsHeadThree">Rear Parking Aid Warning Buzzer H15 - Avant, removing and installing</h2> <ul class="clsBULLET"> <li>Location: In left rear luggage compartment under side trim</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove left side trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> <li>Disconnect electrical connection.</li> <li>Remove expander clip threaded pin using a TORX screwdriver.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021734" name="S18184487652008020700000">Fig. 491: Removing Warning Buzzer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove warning buzzer - <span class="clsEmphBOLD">arrow</span> - upward.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Press threaded pins into expander clips.</li> <li>Install left side trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul><a name="S08834330362008020700000"></a><h2 class="clsHeadThree">Rear parking aid sensors, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021735" name="S30590599392008020700000">Fig. 492: Locating Parking Aid Sensors In Rear Bumper Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Location: In rear bumper cover - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove rear bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> </li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021736" name="S14002248752008020700000">Fig. 493: Identifying Electrical Connection, Catches, And Sensor</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect applicable electrical connection - <span class="clsEmphBOLD">1</span> - from sensor.</li> <li>Press both catches - <span class="clsEmphBOLD">arrows</span> - to side and press sensor - <span class="clsEmphBOLD">2</span> - inward from outside.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install rear bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul><a name="S13995529532008020700000"></a><h2 class="clsHeadTwo">Automatic Headlamp Range Control</h2><a name="S15430243392008020700000"></a><h2 class="clsHeadThree">General information</h2> <p>The automatic headlight aim control system is installed on vehicles with High Intensity Gas Discharge (HID) headlamps.</p> <p>The system contains the following components:</p> <ul class="clsBULLET"> <li>Level control system sensors at front and rear axles</li> <li>Headlight range control module</li> <li>Headlight beam adjusting motors integrated with headlight units</li> </ul> <p>When driving, the system automatically adapts the headlight beam inclination dependent on vehicle suspension movement and load. Headlight glare to oncoming traffic is minimized.</p><a name="S00565630012008020700000"></a><h2 class="clsHeadThree">On Board Diagnostic (OBD), function</h2> <p>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.</p> <p>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".</p><a name="S06625988612008020700000"></a><h2 class="clsHeadThree">Automatic headlamp range control, component overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021737" name="S29996665792008020700000">Fig. 494: Automatic Headlamp Range Control, Component Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Headlamp beam adjustment motors</p> <ul class="clsBULLET"> <li>Left Headlamp Beam Adjustment Motor V48</li> <li>Right Headlamp Beam Adjustment Motor V49</li> </ul> <p>2 - Headlamp Range Control Module J431</p> <ul class="clsBULLET"> <li>Location: behind glove box at instrument panel support</li> <li>Removing and installing --> <a class="clsHyperlink" href="#S30299939382008020700000">Headlamp Range Control Module J431 , removing and installing</a></li> </ul> <p>3 - Left Rear Level Control System Sensor G76</p> <ul class="clsBULLET"> <li>Location: at left rear suspension ink</li> <li>Removing and installing --> <a class="clsExtHyperlink" id="A00278916_S06305075762008020700000">42 - REAR SUSPENSION</a> </li> </ul> <p>4 - Left Front Level Control System Sensor G78</p> <ul class="clsBULLET"> <li>Location: at left front track control link</li> <li>Removing and installing --> <a class="clsExtHyperlink" id="A00278916_S20573127852008020700000">40 - FRONT SUSPENSION</a> </li> </ul><a name="S30299939382008020700000"></a><h2 class="clsHeadThree">Headlamp Range Control Module J431 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsBULLET"> <li>Location: at instrument panel carrier behind glove box</li> </ul> <ul class="clsDASH"> <li>Remove glove box --> <a class="clsExtHyperlink" id="A00278922_S29273609722008020700000">68 - INTERIOR EQUIPMENT</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021738" name="S28054649672008020700000">Fig. 495: Identifying Connector, Bolts, And Headlight Range Control Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove module.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S302999393820080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Control module to body - screw</td> <td align="" class="clsCellNormal">3</td> </tr> </tbody> </table></span></p><a name="S13016769502008020700000"></a><h2 class="clsHeadOne">96 Lights, Switches - Interior, Anti-theft</h2><a name="S04755484272008020700000"></a><h2 class="clsHeadTwo">Switches - Interior</h2><a name="S08700635682008020700000"></a><h2 class="clsHeadThree">Light Switch E1 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020811" name="S03962422512008020700000">Fig. 496: Pressing Light Switch And Turning It Clockwise</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Push in light switch rotary knob - <span class="clsEmphBOLD">arrow 1</span> - and simultaneously turn clockwise - <span class="clsEmphBOLD">arrow 2</span> -.</li> <li>Hold switch in this position.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020812" name="S12197313412008020700000">Fig. 497: Pulling Off Light Switch From Switch Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull light switch out of switch housing - <span class="clsEmphBOLD">arrow 3</span> -.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Press switch into switch housing until catch engages.</li> </ul><a name="S30940118632008020700000"></a><h2 class="clsHeadThree">Ambient Illumination Deactivation Switch E491 , removing and installing</h2> <p>Where equipped, the Ambient Illumination Deactivation Switch E491 controls the "coming home " and "leaving home" lighting function.</p> <p>Additional information Owners Manual</p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove light switch --> <a class="clsHyperlink" href="#S08700635682008020700000">Light Switch E1 , removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020813" name="S11809298902008020700000">Fig. 498: Pressing Headlamp Range Control Adjuster Out Of Switch Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Reach through opening for light switch and press the switch unit out of the switch housing in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install light switch --> <a class="clsHyperlink" href="#S08700635682008020700000">Light Switch E1 , removing and installing</a>.</li> </ul><a name="S00666872992008020700000"></a><h2 class="clsHeadThree">Daytime running lamps (DRL) switch, removing and installing</h2> <p>Where equipped, the daytime running lamps switch controls DRL lighting function where desired (on US vehicles only).</p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove light switch --> <a class="clsHyperlink" href="#S08700635682008020700000">Light Switch E1 , removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020813" name="S32656179142008020700000">Fig. 499: Pressing Headlamp Range Control Adjuster Out Of Switch Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Reach through opening for light switch and press the switch unit out of the switch housing in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install light switch --> <a class="clsHyperlink" href="#S08700635682008020700000">Light Switch E1 , removing and installing</a>.</li> </ul><a name="S00021481072008020700000"></a><h2 class="clsHeadThree">Emergency Flasher Button E229 , removing and installing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S40332684272008020700000">Fig. 500: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Open glove compartment.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020733" name="S23154001502008020700000">Fig. 501: Removing Trim Using Hook For Front End 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully pull off trim panel - <span class="clsEmphBOLD">1</span> - using hook 3370 as illustrated.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021739" name="S29585761452008020700000">Fig. 502: Levering Out Emergency Flasher Button E229 From Switch Mounting Using Flat Screwdriver</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully lever out Emergency Flasher Button E229 - <span class="clsEmphBOLD">1</span> - from switch mounting - <span class="clsEmphBOLD">arrows</span> - using a flat screwdriver.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Push switch into mounting in instrument panel and ensure it is properly engaged.</li> </ul><a name="S21480854002008020700000"></a><h2 class="clsHeadThree">Switches in center console, removing and installing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S38827769072008020700000">Fig. 503: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Open glove compartment.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020733" name="S30477177302008020700000">Fig. 504: Removing Trim Using Hook For Front End 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully pull off trim panel - <span class="clsEmphBOLD">1</span> - to rear using hook 3370.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021740" name="S14729945362008020700000">Fig. 505: Prying Switch Out Of Mounting Using Flat Screwdriver</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use flat screwdriver to carefully pry appropriate switch out of mounting - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Push switch into mounting in instrument panel and ensure it is properly engaged.</li> </ul><a name="S10613530832008020700000"></a><h2 class="clsHeadThree">Front heated seat regulating switches, removing and installing</h2> <p>Front seat heating switches are integrated into A/C Control Head E87 and cannot be replaced separately.</p><a name="S31243149212008020700000"></a><h2 class="clsHeadThree">Rear heated seat regulating switches, removing and installing</h2> <p>Procedure for Left Rear Heated Seat Regulating Switch E128 and Right Rear Heated Seat Regulating Switch E129 is the same.</p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove rear ashtray.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020737" name="S29310208592008020700000">Fig. 506: Switch Mount Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press retaining hooks - <span class="clsEmphBOLD">arrow A</span> - on right and left outwards and swivel switch mounting to rear - <span class="clsEmphBOLD">arrow B</span> -.</li> <li>Disengage switch mounting at rear center console.</li> <li>Disconnect electrical connections.</li> <li>Unclip switches - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - from switch mounting.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S07143073642008020700000"></a><h2 class="clsHeadThree">Start System Button E378 - Audi RS4, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021741" name="S37785764362008020700000">Fig. 507: Identifying Cigarette Lighter Cover And Start System Button E378</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Open cigarette lighter cover - <span class="clsEmphBOLD">2</span> -.</li> <li>Lift Start System Button E378 - <span class="clsEmphBOLD">1</span> - up - <span class="clsEmphBOLD">arrow</span> - and remove from installation frame as illustrated.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S04791709092008020700000"></a><h2 class="clsHeadThree">Glove Compartment Lamp Switch E26 , removing and installing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S35080784872008020700000">Fig. 508: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Open glove compartment.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020706" name="S05915386492008020700000">Fig. 509: Removing Right Instrument Panel Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull off cover on right of instrument panel - <span class="clsEmphBOLD">arrow</span> - using hook 3370.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020711" name="S05454603902008020700000">Fig. 510: Identifying Connector, Joint Pin, And Switch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> -.</li> <li>Pull out hinge pin - <span class="clsEmphBOLD">1</span> -.</li> <li>Release switch - <span class="clsEmphBOLD">3</span> - in clockwise direction - <span class="clsEmphBOLD">arrow</span> - and detach.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Switch illustrated with glove compartment removed..</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S06204070052008020700000"></a><h2 class="clsHeadThree">Mirror selector/adjustment switch, removing and installing</h2> <p>Mirror Adjustment Switch E43 , Mirror Selector Switch E48 , and Mirror (with fold-away function) Switch E168 (where applicable) are integrated into a single module.</p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove front door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021742" name="S12551529182008020700000">Fig. 511: Identifying Electrical Connection, Mirror Adjustment Switch, And Fasteners</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> - at mirror adjustment switch - <span class="clsEmphBOLD">2</span> -.</li> <li>Use small screwdriver to carefully release fasteners - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Pull mirror adjustment switch downwards out of door trim.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When installing, ensure symbol trim is inserted before the mirror adjustment switch.</li> <li>Press mirror adjustment switch into switch mounting until retaining hooks engage.</li> <li>Install front door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul> </td> </tr> </table></span></p><a name="S31430110292008020700000"></a><h2 class="clsHeadThree">Drivers power window switch panel - 2 switches, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove front door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021743" name="S28606571282008020700000">Fig. 512: Identifying Fasteners, Electrical Connection, And Window Switch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use small screwdriver to carefully release fasteners - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Pull window switch downwards out of door trim.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> - at window switch - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Press window switch into switch mounting until retaining hooks engage.</li> <li>Install front door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul><a name="S05565835442008020700000"></a><h2 class="clsHeadThree">Drivers power window switch panel - four switches, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove front door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021744" name="S25388304592008020700000">Fig. 513: Identifying Retaining Element, Retaining Hooks, Window Switches, And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining hooks on armrest side by pressing retaining element - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Use small screwdriver to carefully release retaining hooks - <span class="clsEmphBOLD">1</span> - on trim side.</li> <li>Pull window switches - <span class="clsEmphBOLD">2</span> - downwards out of door trim.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> - at window switch.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Press window switch into switch mounting until it engages.</li> <li>Install front door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul><a name="S05371160882008020700000"></a><h2 class="clsHeadThree">Front passengers power window switch panel, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove front door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021745" name="S03354323142008020700000">Fig. 514: Identifying Fasteners, Electrical Connection, And Window Switch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use small screwdriver to carefully release fasteners - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Pull window switch downwards out of door trim.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> - at window switch - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Press window switch into switch mounting until retaining hooks engage.</li> <li>Install front door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul><a name="S38857896592008020700000"></a><h2 class="clsHeadThree">Rear door power window switches, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove rear door trim: --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021746" name="S07635313322008020700000">Fig. 515: Locating Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">1... 3</span> -.</li> <li>Remove armrest and disconnect electrical connection.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021747" name="S27500439542008020700000">Fig. 516: Pulling Switch Mounting From Armrest</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull switch mounting - <span class="clsEmphBOLD">1</span> - from armrest - <span class="clsEmphBOLD">2</span> - - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021748" name="S09887211322008020700000">Fig. 517: Using Small Screwdriver To Carefully Release Fasteners</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use small screwdriver to carefully release fasteners - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Pull out window switch downwards.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Press window switch into switch mounting until retaining hooks engage.</li> <li>Install rear door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul><a name="S00355555822008020700000"></a><h2 class="clsHeadThree">Sunroof Switch E8 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove front interior/reading lamp --> <a class="clsHyperlink" href="#S21204851382008020700000">Front interior lamp module, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021749" name="S41534444102008020700000">Fig. 518: Identifying Electrical Connection, Screws, And Sunroof Switch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Take sunroof switch E8 - <span class="clsEmphBOLD">1</span> - out of interior light/reading light.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install front interior/reading lamp --> <a class="clsHyperlink" href="#S21204851382008020700000">Front interior lamp module, removing and installing</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S003555558220080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Sunroof Switch E8 to interior light/reading light</td> <td align="" class="clsCellNormal">1.5</td> </tr> </tbody> </table></span></p><a name="S42466449312008020700000"></a><h2 class="clsHeadThree">Door contact switches, removing and installing</h2> <p>Door contact switches are integrated with the individual door locks and cannot be serviced or replaced separately.</p> <ul class="clsDASH"> <li>Replacing front door lock: --> <a class="clsExtHyperlink" id="A00278920_S10271524432008020700000">57 FRONT DOORS/DOOR COMPONENTS/CENTRAL LOCKING SYSTEM</a> .</li> <li>Replacing rear door lock: --> <a class="clsExtHyperlink" id="A00278920_S02895053652008020700000">58 REAR DOORS/DOOR COMPONENTS</a> .</li> </ul><a name="S14746321162008020700000"></a><h2 class="clsHeadThree">Drivers Interior Locking Switch E150 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove front door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021750" name="S29162477742008020700000">Fig. 519: Identifying Connector, Central Locking Switch, And Driver Side Door Trim</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press switch - <span class="clsEmphBOLD">1</span> - out of drivers door trim towards inside of vehicle - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install front door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul><a name="S21842139492008020700000"></a><h2 class="clsHeadThree">Rear/Center Central Locking Switch E286 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove rear ashtray.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021751" name="S28762429082008020700000">Fig. 520: Pressing Retaining Hooks And Swiveling Switch Mounting To Rear</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press retaining hooks - <span class="clsEmphBOLD">arrow A</span> - on left and right outwards and swivel switch mounting to rear - <span class="clsEmphBOLD">arrow B</span> -.</li> <li>Disengage switch mounting at center console.</li> <li>Disconnect electrical connection.</li> <li>Unclip switch - <span class="clsEmphBOLD">1</span> - from switch mounting.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S28040805412008020700000"></a><h2 class="clsHeadThree">Remote Fuel Tank Flap Switch E204 and Rear Lid Remote Control Lock Switch E233 , removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021752" name="S34259940402008020700000">Fig. 521: Locating Switch For Interior Monitoring And Towing Protection Or Trunk Release Switch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Location: drivers door trim in storage compartment - <span class="clsEmphBOLD">detail</span> -</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove drivers door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> <li>Disconnect electrical connections.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021753" name="S39777983722008020700000">Fig. 522: Identifying Catches, Interior Monitoring And Towing Protection, And Trunk Release Switch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully release retaining hooks - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Press switches as applicable - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - towards rear out of trim.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install drivers door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul><a name="S21449031692008020700000"></a><h2 class="clsHeadThree">Drivers Seat Memory Program Control E97 , removing and installing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00002640" name="S41488477782008020700000">Fig. 523: Identifying Trim Removal Wedge 3409</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Removal wedge 3409</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021754" name="S28281496872008020700000">Fig. 524: Removing Switch Using Removal Wedge 3409</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove switch - <span class="clsEmphBOLD">1</span> - using removal wedge 3409 as illustrated.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021755" name="S25910583422008020700000">Fig. 525: Identifying Fasteners, Switch, And Mounting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use small screwdriver to carefully release fasteners - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove switch - <span class="clsEmphBOLD">1</span> - from mounting - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Press switch into switch mounting until fasteners engage.</li> </ul><a name="S02664545112008020700000"></a><h2 class="clsHeadThree">Trunk Lock/Alarm/Central Locking Switch F124 - Sedan through 10.04, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove rear lid lock --> <a class="clsExtHyperlink" id="A00278920_S06872438102008020700000">55 HOOD, LIDS</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021756" name="S05904797772008020700000">Fig. 526: Identifying Catch, Retaining Bolts, And Contact Switch</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use flat screwdriver to pry plastic tab - <span class="clsEmphBOLD">3</span> - from retaining pins - <span class="clsEmphBOLD">1</span> -.</li> <li>Fold plastic tab completely to rear.</li> <li>First pull contact switch - <span class="clsEmphBOLD">2</span> - to one side and then upwards out of lock for rear lid.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure washers are properly positioned between plastic tab and lock for rear lid.</li> <li>Install rear lid lock --> <a class="clsExtHyperlink" id="A00278920_S06872438102008020700000">55 HOOD, LIDS</a> .</li> </ul> </td> </tr> </table></span></p><a name="S24993134142008020700000"></a><h2 class="clsHeadThree">Trunk Lock/Alarm/Central Locking Switch F124 - Avant through 10.04, removing and installing</h2> <p>The rear lid contact switch is integrated with the rear lid lock and cannot be serviced or replaced separately.</p> <ul class="clsDASH"> <li>Replace rear lid lock --> <a class="clsExtHyperlink" id="A00278920_S06872438102008020700000">55 HOOD, LIDS</a> .</li> </ul><a name="S00278026532008020700000"></a><h2 class="clsHeadThree">Trunk Lock/Alarm/Central Locking Switch F124 - from 11.04, removing and installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021757" name="S35685924712008020700000">Fig. 527: Identifying Rear Lid Contact And Rear Lid Lock</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>The rear lid contact switch is integrated with the rear lid lock - <span class="clsEmphBOLD">arrow</span> - and cannot be serviced or replaced separately.</p> <ul class="clsDASH"> <li>Replace rear lid lock --> <a class="clsExtHyperlink" id="A00278920_S06872438102008020700000">55 HOOD, LIDS</a> .</li> </ul><a name="S09676784532008020700000"></a><h2 class="clsHeadThree">12 V Socket U5 - in luggage compartment through 10.04, removing and installing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S38549828512008020700000">Fig. 528: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020886" name="S10357733402008020700000">Fig. 529: Rear Power Outlet Remove/Install Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully pull 12 V socket - <span class="clsEmphBOLD">1</span> - from luggage compartment trim using hook 3370.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Pay attention to retaining hooks - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">4</span> - when pulling out socket.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> -.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S20804120292008020700000"></a><h2 class="clsHeadThree">12 V Socket U5 - in luggage compartment from 11.04, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Audi A4 S4: Release lower right part of luggage compartment side trim: --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> <li>Audi RS4: Release lower right part of luggage compartment rear trim: --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> <li>Disconnect electrical connection at socket.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021758" name="S04056933682008020700000">Fig. 530: Identifying Nut And 12 V Socket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nut - <span class="clsEmphBOLD">1</span> -.</li> <li>Remove 12 V socket - <span class="clsEmphBOLD">2</span> - from trim.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install luggage compartment trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul><a name="S27391325332008020700000"></a><h2 class="clsHeadTwo">Anti-Theft Immobilizer</h2><a name="S03315095912008020700000"></a><h2 class="clsHeadThree">General information</h2> <p>All A4 from model year 2002 are equipped with Immobilizer Generation III.</p> <p>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).</p> <p>The immobilizer control module is integrated into the instrument cluster, i.e. it is replaced together with instrument cluster --> <a class="clsHyperlink" href="#S21852926562008020700000">Instrument cluster, removing and installing</a>.</p> <p>Data exchange between the Immobilizer control module and ECM takes place over the vehicle CAN-Bus network.</p><a name="S30671307362008020700000"></a><h2 class="clsHeadFour">Function</h2> <p>Immobilizer III consists of:</p> <ul class="clsBULLET"> <li>an adapted control module for anti-theft immobilizer (integrated in instrument cluster)</li> <li>a warning light in instrument cluster</li> <li>a reading coil at ignition lock</li> <li>an adapted Engine Control Module (ECM)</li> </ul> <ul class="clsBULLET"> <li>and adapted ignition keys with electronics (transponder)</li> </ul> <p>The anti-theft immobilizer is a system for enabling/locking the Engine Control Module (ECM) via the CAN wire.</p> <p>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.</p> <p>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.</p> <p>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.</p> <p>The warning lamp lights up briefly (max. 3 seconds) and then goes out when an authorized vehicle key is used.</p> <p>When an unauthorized vehicle key is used or when a system malfunction occurs, the warning lamp blinks constantly during ignition "on".</p><a name="S24129825782008020700000"></a><h2 class="clsHeadThree">On Board Diagnostic (OBD), function</h2> <p>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.</p> <p>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".</p><a name="S26811813502008020700000"></a><h2 class="clsHeadThree">Malfunctioning transponder and/or lost keys</h2> <ul class="clsBULLET"> <li>The transponder is integrated into the vehicle key and cannot be replaced separately.</li> <li>The complete vehicle key must be replaced if the transponder malfunctions.</li> </ul> <ul class="clsDASH"> <li>Order replacement key with integrated transponder on the basis of the lock number and/or VIN.</li> <li>Adapt all vehicle keys using VAS 5051/5052 in mode "Guided Fault Finding".</li> </ul><a name="S00317162112008020700000"></a><h2 class="clsHeadThree">Reader coil, replacing</h2> <ul class="clsBULLET"> <li>The reader coil is integrated into the lock cylinder and cannot be serviced or replaced separately.</li> <li>The complete lock cylinder must be replaced if the reader coil malfunctions --> <a class="clsHyperlink" href="#S17582230242008020700000">Lock cylinder, removing and installing</a></li> </ul> <ul class="clsDASH"> <li>Order replacement lock cylinder on the basis of the lock number and/or VIN.</li> </ul><a name="S32067882892008020700000"></a><h2 class="clsHeadThree">Lock set or instrument cluster, replacing.</h2> <p>Follow replacement procedures as specified using VAS 5051/5052 in mode "Guided Fault Finding".</p><a name="S23886561652008020700000"></a><h2 class="clsHeadTwo">Alarm Horn H12</h2><a name="S07772003242008020700000"></a><h2 class="clsHeadThree">Alarm Horn H12 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove right interior trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021759" name="S34884332382008020700000">Fig. 531: Identifying Nut, Electrical Connection, Horn, Bolt, And Horn Bracket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nut - <span class="clsEmphBOLD">1</span> -.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove horn - <span class="clsEmphBOLD">3</span> -.</li> <li>If necessary, remove horn bracket - <span class="clsEmphBOLD">5</span> - by removing bolt - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S077720032420080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Alarm Horn H12 to bracket - nut</td> <td align="" class="clsCellNormal">5</td> </tr> <tr> <td align="" class="clsCellNormal">Bracket to body - bolt</td> <td align="" class="clsCellNormal">9</td> </tr> </tbody> </table></span></p><a name="S39118670472008020700000"></a><h2 class="clsHeadTwo">Lights - Interior</h2><a name="S21286384572008020700000"></a><h2 class="clsHeadThree">Make-up Mirror Illumination L31 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021760" name="S05899003072008020700000">Fig. 532: Prying Out Light At Recess Using Flat-Head Screwdriver</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully pry out light at recess - <span class="clsEmphBOLD">arrow</span> - using a flat-head screwdriver.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017128" name="S00327292002008020700000">Fig. 533: Bulb Holder And Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bulb cover - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove bulb (12 V, 5W) from socket on reverse side of make-up mirror light.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S21204851382008020700000"></a><h2 class="clsHeadThree">Front interior lamp module, removing and installing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S11815256752008020700000">Fig. 534: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021420" name="S14489624062008020700000">Fig. 535: Removing Interior Lamp Module Trim Using Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully remove interior lamp module trim using hook 3370 as illustrated - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021463" name="S19943147932008020700000">Fig. 536: Disconnection Microphone Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Where applicable, disconnect microphone electrical connection - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021761" name="S40584435082008020700000">Fig. 537: Locating Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Swivel down module and remove from opening in headliner.</li> <li>Disconnect electrical connections.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Engage interior lamp module and tighten screws to 3 Nm.</li> </ul><a name="S38495566522008020700000"></a><h2 class="clsHeadThree">Ambient lighting LEDs, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove front interior lamp module --> <a class="clsHyperlink" href="#S21204851382008020700000">Front interior lamp module, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021762" name="S12940388532008020700000">Fig. 538: Identifying Electrical Connections, Retaining Clips, And LED</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections - <span class="clsEmphBOLD">1... 3</span> -.</li> <li>Release retaining clips - <span class="clsEmphBOLD">arrows</span> - and remove LED - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install front interior lamp module --> <a class="clsHyperlink" href="#S21204851382008020700000">Front interior lamp module, removing and installing</a>.</li> </ul><a name="S19043912892008020700000"></a><h2 class="clsHeadThree">Front Interior Light W1 - bulbs, replacing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S14930548292008020700000">Fig. 539: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021763" name="S37630600212008020700000">Fig. 540: Removing Interior Lamp Lens Using Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully remove interior lamp lens using hook 3370 as illustrated.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021764" name="S06655500442008020700000">Fig. 541: Removing Bulb From Holder</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bulb as applicable - <span class="clsEmphBOLD">1</span> - or - <span class="clsEmphBOLD">2</span> - (12 V, 10 W) from holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Press on lens until it engages.</li> </ul><a name="S37671292892008020700000"></a><h2 class="clsHeadThree">Front Passengers Map/Reading Light W13 , Drivers Map/Reading Light W19 - bulbs, replacing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S36454921052008020700000">Fig. 542: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021420" name="S13999289992008020700000">Fig. 543: Removing Interior Lamp Module Trim Using Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully remove interior lamp module trim using hook 3370 as illustrated.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021765" name="S12494721852008020700000">Fig. 544: Remove Bulb From Holder</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bulb as applicable - <span class="clsEmphBOLD">1</span> - or - <span class="clsEmphBOLD">2</span> - (12 V, 5 W) from bulb holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Press on trim until it engages.</li> </ul><a name="S03557185142008020700000"></a><h2 class="clsHeadThree">Front Passengers Airbag Disabled Indicator Lamp K145 - from 11.04, removing and installing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S16944798932008020700000">Fig. 545: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Open glove compartment.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020733" name="S35360382192008020700000">Fig. 546: Removing Trim Using Hook For Front End 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully remove trim panel - <span class="clsEmphBOLD">1</span> - using hook 3370 as illustrated.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020768" name="S05531866052008020700000">Fig. 547: Prying Out Indicator Lamp From Switch Mounting</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully pry out lever out indicator lamp - <span class="clsEmphBOLD">1</span> - from switch mounting - <span class="clsEmphBOLD">arrows</span> - using a flat screwdriver.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Push lamp assembly into mounting in instrument panel and ensure it is properly engaged.</li> </ul><a name="S01032166122008020700000"></a><h2 class="clsHeadThree">Rear interior lamp module, removing and installing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S14781400342008020700000">Fig. 548: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021766" name="S37465528282008020700000">Fig. 549: Removing Rear Interior Lamp Module From Headliner Opening Using Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully remove rear interior lamp module from headliner opening using hook 3370 as illustrated.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Insert interior lamp module in opening in headliner and clip into place.</li> </ul><a name="S30251585252008020700000"></a><h2 class="clsHeadThree">Left Rear Reading Light W11 , Right Rear Reading Light W12 - bulbs, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove rear interior lamp module --> <a class="clsHyperlink" href="#S01032166122008020700000">Rear interior lamp module, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017125" name="S39609857842008020700000">Fig. 550: Interior/Reading Light Bulbs</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Screw applicable bulb 12 V, 5 W - <span class="clsEmphBOLD">arrow</span> - from holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S21753739642008020700000"></a><h2 class="clsHeadThree">Glove Compartment Light W6 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Turn light switch to position "0".</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021767" name="S03800300122008020700000">Fig. 551: Identifying Retaining Tab, Glove Box Light, And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Using a flat-head screwdriver, press in retaining tab - <span class="clsEmphBOLD">1</span> - and pry out glove box light - <span class="clsEmphBOLD">2</span> -.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove bulb (12 V, 5 W) from bulb holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Insert glove box light in opening and engage on opposite side.</li> </ul><a name="S18460859452008020700000"></a><h2 class="clsHeadThree">Front ashtray light, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Pull radio approx 10 mm out of mounting slot --> <a class="clsExtHyperlink" id="A00278928_S09336703492008020700000">91 - COMMUNICATION</a> .</li> <li>Remove A/C Control Head E87 --> <a class="clsExtHyperlink" id="A00278926_S29600620052008020700000">87 AIR CONDITIONING</a> .</li> <li>Open front ashtray.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021768" name="S14264239382008020700000">Fig. 552: Identifying Ashtray Insert And Gear Lever Cover</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove front ashtray insert - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove cover - <span class="clsEmphBOLD">1</span> - for gear lever or selector lever on both sides - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021769" name="S32228678422008020700000">Fig. 553: Locating Screws For Ashtray</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Lift out front ashtray upwards.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021770" name="S13400678632008020700000">Fig. 554: Releasing Retaining Clips And Swivel Light For Front Ashtray Out Of Retainer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clips - <span class="clsEmphBOLD">2</span> - and swivel light - <span class="clsEmphBOLD">1</span> - for front ashtray out of retainer - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install A/C Control Head E87 --> <a class="clsExtHyperlink" id="A00278926_S29600620052008020700000">87 AIR CONDITIONING</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S184608594520080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Front ashtray to center console</td> <td align="" class="clsCellNormal">5</td> </tr> </tbody> </table></span></p><a name="S27253914172008020700000"></a><h2 class="clsHeadThree">Rear ashtray light, removing and installing</h2> <p>If rear ashtray light malfunctions, replace complete switch mounting panel:</p> <ul class="clsBULLET"> <li>Rear seat heating switch mount --> <a class="clsHyperlink" href="#S31243149212008020700000">Rear heated seat regulating switches, removing and installing</a></li> <li>Rear central locking switch mount --> <a class="clsHyperlink" href="#S21842139492008020700000">Rear/Center Central Locking Switch E286 , removing and installing</a></li> </ul><a name="S03186818492008020700000"></a><h2 class="clsHeadThree">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</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove applicable door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021771" name="S35099347022008020700000">Fig. 555: Identifying Bulb For Socket At Door Trim And Connector For Socket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull bulb holder with bulb - <span class="clsEmphBOLD">1</span> - out of door opener.</li> <li>Remove bulb.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Insert bulb for door opener light in opening and engage.</li> <li>Install door trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul><a name="S16859491602008020700000"></a><h2 class="clsHeadThree">Door entry warning lights, removing and installing</h2> <p>Procedure for all door entry and warning lights</p> <ul class="clsBULLET"> <li>Drivers Door Warning Light W30</li> <li>Left Front Entry Light W31</li> <li>Right Front Entry Light W32</li> <li>Left Rear Entry Light W33</li> </ul> <ul class="clsBULLET"> <li>Right Rear Entry Light W34</li> <li>Front Passengers Door Warning Light W36</li> <li>Left Rear Door Warning Light W37</li> <li>Right Rear Door Warning Light W38</li> </ul> <p>is the same.</p> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021772" name="S27965927572008020700000">Fig. 556: Identifying Door Safety/Entry Light And Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use a flat-head screwdriver to press in retaining tab - <span class="clsEmphBOLD">1</span> - and pry out door light - <span class="clsEmphBOLD">2</span> -.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021773" name="S21155430422008020700000">Fig. 557: Prying Off Cover On Door Safety Light</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Where applicable, carefully pry off cover at door light - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove bulb (12 V, 5 W) from bulb holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>If applicable, attach cover at door light.</li> <li>Insert door light in opening and engage on opposite side.</li> </ul><a name="S13071920682008020700000"></a><h2 class="clsHeadThree">Left Footwell Light W9 , Right Footwell Light W10 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021774" name="S24086837022008020700000">Fig. 558: Identifying Retaining Tab, Footwell Light, And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use a flat screwdriver to press in retaining tab - <span class="clsEmphBOLD">1</span> - and pry out footwell light - <span class="clsEmphBOLD">2</span> -.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove bulb (12 V, 5 W) from holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Insert footwell light in opening and engage on opposite side.</li> </ul><a name="S39828079682008020700000"></a><h2 class="clsHeadThree">Left Rear Footwell Light W45 , Right Rear Footwell Light W46 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021775" name="S26567330772008020700000">Fig. 559: Slide Footwell And Disengage</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Slide footwell light in direction of - <span class="clsEmphBOLD">arrow</span> - and disengage.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021776" name="S11348334212008020700000">Fig. 560: Prying Off Cap</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pry off cap - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove bulb (12 V, 5 W) from holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S33829114832008020700000"></a><h2 class="clsHeadThree">Left Luggage Compartment Light W18 , Right Luggage Compartment Light W35 - Sedan, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021777" name="S02099208392008020700000">Fig. 561: Identifying Retaining Tab, Luggage Compartment Light, And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use a flat screwdriver to press in retaining tab - <span class="clsEmphBOLD">1</span> - and pry out luggage compartment light - <span class="clsEmphBOLD">2</span> -.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove bulb (12 V, 5 W) from holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S08454648502008020700000"></a><h2 class="clsHeadThree">Luggage Compartment Light W3 - Avant, removing and installing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S10253130572008020700000">Fig. 562: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021778" name="S21329756232008020700000">Fig. 563: Removing Luggage Compartment Light From Headliner Opening Using Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully remove luggage compartment light from headliner opening using hook 3370 as illustrated - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S33904355062008020700000"></a><h2 class="clsHeadThree">Luggage Compartment Light W3 - bulb, Avant, replacing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021779" name="S02514166522008020700000">Fig. 564: Prying Off Lens With Screwdriver</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Insert small screwdriver at recess in lens and carefully pry off lens - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove bulb (12 V, 6 W) from holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Press on lens until it engages.</li> </ul><a name="S11408492412008020700000"></a><h2 class="clsHeadThree">Rear Lid Courtesy Lamp W51 - Avant, removing and installing</h2> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00003536" name="S00605538572008020700000">Fig. 565: Identifying Special Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hook 3370</li> </ul> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021780" name="S07004397722008020700000">Fig. 566: Pulling Rear Lid Light Using Hook 3370</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Carefully pull rear lid light in direction of - <span class="clsEmphBOLD">arrow</span> - using hook 3370 as illustrated.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021781" name="S16086332432008020700000">Fig. 567: Pulling Reflector Out Of Rear Lid Light</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Where applicable, pull reflector - <span class="clsEmphBOLD">1</span> - out of rear lid light - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove bulb (12 V, 6 W) from holder.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Insert rear lid light in opening and engage on opposite side.</li> </ul><a name="S29280553352008020700000"></a><h2 class="clsHeadTwo">Horn</h2><a name="S25985338492008020700000"></a><h2 class="clsHeadThree">Signal Horn/Dual Tone Horn H1 - through 10.04, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove applicable headlamp:</li> </ul> <ul class="clsBULLET"> <li>Halogen headlamp through 10.04 --> <a class="clsHyperlink" href="#S34557770512008020700000">Headlamps, removing and installing</a></li> <li>HID headlamp through 10.04 --> <a class="clsHyperlink" href="#S25343297202008020700000">Headlamps, removing and installing</a></li> <li>HID "Bi-Xenon" headlamp through 10.04 --> <a class="clsHyperlink" href="#S12098580432008020700000">Headlamps, removing and installing</a></li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021782" name="S25333723592008020700000">Fig. 568: Identifying Connector, Nut, And Horn</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove nut - <span class="clsEmphBOLD">1</span> - and detach horn from retainer.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Illustration shows bumper removed for clarity.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install headlamp.</li> </ul> <ul class="clsBULLET"> <li>Halogen headlamp through 10.04 --> <a class="clsHyperlink" href="#S34557770512008020700000">Headlamps, removing and installing</a></li> <li>HID headlamp through 10.04 --> <a class="clsHyperlink" href="#S25343297202008020700000">Headlamps, removing and installing</a></li> <li>HID "Bi-Xenon" headlamp through 10.04 --> <a class="clsHyperlink" href="#S12098580432008020700000">Headlamps, removing and installing</a></li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S259853384920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Horn to bracket - nut</td> <td align="" class="clsCellNormal">5</td> </tr> </tbody> </table></span></p><a name="S15178864292008020700000"></a><h2 class="clsHeadThree">Signal Horn/Dual Tone Horn H1 - from 11.04, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p>Vehicles without charge air cooler or additional radiator:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017429" name="S31402138902008020700000">Fig. 569: Identifying Quick-Release Fasteners And Noise Insulation</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release fasteners - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - and remove front noise insulation.</li> </ul> <p>Vehicles with charge air cooler or additional radiator:</p> <ul class="clsDASH"> <li>Remove front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017439" name="S14452940702008020700000">Fig. 570: Disconnecting Left/Right Electrical Connectors Of Horns</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>All models:</p> <ul class="clsDASH"> <li>Disconnect electrical connection - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove nut - <span class="clsEmphBOLD">1</span> - and detach horn - <span class="clsEmphBOLD">2</span> - from retainer.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Illustration shows bumper removed for clarity.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p>Vehicles with charge air cooler or additional radiator:</p> <ul class="clsDASH"> <li>Install front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S151788642920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Horn to bracket - nut</td> <td align="" class="clsCellNormal">5</td> </tr> </tbody> </table></span></p><a name="S14969910092008020700000"></a><h2 class="clsHeadTwo">Heated Steering Wheel</h2><a name="S27815017282008020700000"></a><h2 class="clsHeadThree">Heated steering wheel, servicing</h2> <ul class="clsDASH"> <li>Remove airbag module and steering wheel --> <a class="clsExtHyperlink" id="A00278922_S12872913122008020700000">69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS</a> .</li> <li>Check wiring connections Wiring Diagrams.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Steering wheel must be replaced if heated steering wheel malfunctions.</li> </ul> </td> </tr> </table></span></p><a name="S03650463852008020700000"></a><h2 class="clsHeadTwo">Garage Door Opener - HomeLink (R)</h2><a name="S25055797002008020700000"></a><h2 class="clsHeadThree">Garage Door Opener Control Head E284 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017120" name="S13409824242008020700000">Fig. 571: Prying Control Head Out Of Windshield Frame</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use small screwdriver to pry control head out of sun visor at locations indicated - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S25743823802008020700000"></a><h2 class="clsHeadThree">Garage Door Opener Control Module J530 - through 10.04, removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021783" name="S39416597052008020700000">Fig. 572: Identifying Bolt And Module For Removal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolt - <span class="clsEmphBOLD">2</span> - and disengage retainer.</li> <li>Remove module - <span class="clsEmphBOLD">1</span> - from bumper cover.</li> <li>Disconnect electrical connection.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul><a name="S33388469622008020700000"></a><h2 class="clsHeadThree">Garage Door Opener Control Module J530 - from 11.04, removing and installing</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul> <p>Vehicles with headlamp washers</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021635" name="S06178364532008020700000">Fig. 573: Identifying Hose, Spray Jet, And Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release clamp and remove hose - <span class="clsEmphBOLD">1</span> -.</li> <li>Turn hose connector - <span class="clsEmphBOLD">2</span> - on headlight washer system upward.</li> </ul> <p>Continued for all</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021784" name="S28229671252008020700000">Fig. 574: Identifying Retaining Clips, Retainer, Module, And Electrical Connection</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clips - <span class="clsEmphBOLD">4</span> - and fold back retainer - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove module - <span class="clsEmphBOLD">2</span> - from bumper cover.</li> <li>Disconnect electrical connection - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install front bumper cover --> <a class="clsExtHyperlink" id="A00278920_S18413101412008020700000">63 BUMPER</a> .</li> </ul><a name="S11898840482008020700000"></a><h2 class="clsHeadOne">97 Wiring</h2><a name="S25488818992008020700000"></a><h2 class="clsHeadTwo">Relay and fuse panels</h2><a name="S02856621532008020700000"></a><h2 class="clsHeadThree">General information</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before beginning repairs on the electrical system:<ul class="clsBULLET"> <li>Where applicable, obtain anti-theft radio security code.</li> <li>Switch off all electrical consumers.</li> <li>Switch the ignition off and remove ignition key.</li> <li>Disconnect negative ( - ) battery terminal.</li> </ul> <ul class="clsBULLET"> <li>On vehicles equipped with Audi Telematics by OnStar <sup>(R)</sup> , switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery --> <a class="clsExtHyperlink" id="A00278928_S09336703492008020700000">91 - COMMUNICATION</a> </li> <li>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.</li> <li>After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar <sup>(R)</sup> , switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module --> <a class="clsExtHyperlink" id="A00278928_S09336703492008020700000">91 - COMMUNICATION</a> </li> </ul> </td> </tr> </table></span></p><a name="S15976379892008020700000"></a><h2 class="clsHeadThree">Fuse panel, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery. Audi A4 S4 --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>. Audi RS4 --> <a class="clsHyperlink" href="#S36611140512008020700000">Battery in luggage compartment, disconnecting and connecting</a>.</li> <li>Where applicable, remove drivers storage compartment --> <a class="clsExtHyperlink" id="A00278922_S29273609722008020700000">68 - INTERIOR EQUIPMENT</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020833" name="S32247209092008020700000">Fig. 575: Identifying Bolts For Fuse Box</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">1</span> - for fuse panel - <span class="clsEmphBOLD">2</span> -.</li> <li>Release upper an d lower retaining clips and detach fuse panel from central tube for instrument panel.</li> <li>Disengage wiring harness at central tube for instrument panel and set aside.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017134" name="S14372742282008020700000">Fig. 576: Fuse Panel Cover And Cable Tie</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Cut open cable tie - <span class="clsEmphBOLD">1</span> -.</li> <li>Release cover for fuse panel - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove fuses at fuse panel.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017135" name="S11842638462008020700000">Fig. 577: Removing Retaining Strip For Connectors</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove retaining strip for connectors - <span class="clsEmphBOLD">arrows</span> - and take connectors out of fuse panel.</li> <li>Unclip socket - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018580" name="S23735729562008020700000">Fig. 578: Identifying Main Fuse Panel</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Refer to the applicable wiring diagram for exact identification of connections on fuse box Wiring Diagrams.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install drivers storage compartment --> <a class="clsExtHyperlink" id="A00278922_S29273609722008020700000">68 - INTERIOR EQUIPMENT</a> .</li> <li>Reconnect battery. Required steps Audi A4 S4 <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>. Required steps Audi RS4 <a class="clsHyperlink" href="#S39123246362008040900000">Connecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S159763798920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Fuse carrier to central tube for instrument panel - screw</td> <td align="" class="clsCellNormal">3</td> </tr> </tbody> </table></span></p><a name="S15823261452008020700000"></a><h2 class="clsHeadThree">Vehicle Electrical System Control Module J519 , removing and installing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Should Vehicle Electrical System Control Module J519 require replacement, follow replacement procedures as specified using VAS 5051/5052 in mode "Guided Fault Finding".</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Where applicable, remove drivers storage compartment --> <a class="clsExtHyperlink" id="A00278922_S29273609722008020700000">68 - INTERIOR EQUIPMENT</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021785" name="S10882929412008020700000">Fig. 579: Identifying Nuts And Vehicle Electrical System Control Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nuts - <span class="clsEmphBOLD">arrows</span> - and remove Vehicle Electrical System Control Module J519 - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021786" name="S01377775152008020700000">Fig. 580: Identifying Fuse Carrier And Connectors</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Unclip fuse carriers - <span class="clsEmphBOLD">1... 3</span> -.</li> <li>Release retaining clip at connector - <span class="clsEmphBOLD">4</span> - and disconnect connector.</li> <li>Disconnect electrical connections - <span class="clsEmphBOLD">5</span> - and - <span class="clsEmphBOLD">6</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install drivers storage compartment --> <a class="clsExtHyperlink" id="A00278922_S29273609722008020700000">68 - INTERIOR EQUIPMENT</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S158232614520080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Control module to central tube for instrument panel - nut</td> <td align="" class="clsCellNormal">2.4</td> </tr> </tbody> </table></span></p><a name="S26701955832008020700000"></a><h2 class="clsHeadThree">9-position relay carrier, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Where applicable, remove drivers storage compartment --> <a class="clsExtHyperlink" id="A00278922_S29273609722008020700000">68 - INTERIOR EQUIPMENT</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020834" name="S34044404252008020700000">Fig. 581: Identifying Nuts, And Relay Carrier</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nuts - <span class="clsEmphBOLD">3</span> - remove Vehicle Electrical System Control Module J519 with wires attached.</li> <li>Remove 9-position relay carrier - <span class="clsEmphBOLD">4</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Disregard - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> -.</li> <li>Unclip the fuse carriers at the 9-position relay carrier.</li> <li>Remove relays and control modules and then unclip appropriate relay carrier.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021787" name="S25656784582008020700000">Fig. 582: Identifying 9-Way Relay Carrier</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Refer to the applicable wiring diagram for exact identification of connections on relay carrier Wiring Diagrams.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install drivers storage compartment --> <a class="clsExtHyperlink" id="A00278922_S29273609722008020700000">68 - INTERIOR EQUIPMENT</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S267019558320080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">9-position relay carrier to central tube for instrument panel - nut</td> <td align="" class="clsCellNormal">2.4</td> </tr> </tbody> </table></span></p><a name="S29354922142008020700000"></a><h2 class="clsHeadThree">3-position relay carrier, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Where applicable, remove drivers storage compartment --> <a class="clsExtHyperlink" id="A00278922_S29273609722008020700000">68 - INTERIOR EQUIPMENT</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020834" name="S27077487622008020700000">Fig. 583: Identifying Nuts, And Relay Carrier</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and detach 3-position relay carrier - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Disregard - <span class="clsEmphBOLD">3</span> - and - <span class="clsEmphBOLD">4</span> -.</li> <li>Unclip the fuse carriers at the 3-position relay carrier.</li> <li>Remove relays and control modules and then unclip appropriate relay carrier.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021788" name="S19712486362008020700000">Fig. 584: Identifying 3-Position Relay Carrier</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Refer to the applicable wiring diagram for exact identification of connections on relay carrier Wiring Diagrams.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install drivers storage compartment --> <a class="clsExtHyperlink" id="A00278922_S29273609722008020700000">68 - INTERIOR EQUIPMENT</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S293549221420080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">3-position relay carrier to central tube for instrument panel - nut</td> <td align="" class="clsCellNormal">3</td> </tr> </tbody> </table></span></p><a name="S17840405262008020700000"></a><h2 class="clsHeadThree">4-position relay carrier, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery. Audi A4 S4 --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>. Audi RS4 --> <a class="clsHyperlink" href="#S36611140512008020700000">Battery in luggage compartment, disconnecting and connecting</a>.</li> <li>Where applicable, remove drivers storage compartment --> <a class="clsExtHyperlink" id="A00278922_S29273609722008020700000">68 - INTERIOR EQUIPMENT</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020833" name="S21855346712008020700000">Fig. 585: Identifying Bolts For Fuse Box</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">1</span> - for fuse panel - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove fuse panel from central tube for instrument panel.</li> <li>Disengage wiring harness at central tube for instrument panel and set aside.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021785" name="S05967731792008020700000">Fig. 586: Identifying Nuts And Vehicle Electrical System Control Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nuts - <span class="clsEmphBOLD">arrows</span> - and detach Vehicle Electrical System Control Module J519 - <span class="clsEmphBOLD">1</span> - with wiring attached.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021789" name="S00399989532008020700000">Fig. 587: Identifying Screw Connections, Bolts, And Nuts, For Fuse Carrier</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull the relays or control modules out of 4-position relay carrier.</li> <li>Mark assignment of wires at threaded connections - <span class="clsEmphBOLD">2</span> - , - <span class="clsEmphBOLD">3</span> - and - <span class="clsEmphBOLD">5</span> -.</li> <li>Remove wires at threaded connections.</li> <li>Remove bolt - <span class="clsEmphBOLD">1</span> - and nut - <span class="clsEmphBOLD">4</span> -.</li> </ul> <ul class="clsDASH"> <li>Unclip fuse carriers at 4-position relay carrier.</li> <li>Remove relays and control modules and then unclip appropriate relay carrier.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021790" name="S15311943142008020700000">Fig. 588: Identifying 4-Way Relay Carrier</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Refer to the applicable wiring diagram for exact identification of connections on relay carrier Wiring Diagrams.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021789" name="S06800593602008020700000">Fig. 589: Identifying Screw Connections, Bolts, And Nuts, For Fuse Carrier</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Install wires at threaded connections - <span class="clsEmphBOLD">2</span> - , - <span class="clsEmphBOLD">3</span> - and - <span class="clsEmphBOLD">5</span> - according to markings.</li> <li>Reconnect battery. Required steps Audi A4 S4 <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>. Required steps Audi RS4 <a class="clsHyperlink" href="#S39123246362008040900000">Connecting</a>.</li> <li>Install drivers storage compartment --> <a class="clsExtHyperlink" id="A00278922_S29273609722008020700000">68 - INTERIOR EQUIPMENT</a> .</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S178404052620080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> <col span="1" id="COL3"> </colgroup> <tbody> <tr> <td colspan="2" align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">4-pin relay carrier to chassis</td> <td align="" class="clsCellNormal">Nut</td> <td align="" class="clsCellNormal">2.4</td> </tr> <tr> <td align="" class="clsCellNormal">Screw</td> <td align="" class="clsCellNormal">1.7</td> </tr> <tr> <td colspan="2" align="" class="clsCellNormal">Wiring terminal connections - nut</td> <td align="" class="clsCellNormal">9</td> </tr> </tbody> </table></span></p><a name="S01197330512008020700000"></a><h2 class="clsHeadThree">Left connector station, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021791" name="S05383489792008020700000">Fig. 590: Locating Left Connection Point</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Location: Left connector station - <span class="clsEmphBOLD">arrow</span> - is located in left footwell beneath A-pillar trim.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove A-pillar trim: --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> <li>Press retaining clip and detach connector point from A-pillar - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Unclip fuse panel at connector point.</li> <li>Remove relays or control modules and then unclip appropriate relay carrier.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021792" name="S21099374642008020700000">Fig. 591: Identifying Connection Point</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Refer to the applicable wiring diagram for exact identification of connections on connector station Wiring Diagrams.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install A-pillar trim: --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul><a name="S30662406742008020700000"></a><h2 class="clsHeadThree">Comfort System Central Control Module J393 , removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove A-pillar trim: --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> <li>Remove drivers seat --> <a class="clsExtHyperlink" id="A00278922_S17706875992008020700000">72 - SEAT - FRAMES</a> .</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Safety belts at seat frame do not have to be unfastened.</li> <li>Fold back floor covering.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021793" name="S31900520792008020700000">Fig. 592: Identifying Cover For Drivers Side Electronics Box</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release cover for electronics box (drivers side) - <span class="clsEmphBOLD">arrows</span> - and fold cover towards right.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021794" name="S26502520522008020700000">Fig. 593: Identifying Retaining Clips, Comfort System Central Control Module J393, And Electrical Connections</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clips - <span class="clsEmphBOLD">arrows</span> - and remove Comfort System Central Control Module J393 - <span class="clsEmphBOLD">1</span> - from electronics box.</li> <li>Disconnect electrical connections - <span class="clsEmphBOLD">2... 6</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Refer to the applicable wiring diagram for exact identification of connections on electronics box Wiring Diagrams.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install A-pillar trim: --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> <li>Install drivers seat --> <a class="clsExtHyperlink" id="A00278922_S17706875992008020700000">72 - SEAT - FRAMES</a> .</li> </ul><a name="S25442666442008020700000"></a><h2 class="clsHeadThree">Right connector station, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021795" name="S32361784002008020700000">Fig. 594: Locating Right Connection Point</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Location: Right connector station - <span class="clsEmphBOLD">arrow</span> - is located in right footwell beneath A-pillar trim.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove A-pillar trim: --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> <li>Press retaining clip and detach connector point from A-pillar - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Unclip fuse panel at connector point.</li> <li>Remove relays or control modules and then unclip appropriate relay carrier.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021792" name="S35749299662008020700000">Fig. 595: Identifying Connection Point</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Refer to the applicable wiring diagram for exact identification of connections on connector station Wiring Diagrams.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Install A-pillar trim: --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul><a name="S14220401612008020700000"></a><h2 class="clsHeadThree">Main fuse panel in left rear luggage compartment - Audi RS4, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S36611140512008020700000">Battery in luggage compartment, disconnecting and connecting</a>.</li> <li>Remove left luggage compartment side trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00020757" name="S27428593132008020700000">Fig. 596: Identifying Quick-Release Fasteners, Main Fuse Box Cover, And Luggage Compartment</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Loosen quick-release fasteners - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">3</span> - and open main fuse box cover - <span class="clsEmphBOLD">2</span> - in luggage compartment - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021796" name="S33882579252008020700000">Fig. 597: Removing Nuts And Main Fuse</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nuts - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Remove main fuse.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021797" name="S19266899212008020700000">Fig. 598: Identifying Main Fuse</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Refer to the applicable wiring diagram for exact identification of relays and fuses Wiring Diagrams.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, observing the following:</p> <ul class="clsDASH"> <li>Install left luggage compartment side trim --> <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> .</li> <li>Connect battery. Required steps <a class="clsHyperlink" href="#S39123246362008040900000">Connecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S142204016120080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> <col span="1" id="COL3"> </colgroup> <tbody> <tr> <td colspan="2" align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td colspan="2" align="" class="clsCellNormal">Main fuse to main fuse box</td> <td align="" class="clsCellNormal">7,5</td> </tr> </tbody> </table></span></p><a name="S18818210412008020700000"></a><h2 class="clsHeadThree">Electronics box in plenum chamber, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014442" name="S07382977982008020700000">Fig. 599: Identifying Plenum Chamber Cover & Removing Rubber Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rubber seal of plenum chamber cover in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove plenum chamber cover - <span class="clsEmphBOLD">1</span> - to front.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014443" name="S19511738692008020700000">Fig. 600: Removing Securing Clips And Cowl</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use screwdriver to pry off the two caps - <span class="clsEmphBOLD">3</span> -.</li> <li>Loosen nuts - <span class="clsEmphBOLD">4</span> - (do not remove).</li> <li>Remove wiper arms - <span class="clsEmphBOLD">2</span> - from wiper shaft by tilting slightly.</li> <li>Remove nuts completely and remove wiper arms.</li> </ul> <ul class="clsDASH"> <li>Pull off retaining clips - <span class="clsEmphBOLD">1</span> - and detach cowl panel grille - <span class="clsEmphBOLD">5</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014444" name="S11424308182008020700000">Fig. 601: Removing Screws And Cover From E-Box In Plenum Chamber</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove cover for electronics box in plenum chamber - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014445" name="S05520916702008020700000">Fig. 602: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use screwdriver to pry off retaining strap - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017598" name="S17112057382008020700000">Fig. 603: Releasing Connector Latches And Pulling Off Connectors On Engine Control Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release connector locks tabs - <span class="clsEmphBOLD">arrows</span> - and disconnect electrical connections - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - for Motronic Engine Control Module (ECM) J220 (where applicable).</li> <li>Where applicable, release retaining clip for transmission control module.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017599" name="S11335319882008020700000">Fig. 604: Releasing Connector Lock And Disconnecting From Transmission Control Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release connector lock - <span class="clsEmphBOLD">arrow</span> - and disconnect from transmission control module.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017600" name="S27397269482008020700000">Fig. 605: Identifying Electrical Connections And Wire</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Disconnect electrical connections - <span class="clsEmphBOLD">2</span> - at rear of connector console.</li> <li>Remove wire - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017601" name="S33920064712008020700000">Fig. 606: Releasing Retaining Clips And Lifting Auxiliary Relay Carrier Out Of Electronics Box</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clips - <span class="clsEmphBOLD">arrows</span> - and lift auxiliary relay carrier out of electronics box.</li> <li>Remove the engine wiring harness at electronics box and bulkhead and set aside.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021798" name="S01312272182008020700000">Fig. 607: Identifying Securing Nuts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove nuts - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Lift electronics box and remove upwards.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S188182104120080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Plenum chamber electronics box to body</td> <td align="" class="clsCellNormal">3</td> </tr> </tbody> </table></span></p><a name="S21998238112008020700000"></a><h2 class="clsHeadThree">Electronics box fan in plenum chamber, removing and installing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Depending on market version, the plenum chamber electronics box may be equipped with a fan motor.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove the electronics box (plenum chamber) --> <a class="clsHyperlink" href="#S18818210412008020700000">Electronics box in plenum chamber, removing and installing</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021799" name="S06469382262008020700000">Fig. 608: Identifying Bolts, Fan, And Air Duct</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">4</span> - and remove fan - <span class="clsEmphBOLD">2</span> - with air cowl - <span class="clsEmphBOLD">3</span> - from electronics box in plenum chamber - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p> <p><span class="clsEmphBOLD">Tightening torque</span> </p> <p><span class="clsArticleTable"><a name="S219982381120080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Fan to plenum chamber electronics box</td> <td align="" class="clsCellNormal">3</td> </tr> </tbody> </table></span></p><a name="S19601739422008020700000"></a><h2 class="clsHeadThree">4-way relay carrier in electronics box in plenum chamber, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014442" name="S38761768832008020700000">Fig. 609: Identifying Plenum Chamber Cover & Removing Rubber Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rubber seal of plenum chamber cover in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove plenum chamber cover - <span class="clsEmphBOLD">1</span> - to front.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014443" name="S38298547422008020700000">Fig. 610: Removing Securing Clips And Cowl</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use screwdriver to pry off the two caps - <span class="clsEmphBOLD">3</span> -.</li> <li>Loosen nuts - <span class="clsEmphBOLD">4</span> - (do not remove).</li> <li>Remove wiper arms - <span class="clsEmphBOLD">2</span> - from wiper shaft by tilting slightly.</li> <li>Remove nuts completely and remove wiper arms.</li> </ul> <ul class="clsDASH"> <li>Pull off retaining clips - <span class="clsEmphBOLD">1</span> - and detach cowl panel grille - <span class="clsEmphBOLD">5</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014444" name="S42740727002008020700000">Fig. 611: Removing Screws And Cover From E-Box In Plenum Chamber</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove cover for electronics box in plenum chamber - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014445" name="S40424348882008020700000">Fig. 612: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use screwdriver to pry off retaining strap - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Lay aside engine control module with wires attached.</li> <li>Where applicable, release the retaining clip for the transmission control module.</li> <li>Lay aside transmission control module with wires attached.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017601" name="S34923830302008020700000">Fig. 613: Releasing Retaining Clips And Lifting Auxiliary Relay Carrier Out Of Electronics Box</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clips - <span class="clsEmphBOLD">arrows</span> - and lift auxiliary relay carrier out of electronics box.</li> <li>Unclip the fuse carriers at the 4-position relay carrier.</li> <li>Remove relays and control modules and then unclip appropriate relay carrier.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014451" name="S25740705152008020700000">Fig. 614: Removing Motronic Engine Control Module (ECM) Power Supply Relay J271 From E-Box</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Refer to the applicable wiring diagram for exact identification of connections on electronics box Wiring Diagrams.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal.</p><a name="S14934805552008020700000"></a><h2 class="clsHeadThree">Connector junction, electronics box in plenum chamber, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery. Audi A4 S4 --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>. Audi RS4 --> <a class="clsHyperlink" href="#S36611140512008020700000">Battery in luggage compartment, disconnecting and connecting</a>.</li> <li>Where applicable, remove drivers storage compartment --> <a class="clsExtHyperlink" id="A00278922_S29273609722008020700000">68 - INTERIOR EQUIPMENT</a> .</li> <li>Remove electrical wire at bottom of connector point in plenum chamber electronics box.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014442" name="S15612722902008020700000">Fig. 615: Identifying Plenum Chamber Cover & Removing Rubber Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rubber seal of plenum chamber cover in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove plenum chamber cover - <span class="clsEmphBOLD">1</span> - to front.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014443" name="S08856129442008020700000">Fig. 616: Removing Securing Clips And Cowl</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use screwdriver to pry off the two caps - <span class="clsEmphBOLD">3</span> -.</li> <li>Loosen nuts - <span class="clsEmphBOLD">4</span> - (no not remove).</li> <li>Remove wiper arms - <span class="clsEmphBOLD">2</span> - from wiper shaft by tilting slightly.</li> <li>Remove nuts completely and remove wiper arms.</li> </ul> <ul class="clsDASH"> <li>Pull off retaining clips - <span class="clsEmphBOLD">1</span> - and detach cowl panel grille - <span class="clsEmphBOLD">5</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014444" name="S19332748962008020700000">Fig. 617: Removing Screws And Cover From E-Box In Plenum Chamber</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove cover for electronics box in plenum chamber - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014445" name="S38471436702008020700000">Fig. 618: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use screwdriver to pry off retaining strap - <span class="clsEmphBOLD">arrows</span> -.</li> <li>Lay aside engine control module with wires attached.</li> <li>Release retaining clip for transmission control module.</li> <li>Lay aside transmission control module with wires attached.</li> </ul> <ul class="clsDASH"> <li>Disconnect electrical connections at rear of connector console.</li> </ul> <p>Vehicles through 10.04:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021800" name="S03852920122008020700000">Fig. 619: Identifying Wire Connection And Bolts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove electrical wire - <span class="clsEmphBOLD">2</span> -.</li> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">3</span> -.</li> <li>Unclip appropriate socket.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021801" name="S20481036132008020700000">Fig. 620: Identifying Connection Point E-Box Plenum Chamber</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Refer to the applicable wiring diagram for exact identification of connections on connector station Wiring Diagrams.</li> </ul> </td> </tr> </table></span></p> <p>Vehicles from 11.04:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021802" name="S16717794022008020700000">Fig. 621: Identifying Electrical Wire, Screws, And Socket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove electrical wire - <span class="clsEmphBOLD">3</span> -.</li> <li>Remove screws - <span class="clsEmphBOLD">2</span> - and - <span class="clsEmphBOLD">4</span> -.</li> <li>Unclip appropriate socket - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021803" name="S12037378132008020700000">Fig. 622: Identifying Electronics Box</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Refer to the applicable wiring diagram for exact identification of connections on connector station Wiring Diagrams.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Reconnect battery. Required steps Audi A4 S4 <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>. Required steps Audi RS4 <a class="clsHyperlink" href="#S39123246362008040900000">Connecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S149348055520080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Connector point in plenum chamber electronics box to central tube for instrument panel</td> <td align="" class="clsCellNormal">3</td> </tr> <tr> <td align="" class="clsCellNormal">Bolt connection for electrical wires</td> <td align="" class="clsCellNormal">9</td> </tr> </tbody> </table></span></p><a name="S12066197212008020700000"></a><h2 class="clsHeadThree">Main fuse panel - vehicles with battery in engine compartment, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014442" name="S19922997652008020700000">Fig. 623: Identifying Plenum Chamber Cover & Removing Rubber Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove rubber seal of plenum chamber cover in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove plenum chamber cover - <span class="clsEmphBOLD">1</span> - to front.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021804" name="S00653861352008020700000">Fig. 624: Identifying Cap, Nut At Electric Cable, And Nut For Carrier Fuse On Positive Post</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Fold cover - <span class="clsEmphBOLD">2</span> - aside and remove nut - <span class="clsEmphBOLD">3</span> - at terminal.</li> <li>Remove nut - <span class="clsEmphBOLD">1</span> - for fuse (positive terminal).</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Reconnect battery. Required steps Audi A4 S4 <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>. Required steps Audi RS4 <a class="clsHyperlink" href="#S39123246362008040900000">Connecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S120661972120080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Component - fastener</td> <td align="" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Fuse panel to positive terminal - nut</td> <td align="" class="clsCellNormal">6</td> </tr> <tr> <td align="" class="clsCellNormal">Fuse to fuse panel terminal - nut</td> <td align="" class="clsCellNormal">6</td> </tr> </tbody> </table></span></p><a name="S17359980882008020700000"></a><h2 class="clsHeadThree">Positive terminal in plenum chamber - Audi RS4, removing and installing</h2> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Disconnect battery --> <a class="clsHyperlink" href="#S36611140512008020700000">Battery in luggage compartment, disconnecting and connecting</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00014442" name="S26525833512008020700000">Fig. 625: Identifying Plenum Chamber Cover & Removing Rubber Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove plenum chamber cover rubber seal in direction of - <span class="clsEmphBOLD">arrow</span> -.</li> <li>Remove plenum chamber cover - <span class="clsEmphBOLD">1</span> - forward.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00021805" name="S24580201492008020700000">Fig. 626: Removing Screw, Retaining Clip, And Positive Terminal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screw - <span class="clsEmphBOLD">1</span> -.</li> <li>Release retaining clip - <span class="clsEmphBOLD">2</span> - in direction of - <span class="clsEmphBOLD">arrow A</span> -.</li> <li>Remove positive terminal in direction of - <span class="clsEmphBOLD">arrow B</span> - from bracket.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018636" name="S26042455032008020700000">Fig. 627: Releasing Retaining Clip And Opening Cover Over Positive Terminal Pick-Off</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Release retaining clip - <span class="clsEmphBOLD">arrow A</span> - and open cover - <span class="clsEmphBOLD">2</span> - over positive terminal.</li> <li>Release wiring cover - <span class="clsEmphBOLD">1</span> - in direction of - <span class="clsEmphBOLD">arrow B</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00018362" name="S03356439892008020700000">Fig. 628: Removing Terminal Nuts, Cables, And Positive Terminal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove terminal nuts - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">4</span> - and remove cables.</li> <li>Remove positive terminal.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <ul class="clsDASH"> <li>Connect battery. Required steps <a class="clsHyperlink" href="#S39123246362008040900000">Connecting</a>.</li> </ul> <p><span class="clsEmphBOLD">Tightening torques</span> </p> <p><span class="clsArticleTable"><a name="S173599808820080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="LEFT" class="clsCellNormal">Component</td> <td align="CENTER" class="clsCellNormal">Nm</td> </tr> <tr> <td align="" class="clsCellNormal">Positive cables to positive terminal grip</td> <td align="CENTER" class="clsCellNormal">15</td> </tr> <tr> <td align="" class="clsCellNormal">Positive terminal grip to bracket</td> <td align="CENTER" class="clsCellNormal">9</td> </tr> </tbody> </table></span></p><a name="S34563117172008020700000"></a><h2 class="clsHeadTwo">Wiring Harness and Connectors, servicing</h2><a name="S38432866032008020700000"></a><h2 class="clsHeadThree">General information</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Before beginning repairs on the electrical system:<ul class="clsBULLET"> <li>Where applicable, obtain anti-theft radio security code.</li> <li>Switch off all electrical consumers.</li> <li>Switch the ignition off and remove ignition key.</li> <li>Disconnect negative ( - ) battery terminal.</li> </ul> <ul class="clsBULLET"> <li>On vehicles equipped with Audi Telematics by OnStar <sup>(R)</sup> , switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery --> <a class="clsExtHyperlink" id="A00278928_S09336703492008020700000">91 - COMMUNICATION</a> </li> <li>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.</li> <li>After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar <sup>(R)</sup> , switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module --> <a class="clsExtHyperlink" id="A00278928_S09336703492008020700000">91 - COMMUNICATION</a> </li> </ul> </td> </tr> </table></span></p> <p>Special tools, testers and auxiliary items required</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00002540" name="S35499178622008020700000">Fig. 629: Wiring Harness Repair Kit V.A.S 1978</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Wiring harness repair set VAS 1978</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017141" name="S39058887502008020700000">Fig. 630: Opened Wiring Harness Repair Kit VAS 1978</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Wiring harness and connector repairs on the vehicle electrical system are only to be performed using wiring harness repair set VAS 1978.</li> <li>An instruction manual is included in the wiring harness repair set VAS 1978 , in which the procedure for repairs is described in detail.</li> </ul> </td> </tr> </table></span></p><a name="S03844250792008020700000"></a><h2 class="clsHeadThree">Safety precautions for repairing wiring harnesses and connectors</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Wiring harness and connector repairs on the vehicle electrical system are only to be performed using wiring harness repair set VAS 1978.</li> <li>Pay attention to the relevant regulations in the individual countries.</li> <li>Disconnecting the battery negative ( - ) terminal prevents accidents when working on electrical system. Disconnect battery. Audi A4 S4 --> <a class="clsHyperlink" href="#S38741429262008020700000">Battery in engine compartment, disconnecting and reconnecting</a>. Audi RS4 --> <a class="clsHyperlink" href="#S36611140512008020700000">Battery in luggage compartment, disconnecting and connecting</a>.</li> <li>Heed stickers on vehicle pointing out components with high voltage. Remaining voltage must be dissipated before commencing repair work.</li> </ul> <ul class="clsBULLET"> <li>Before commencing repair work, always eliminate cause of damage, e.g. sharp body edges, malfunctioning electrical components, corrosion etc.</li> <li>Do not loosen ground straps on body if this can be avoided (danger of corrosion).</li> <li>Further information, for example about removal and installation of individual components, can be found in the appropriate Workshop Manual.</li> </ul> </td> </tr> </table></span></p><a name="S04202025932008020700000"></a><h2 class="clsHeadThree">Notes on repairs on wiring harnesses and connectors</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Do not solder components of the vehicle electrical system.</li> <li>Do not perform repairs on heat-shrink sleeves. Route a new wire along the faulty wire if necessary.</li> <li>Shielded wires, e.g. on speed sensor and knock sensors, are NOT to be repaired. These wires must be replaced complete if damaged.</li> <li>Only use yellow wires for repairs to wiring. Mark location of repair with yellow insulating tape.</li> </ul> <ul class="clsBULLET"> <li>Yellow wiring and locations with yellow insulating tape on wiring harness designate a previous repair.</li> </ul> </td> </tr> </table></span></p><a name="S35658560082008020700000"></a><h2 class="clsHeadThree">Notes on repairs to airbag and safety belt tensioner wiring harness</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>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).</li> <li>Wires on the individual airbag modules are NOT to be repaired.</li> <li>If wires or connectors at airbag modules are damaged, the corresponding airbag modules must be replaced for safety reasons.</li> <li>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.</li> </ul> <ul class="clsBULLET"> <li>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.</li> </ul> </td> </tr> </table></span></p><a name="S15789688822008020700000"></a><h2 class="clsHeadThree">Notes for repairs on CAN-Bus wires</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004273" name="S33832801492008020700000">Fig. 631: Repairing Twisted Wire Pairs</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Use an unshielded two-wire line - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - (cross-section 0.35 mm <sup>2</sup> or 0.5 mm <sup>2</sup> ) as CAN-Bus bus wire.</li> <li>color coding of CAN-Bus bus wires:</li> </ul> <p><span class="clsArticleTable"><a name="S157896888220080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1"> <col span="1" id="COL2"> </colgroup> <tbody> <tr> <td align="" class="clsCellNormal">Drive CAN-Bus High</td> <td align="" class="clsCellNormal">orange/black</td> </tr> <tr> <td align="" class="clsCellNormal">Convenience CAN-Bus High</td> <td align="" class="clsCellNormal">orange/green</td> </tr> <tr> <td align="" class="clsCellNormal">Infotainment CAN-Bus High</td> <td align="" class="clsCellNormal">orange/violet</td> </tr> <tr> <td align="" class="clsCellNormal">CAN-Bus Low (all)</td> <td align="" class="clsCellNormal">orange/brown</td> </tr> </tbody> </table></span></p> <ul class="clsBULLET"> <li>Only use yellow wires for repairs to wiring. Mark location of repair with yellow insulating tape.</li> <li>Both bus wires must be of the same length when repairing. When twisting the wires - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">2</span> - , length of twist - <span class="clsEmphBOLD">A</span> - = 20 mm must be attained.</li> <li>When making repairs, there must be no untwisted section of wire which is longer than - <span class="clsEmphBOLD">B</span> - = 50 mm, e.g. in the vicinity of heat-shrink sleeves - <span class="clsEmphBOLD">arrow</span> -.</li> </ul><a name="S25309491772008020700000"></a><h2 class="clsHeadThree">Repairing a wire with cross-section 0.22 mm 2 or 0.35 mm 2</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Wiring harness repair set VAS 1978 contains repair wires of three different cross-sections (0.5 mm <sup>2</sup> , 1.5 mm <sup>2</sup> , 4.0 mm <sup>2</sup> ) and the corresponding crimp connectors.</li> <li>0.5 mm <sup>2</sup> repair wire must be used for repairing 0.35 mm <sup>2</sup> wire.</li> </ul> </td> </tr> </table></span></p> <p>Perform the repair as follows:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00002550" name="S04518323272008020700000">Fig. 632: Stripping Insulation At Wiring Using Stripping Pliers</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Strip the ends of the 0.22 mm <sup>2</sup> and 0.35 mm <sup>2</sup> wires to a length of 12... 14 mm using the stripping pliers VAS 1978/3.</li> <li>Fold back half of the stripped wire ends.</li> <li>Strip the ends of the 0.5 mm <sup>2</sup> repair wire to a length of 6 to 7 mm using the stripping pliers VAS 1978/3.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017142" name="S20541797012008020700000">Fig. 633: Crimping On Both Sides With Crimping Pliers</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Slip crimp connector over ends of wires and crimp on both sides using crimping tool VAS 1978/1.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Be sure to select the correct red crimp insert VAS 1978/24 for 0.5 mm <sup>2</sup> wires.</li> <li>Do NOT crimp the insulation on the wires.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004308" name="S23558899122008020700000">Fig. 634: Heating Crimp Connection Using Hot Air Gun</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>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.</li> </ul> <ul class="clsBULLET"> <li>Crimp connector must be heated working outwards from center until it is completely sealed and adhesive emerges.</li> <li>Set the hot air blower to the correct temperature; refer to operating manual for VAS 1978.</li> </ul> <ul class="clsDASH"> <li>When shrink-fitting, ensure no other wires, plastic components or insulating materials are damaged by the hot nozzle.</li> <li>If repair wire was previously wrapped, yellow insulating tape must again be wound around this point; reattach wire with a cable tie if necessary.</li> <li>Reconnect battery. Required steps Audi A4 S4 <a class="clsHyperlink" href="#S33206369132008040900000">Reconnecting</a>. Required steps Audi RS4 <a class="clsHyperlink" href="#S39123246362008040900000">Connecting</a>.</li> </ul><a name="S41533090262008020700000"></a><h2 class="clsHeadThree">Antenna cables, replacing</h2> <p>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.</p> <p>Spare part numbers.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Antenna cables are NOT to be repaired, rather replaced using connecting cables and adapter leads available as genuine replacement parts.</li> <li>These genuine replacement parts are suitable for all cable cross-sections and antenna cables which have to be replaced.</li> <li>Replacing of individual antenna connectors during repair work is not intended.</li> <li>The cables are now to be used retrospectively for all Audi models and for all antenna cable-cross sections fitted.</li> <li>All adapter leads and connecting cables are suitable for all transmission and reception signals.</li> <li>The repair concept can also be used for testing and service installation purposes (e.g. retrofitting).</li> </ul> </td> </tr> </table></span></p><a name="S28669033362008020700000"></a><h2 class="clsHeadThree">Antenna connector cable, replacing</h2> <p>Example:</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004274" name="S40916248512008020700000">Fig. 635: Assembly Overview Of Antenna Wire</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Faulty antenna cable from radio to antenna</p> <p>The following are required for repair purposes:</p> <ol class="clsARABICNUM"> <li>Adapter wire for connection to radio; length approx. 30 cm</li> <li>Connecting wire; available in various lengths</li> <li>Adapter wire for connection to antenna; length approx. 30 cm</li> </ol> <ul class="clsDASH"> <li>Disconnect electrical connections of faulty antenna cable from devices.</li> <li>Determine routing of faulty antenna cable in vehicle and measure out overall length of antenna connection to be replaced in vehicle.</li> </ul> <p>Total length of antenna connection = length of adapter leads - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">3</span> - required as well as connecting wire - <span class="clsEmphBOLD">2</span> -.</p> <ul class="clsDASH"> <li>Subtract 60 cm from total length of antenna connection measured to calculate required length of connecting wire needed.</li> <li>Procure the necessary adapter leads and connecting wire in the calculated length as genuine replacement parts.</li> <li>Cut connectors off faulty antenna cable.</li> </ul> <ul class="clsBULLET"> <li>Leave remains of faulty antenna cable in vehicle.</li> </ul> <ul class="clsDASH"> <li>Connect adapter leads to units in vehicle.</li> <li>Fit connectors with a piece of foam sheathing to prevent rattling noise.</li> <li>Lay and secure connecting wire parallel to old antenna cable.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Antenna cable must not be kinked or bent excessively during installation. Do not attempt to bend antenna cable in a radius smaller than 50mm.</td> </tr> </table></span></p> <ul class="clsDASH"> <li>Attach connecting wire to adapter leads.</li> <li>To prevent rattling noise, apply a suitable piece of foam sheathing to antenna connectors.</li> <li>Check operation.</li> </ul> </body> </html>

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ELECTRICAL EQUIPMENT
  • HEADINGS
    • 27 Battery, Starter, Generator, Cruise Control
      • Battery
        • General information
        • Warnings and safety measures for lead-acid batteries
          • Smoking, naked flames, fires and sparks:
          • Electrolyte:
          • Eye protection and protective clothing:
          • Danger of explosion:
        • Battery handling instructions
        • Battery in engine compartment, disconnecting and reconnecting
          • Disconnecting
          • Reconnecting
        • Battery in luggage compartment, disconnecting and connecting
          • Disconnecting
          • Connecting
        • Battery in engine compartment, removing and installing
        • Battery in luggage compartment, removing and installing
        • Battery installation, checking
        • Batteries with central gas venting
        • Battery with charge indicator (magic eye), checking
        • Visual inspection
        • No-load voltage, checking
        • Electrolyte level - batteries with charge indicator (magic eye), checking
        • Electrolyte level - batteries with sealing plugs, checking
        • Electrolyte specific gravity - batteries with sealing plugs, checking
        • Battery, testing
        • Battery, charging
        • Quick-charging
      • Battery Interrupt Igniter N253 - Audi RS4
        • Battery Interrupt Igniter N253 - Audi RS4, removing and installing
      • Generator (GEN)
        • Generator (GEN) - 4-cylinder 1.8L Turbo engine, removing and installing
          • Tightening Torques (1.8L)
        • Generator (GEN) - 4-cylinder 2.0L Turbo FSI engine, removing and installing
          • Tightening Torques (2.0L)
        • Generator (GEN) - 3.0L 6-cylinder engine, removing and installing
          • Removing
          • Installing
        • Generator (GEN) - 3.2L 6-cylinder FSI engine, removing and installing
          • Tightening Torques (3.2L)
        • Generator (GEN) - 4.2L 8-cylinder engine (Audi S4), removing and installing
          • Tightening Torques (4.2L - S4)
        • Generator (GEN) - 4.2L 8-cylinder FSI engine (Audi RS4), removing and installing
          • Tightening Torques (4.2L - RS4)
      • Starter
        • Starter - 1.8L 4-cylinder Turbo engine, removing and installing
        • Starter - 2.0L 4-cyl Turbo FSI engine, removing and installing
        • Starter - 3.0L 6-cylinder engine, removing and installing
        • Starter - 3.2L 6-cylinder FSI engine, removing and installing
        • Starter - 4.2L 8-cylinder engine (Audi S4), removing and installing
        • Starter - 4.2L 8-cylinder FSI engine (Audi RS4), removing and installing
    • 90 Instruments
      • Instrument Cluster
        • General information
        • Instrument cluster, disposal
        • On Board Diagnostic (OBD), function
        • Message "dEF" in trip recorder display
        • Instrument cluster, removing and installing
        • Instrument cluster, rear view
        • Instrument cluster multi-pin connector assignments
        • Fuel Level Sensor G - front-wheel drive, multi-pin connector assignments
        • Fuel Level Sensor G , Fuel Level Sensor 2 G169 - quattro, multi-pin connector assignments
        • Engine Coolant Temperature (ECT) Gauge Sensor G2 - 1.8L 4-cylinder Turbo engine, multi-pin connector assignments
        • Engine Coolant Temperature (ECT) Sensor G62 - 2.0L 4-cylinder Turbo FSI engine, multi-pin connector assignments
        • Engine Coolant Temperature (ECT) Gauge Sensor G2 - 3.0L 6-cylinder engine, multi-pin connector assignments
        • Engine Coolant Temperature (ECT) Sensor G62 - 3.2L 6-cylinder FSI engine, multi-pin connector assignments
        • Engine Coolant Temperature (ECT) Sensor G62 - 4.2L 8-cylinder engine (Audi S4), multi-pin connector assignments
        • Engine Coolant Temperature (ECT) Sensor G62 - 4.2L 8-cylinder engine (Audi RS4), multi-pin connector assignments
        • Radio Frequency Controlled Clock Receiver J489 , removing and installing
    • 92 Windshield Wiper Washer System
      • Windshield Wiper System
        • Windshield wiper system, removing and installing
        • Windshield wiper blade park position, adjusting
        • Windshield wiper blade - through 10.04, replacing
        • Windshield wiper arm - through 10.04, assembly
        • Windshield wiper blade mount - through 10.04, removing and installing
        • Windshield wiper blade - from 11.04, replacing
      • Windshield Washer System
        • Washer fluid reservoir - Audi A4 S4, removing and installing
        • Washer fluid reservoir - Audi RS4, removing and installing
        • Windshield washer spray jets, removing and installing
        • Windshield washer spray jets, adjusting
      • Rear Window Wiper Washer System
        • Rear window wiper/washer, assembly
        • Rear window washer spray jet, removing and installing
        • Rear window washer spray jet, adjusting
        • Rear window wiper arm, removing and installing
        • Rear window wiper arm park position, adjusting
        • Rear window wiper blade, replacing
        • Rear window wiper motor, assembly
        • Rear window wiper motor, removing and installing
        • Washer fluid reservoir, removing and installing
      • Headlamp Washer System - through 10.04
        • Headlamp washer spray jets, removing and installing
        • Headlamp washer spray jets, adjusting
        • Washer fluid reservoir, removing and installing
      • Headlamp Washer System - from 11.04
        • Headlamp washer spray jets, removing and installing
        • Headlamp washer spray jets, adjusting
        • Washer fluid reservoir, removing and installing
    • 94 Lights, Switches - Exterior
      • Halogen Headlamps - through 10.04
        • General information
        • On Board Diagnostic (OBD), functions
        • Halogen headlamps, assembly
        • Headlamps, removing and installing
          • Removing
          • Installing
        • Headlamps, adjusting
        • Headlamps, service preparation
          • Preparation - vehicles with 1.8L 4-cylinder Turbo engine
          • Preparation - vehicles with 3.0L 6-cylinder engine
        • Low Beam Headlamp M29 / M31 - bulb, replacing
        • High Beam Headlamp M30 / M32 - bulb, replacing
        • Turn signal/parking lamp bulb, replacing
        • Headlamp securing lugs, servicing
      • Halogen Headlamps - from 11.04
        • General information
        • On Board Diagnostic (OBD), functions
        • Halogen headlamps, assembly
        • Headlamps, removing and installing
        • Headlamps, adjusting
        • Low Beam Headlamp M29 / M31 - bulb, replacing
        • High Beam Headlamp M30 / M32 - bulb, replacing
        • Parking Lamp M1 / M3 - bulb, replacing
        • Front Turn Signal Lamp M5 / M7 - bulb, replacing
        • Headlamp securing lugs, servicing
      • Headlamps with High Intensity Gas Discharge (HID) Lamps - through 10.04
        • General information
        • On Board Diagnostic (OBD), functions
        • Headlamps with High Intensity Gas Discharge (HID) Lamps, assembly
        • Headlamps, removing and installing
          • Removing
          • Installing
        • Headlamps, adjusting
        • Headlamps, service preparation
          • Preparation - vehicles with 1.8L 4-cylinder Turbo engine
          • Preparation - vehicles with 3.0L 6-cylinder engine
          • Preparation - 4.2L 8-cylinder engine
        • HID low beam headlamp bulb - through approx. 09.01, replacing
        • HID headlamp bulb, disposal
        • HID low beam headlamp bulb - from approx. 09.01, replacing
        • HID headlamp bulb, disposal
        • High Beam Headlamp M30 / M32 - bulb, replacing
        • Turn signal/parking lamp bulb, replacing
        • Headlamp Beam Adjustment Motor V48 / V49, removing and installing
        • High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - through approx. 09.01, removing and installing
        • High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344 - from approx. 09.01, removing and installing
        • Headlamp securing lugs, servicing
      • Headlamps with High Intensity Gas Discharge HID Lamps - through 10.04
        • General information
        • On Board Diagnostic (OBD), functions
        • Headlamps with High Intensity Gas Discharge (HID) "Bi-Xenon" Lamps, assembly
        • Headlamps, removing and installing
          • Removing
          • Installing
        • Headlamps, adjusting
        • HID low beam headlamp bulb, replacing
        • HID headlamp bulb, disposal
        • High Beam Headlamp bulb M30 / M32, replacing
        • High/Low Beam Switch-Over Solenoid N347 / N348, removing and installing
        • Turn signal/parking lamp bulb, replacing
        • Headlamp Beam Adjustment Motor V48 / V49, removing and installing
        • High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344, removing and installing
        • Adapter cable for HID headlamp bulb control module, removing and installing
        • Headlamp securing lugs, servicing
      • Headlamps with High Intensity Gas Discharge HID Bi-Xenon Lamps - through 10.04
        • General information
        • On Board Diagnostic (OBD), functions
        • Headlamps with High Intensity Gas Discharge (HID) "Bi-Xenon" Lamps, assembly
        • Headlamps, removing and installing
          • Removing
          • Installing
        • Headlamps, adjusting
        • Headlamps, service preparation
          • Upper washer fluid reservoir and power steering fluid reservoir, removing and installing
          • Preparation - vehicles with 1.8L 4-cylinder Turbo engine
          • Preparation - vehicles with 2.0L 4-cylinder Turbo FSI engine
          • Preparation - vehicles with 3.0L 6-cylinder engine
          • Preparation - vehicles with 3.2L 6-cylinder FSI engine
          • Preparation - vehicles with 4.2L 8-cylinder engine (Audi S4)
          • Preparation - vehicles with 4.2L 8-cylinder FSI engine (Audi RS4)
        • HID headlamp bulb, replacing
        • HID headlamp bulb, disposal
        • Daytime Running Lamp (DRL) bulb, replacing
        • Parking Lamp M1 / M3 - bulb, replacing
        • High/Low Beam Switch-Over Solenoid N347 / N348 and Dynamic Cornering Light Motor V318 / V319, removing and installing
        • Front Turn Signal Lamp M5 / M7 - bulb, replacing
        • High Intensity Gas Discharge (HID) Lamp Control Module J343 / J344, removing and installing
        • Headlamp securing lugs, servicing
      • Fog Lamps - through 10.04
        • Fog lamp housing, removing and installing
        • Fog lamp bulb, replacing
        • Fog lamps, adjusting
      • Fog Lamps - from 11.04
        • Fog lamp housing - Audi A4, removing and installing
        • Fog lamp housing - Audi A4 with "S-line" equipment Audi S4, removing and installing
        • Fog lamp housing - Audi RS4, removing and installing
        • Fog lamp bulb - Audi A4, replacing
        • Fog lamp bulb - Audi A4 with "S-line" equipment Audi S4, replacing
        • Fog lamp bulb - Audi RS4, replacing
        • Fog lamps, adjusting
      • Side Mounted Turn Signals
        • Side mounted turn signals, removing and installing
      • Rear Lights - through 10.04
        • Rear lights - Sedan, assembly
        • Rear light/bulb carrier - Sedan, removing and installing
        • Rear lights - Avant, assembly
        • Rear light/bulb carrier - Avant, removing and installing
      • Rear Lights - from 11.04
        • Rear lights in rear fender - Sedan, assembly
        • Rear light/bulb carrier in rear fender - Sedan, removing and installing
        • Rear lights in rear lid - Sedan, assembly
        • Rear light/bulb carrier in rear lid - Sedan, removing and installing
        • Taillamp/rear fog lamp bulb, replacing
        • Rear lights in rear fender - Avant, assembly
        • Rear light/bulb carrier in rear fender - Avant, removing and installing
        • Rear lights in rear lid - Avant, assembly
        • Rear light/bulb carrier in rear lid - Avant, removing and installing
        • Taillamp/rear fog lamp bulb, removing and installing
      • High-Mount Brake Lamp - through 10.04
        • High-mount brake lamp - Sedan, removing and installing
        • High-mount brake lamp - Avant, removing and installing
      • High-Mount Brake Lamp - from 11.04
        • High-mount brake lamp - Sedan, removing and installing
        • High-mount brake lamp - Avant, removing and installing
      • License Plate Lamp
        • License plate lamp, removing and installing
      • Steering Column Switch Module
        • General information
        • On Board Diagnostic (OBD), function
        • Steering column switch module, assembly
        • Steering column switch module, removing and installing
          • Removing
          • Installing
        • Spiral spring, removing and installing
        • Steering Angle Sensor G85 , removing and installing
        • Steering Column Electronics Systems Control Module J527 , removing and installing
        • Steering Column Electronics Systems Control Module J527 , front multi-pin connector assignments
        • Steering Column Electronics Systems Control Module J527 , rear multi-pin connector assignments
        • Turn Signal Switch E2 , removing and installing
        • Cruise Control Switch E45 , removing and installing
        • Windshield Wiper/Washer Switch E22 , removing and installing
      • Ignition/Starter Switch and Lock Cylinder
        • Lock cylinder, removing and installing
        • Ignition/starter switch, removing and installing
        • Ignition/starter switch, multi-pin connector assignments
      • Parking Aid System
        • General information
        • On Board Diagnostic (OBD), functions
        • Parking aid system, component overview
        • Parking Aid Control Module J446 , removing and installing
        • Rear Parking Aid Warning Buzzer H15 - Sedan, removing and installing
        • Rear Parking Aid Warning Buzzer H15 - Avant, removing and installing
        • Rear parking aid sensors, removing and installing
      • Automatic Headlamp Range Control
        • General information
        • On Board Diagnostic (OBD), function
        • Automatic headlamp range control, component overview
        • Headlamp Range Control Module J431 , removing and installing
    • 96 Lights, Switches - Interior, Anti-theft
      • Switches - Interior
        • Light Switch E1 , removing and installing
        • Ambient Illumination Deactivation Switch E491 , removing and installing
        • Daytime running lamps (DRL) switch, removing and installing
        • Emergency Flasher Button E229 , removing and installing
        • Switches in center console, removing and installing
        • Front heated seat regulating switches, removing and installing
        • Rear heated seat regulating switches, removing and installing
        • Start System Button E378 - Audi RS4, removing and installing
        • Glove Compartment Lamp Switch E26 , removing and installing
        • Mirror selector/adjustment switch, removing and installing
        • Drivers power window switch panel - 2 switches, removing and installing
        • Drivers power window switch panel - four switches, removing and installing
        • Front passengers power window switch panel, removing and installing
        • Rear door power window switches, removing and installing
        • Sunroof Switch E8 , removing and installing
        • Door contact switches, removing and installing
        • Drivers Interior Locking Switch E150 , removing and installing
        • Rear/Center Central Locking Switch E286 , removing and installing
        • Remote Fuel Tank Flap Switch E204 and Rear Lid Remote Control Lock Switch E233 , removing and installing
        • Drivers Seat Memory Program Control E97 , removing and installing
        • Trunk Lock/Alarm/Central Locking Switch F124 - Sedan through 10.04, removing and installing
        • Trunk Lock/Alarm/Central Locking Switch F124 - Avant through 10.04, removing and installing
        • Trunk Lock/Alarm/Central Locking Switch F124 - from 11.04, removing and installing
        • 12 V Socket U5 - in luggage compartment through 10.04, removing and installing
        • 12 V Socket U5 - in luggage compartment from 11.04, removing and installing
      • Anti-Theft Immobilizer
        • General information
          • Function
        • On Board Diagnostic (OBD), function
        • Malfunctioning transponder and/or lost keys
        • Reader coil, replacing
        • Lock set or instrument cluster, replacing.
      • Alarm Horn H12
        • Alarm Horn H12 , removing and installing
      • Lights - Interior
        • Make-up Mirror Illumination L31 , removing and installing
        • Front interior lamp module, removing and installing
        • Ambient lighting LEDs, removing and installing
        • Front Interior Light W1 - bulbs, replacing
        • Front Passengers Map/Reading Light W13 , Drivers Map/Reading Light W19 - bulbs, replacing
        • Front Passengers Airbag Disabled Indicator Lamp K145 - from 11.04, removing and installing
        • Rear interior lamp module, removing and installing
        • Left Rear Reading Light W11 , Right Rear Reading Light W12 - bulbs, replacing
        • Glove Compartment Light W6 , removing and installing
        • Front ashtray light, removing and installing
        • Rear ashtray light, 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
        • Door entry warning lights, removing and installing
        • Left Footwell Light W9 , Right Footwell Light W10 , removing and installing
        • Left Rear Footwell Light W45 , Right Rear Footwell Light W46 , removing and installing
        • Left Luggage Compartment Light W18 , Right Luggage Compartment Light W35 - Sedan, removing and installing
        • Luggage Compartment Light W3 - Avant, removing and installing
        • Luggage Compartment Light W3 - bulb, Avant, replacing
        • Rear Lid Courtesy Lamp W51 - Avant, removing and installing
      • Horn
        • Signal Horn/Dual Tone Horn H1 - through 10.04, removing and installing
        • Signal Horn/Dual Tone Horn H1 - from 11.04, removing and installing
      • Heated Steering Wheel
        • Heated steering wheel, servicing
      • Garage Door Opener - HomeLink (R)
        • Garage Door Opener Control Head E284 , removing and installing
        • Garage Door Opener Control Module J530 - through 10.04, removing and installing
        • Garage Door Opener Control Module J530 - from 11.04, removing and installing
    • 97 Wiring
      • Relay and fuse panels
        • General information
        • Fuse panel, removing and installing
        • Vehicle Electrical System Control Module J519 , removing and installing
        • 9-position relay carrier, removing and installing
        • 3-position relay carrier, removing and installing
        • 4-position relay carrier, removing and installing
        • Left connector station, removing and installing
        • Comfort System Central Control Module J393 , removing and installing
        • Right connector station, removing and installing
        • Main fuse panel in left rear luggage compartment - Audi RS4, removing and installing
        • Electronics box in plenum chamber, removing and installing
        • Electronics box fan in plenum chamber, removing and installing
        • 4-way relay carrier in electronics box in plenum chamber, removing and installing
        • Connector junction, electronics box in plenum chamber, removing and installing
        • Main fuse panel - vehicles with battery in engine compartment, removing and installing
        • Positive terminal in plenum chamber - Audi RS4, removing and installing
      • Wiring Harness and Connectors, servicing
        • General information
        • Safety precautions for repairing wiring harnesses and connectors
        • Notes on repairs on wiring harnesses and connectors
        • Notes on repairs to airbag and safety belt tensioner wiring harness
        • Notes for repairs on CAN-Bus wires
        • Repairing a wire with cross-section 0.22 mm 2 or 0.35 mm 2
        • Antenna cables, replacing
        • Antenna connector cable, replacing
  • FIGURES
    • Fig. 1: Warning Symbols On Batteries
    • Fig. 2: Identifying Battery Terminal
    • Fig. 3: Identifying Torque Wrench V.A.G. 1331
    • Fig. 4: Pushing Cover Over Battery Toward Right And Removing It Upward
    • Fig. 5: Locating Battery Ground Strap
    • Fig. 6: Identifying Torque Wrench V.A.G. 1331
    • Fig. 7: Disconnecting Battery Ground (GND) Strap
    • Fig. 8: Identifying Torque Wrench V.A.G. 1331
    • Fig. 9: Identifying Plenum Chamber Cover & Removing Rubber Seal
    • Fig. 10: Locating Battery Terminals On Battery
    • Fig. 11: Identifying Angle Piece Of Central Gas Venting System
    • Fig. 12: Battery Foot Strip Cut-Out
    • Fig. 13: Center Cut-Out In Battery Foot Strip Aligned With Threaded Hole In Battery Carrier
    • Fig. 14: Locating Battery Terminals On Battery
    • Fig. 15: Identifying Torque Wrench V.A.G. 1331
    • Fig. 16: Removing/Install Battery From Battery Console Retaining Strip
    • Fig. 17: Identifying Battery Clamping Strip And Battery Holder Mount
    • Fig. 18: Removing/Install Battery From Battery Console Retaining Strip
    • Fig. 19: Locating Magic Eye
    • Fig. 20: Identifying Multimeter V.A.G 1526B
    • Fig. 21: Locating Magic Eye
    • Fig. 22: Battery fill bottle VAS 5045
    • Fig. 23: Identifying Commercially Available Hydrometer
    • Fig. 24: VAS 5045 Battery Filling Bottle
    • Fig. 25: Identifying Commercially Available Hydrometer
    • Fig. 26: Identifying Commercially Available Hydrometer
    • Fig. 27: Hydrometer Specific Gravity Reading
    • Fig. 28: Battery VAS Tester
    • Fig. 29: Pushing Cover Over Battery Toward Right And Removing It Upward
    • Fig. 30: Identifying Battery Terminals, Nuts, And Terminal Clamps
    • Fig. 31: Identifying Battery Charger Connected To Battery
    • Fig. 32: Identifying Drip Tray V.A.G 1306
    • Fig. 33: Identifying Hose Clip Pliers Vag 1921
    • Fig. 34: Identifying Torque Wrench V.A.G. 1331
    • Fig. 35: Identifying Quick-Release Fasteners And Noise Insulation
    • Fig. 36: Locating Retaining Clip And Engine Coolant Temperature (ECT) Sensor
    • Fig. 37: Identifying Top Coolant Hose At Coolant Pipe
    • Fig. 38: Identifying Coolant Fan Control Module
    • Fig. 39: Identifying Ribbed Belt Tensioner
    • Fig. 40: Identifying Electrical Harness Connector
    • Fig. 41: Identifying Upper And Lower Bolts
    • Fig. 42: Generator Electrical Connector And Terminal B+
    • Fig. 43: Ribbed Belt, Seated Correctly
    • Fig. 44: Locking Tool T40098
    • Fig. 45: Identifying Torque Wrench V.A.G. 1331
    • Fig. 46: Removing Engine Cover
    • Fig. 47: Pivoting Belt Tensioner For Ribbed Belt To Relieve Tension On Ribbed Belt
    • Fig. 48: Separating Electrical Connector From Charge Air Pressure Sensor G31 & Removing Left Charge Air Hose
    • Fig. 49: Identifying Upper And Lower Bolts
    • Fig. 50: Generator Electrical Connector And Terminal B+
    • Fig. 51: Ribbed Belt, Seated Correctly
    • Fig. 52: Ribbed Belt Installation Tool 3299 With Tensioner Claw 3299/1
    • Fig. 53: Identifying Torque Wrench V.A.G. 1331
    • Fig. 54: Removing Front Engine Cover
    • Fig. 55: Swinging Ribbed Belt Tensioner To Release Tension On Ribbed Belt
    • Fig. 56: Identifying Quick-Release Fasteners And Noise Insulation
    • Fig. 57: Starter Wiring Bracket Cable Ties
    • Fig. 58: Unscrewing Nut For Clamp For ATF Lines
    • Fig. 59: Identifying Bolts And Generator
    • Fig. 60: Identifying Belt Path
    • Fig. 61: Identifying Torque Wrench V.A.G. 1331
    • Fig. 62: Identifying Front Engine Cover
    • Fig. 63: Identifying Bolts & Air Duct
    • Fig. 64: Identifying Quick-Release Fasteners And Noise Insulation
    • Fig. 65: Pivoting Tensioning Device To Relieve Tension On Ribbed Belt
    • Fig. 66: Identifying Bolts, Electrical Connections, And Generator
    • Fig. 67: Placing Ribbed Belt Over Belt Pulley
    • Fig. 68: Identifying Drip Tray V.A.G 1306
    • Fig. 69: Identifying Old Oil Collecting And Extracting Device V.A.G 1782
    • Fig. 70: Identifying Hose Clip Pliers Vag 1921
    • Fig. 71: Identifying Torque Wrench V.A.G. 1331
    • Fig. 72: Identifying Torque Wrench V.A.G. 1332
    • Fig. 73: Identifying Quick-Release Fasteners And Noise Insulation
    • Fig. 74: Removing Right Air Guide In Front Of Auxiliary Cooler
    • Fig. 75: Removing Left Air Guide In Front Of Auxiliary Cooler
    • Fig. 76: Removing Drain Plug On Coolant Thermostat Housing
    • Fig. 77: Disconnecting Lower Coolant Hose From Radiator
    • Fig. 78: Disconnecting Hydraulic Lines To Cooling Coil At Left Rear Of Bumper
    • Fig. 79: Removing Cover In Engine Compartment (Right Side)
    • Fig. 80: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 81: Disconnecting Top Coolant Hose From Radiator
    • Fig. 82: Removing Cover In Engine Compartment (Left Side)
    • Fig. 83: Removing Electrical Harness Connectors And From Bracket
    • Fig. 84: Disconnecting Electrical Harness Connector For Headlights At Both Sides Of Vehicle
    • Fig. 85: Disconnecting Electrical Harness Connector For Left/Right Airbag Sensors On Lock Carrier
    • Fig. 86: Disconnecting Electrical Harness Connector For Right Fan
    • Fig. 87: Removing Left/Right Air Guides At Radiator
    • Fig. 88: Removing Power Steering Hydraulic Oil Cooling Pipe
    • Fig. 89: Removing Coolant Fan Control (FC) Control Module J293 From Radiator
    • Fig. 90: Disconnecting Electrical Harness Connector At High Pressure Sensor G65
    • Fig. 91: Removing Bolts At Left/Right Side Of Bumper
    • Fig. 92: Removing Bolts At Impact Absorbers At Left/Right
    • Fig. 93: Removing Hose Clamps And Disconnecting Coolant Hose
    • Fig. 94: Loosening Tensioning Bolt And Ribbed Belt
    • Fig. 95: Removing Tensioning Roller
    • Fig. 96: Removing Generator Bolts
    • Fig. 97: Disconnecting Coolant Hose On Generator, Electrical Connector & Removing Electrical Wire On Generator
    • Fig. 98: Placing Ribbed Belt Over Belt Pulley In Sequence
    • Fig. 99: Positioning Torque Wrench On Belt Tensioner Hex Bolt
    • Fig. 100: Identifying Old Oil Collecting And Extracting Device V.A.G 1782
    • Fig. 101: Drip Tray For VAS 6100, VAS 6208
    • Fig. 102: Identifying Torque Wrench V.A.G. 1331
    • Fig. 103: Identifying Torque Wrench V.A.G. 1332
    • Fig. 104: Removing Quick-Release Fasteners, Screws And Noise Insulation
    • Fig. 105: Removing Right Air Guide In Front Of Auxiliary Cooler
    • Fig. 106: Removing Bolts On Oil Cooler Lines At Upper Part Of Oil Pan
    • Fig. 107: Removing Left Air Guide In Front Of Auxiliary Cooler
    • Fig. 108: Removing Bolt On Auxiliary Cooler Upper Bracket, At Left Of Lock Carrier
    • Fig. 109: Removing Drain Plug On Coolant Thermostat Housing
    • Fig. 110: Removing Drain Plug On Front Coolant Pipe
    • Fig. 111: Removing Coolant Hose Downward From Cooler
    • Fig. 112: Disconnecting Hydraulic Lines To Cooling Coil At Left Rear Of Bumper
    • Fig. 113: Identifying Bolts & Air Duct
    • Fig. 114: Disconnecting Top Coolant Hose From Radiator
    • Fig. 115: Removing Cover In Engine Compartment (Left Side)
    • Fig. 116: Removing Electrical Harness Connectors From Bracket
    • Fig. 117: Disconnecting Electrical Harness Connector For Headlights At Both Sides Of Vehicle
    • Fig. 118: Disconnecting Electrical Harness Connector For Left/Right Airbag Sensors On Lock Carrier
    • Fig. 119: Disconnecting Electrical Harness Connector For Right Fan
    • Fig. 120: Removing Bolts On Left/Right Air Guides At Cooler
    • Fig. 121: Disconnecting Electrical Harness Connector At High Pressure Sensor G65
    • Fig. 122: Removing Right Coolant Hose
    • Fig. 123: Removing Bolts At Left/Right Side Of Bumper
    • Fig. 124: Removing Bolts At Impact Absorbers At Left/Right
    • Fig. 125: Releasing Ribbed Belt Tension
    • Fig. 126: Removing Bolts & Ribbed Belt Tensioner At Upper Part Of Oil Pan
    • Fig. 127: Removing Bolts And Coolant Hose From Coolant Pipe Bracket And Generator
    • Fig. 128: Identifying Coolant Hose, Electrical Connector, Bolt & Heat Shield
    • Fig. 129: Placing Ribbed Belt Over Belt Pulley In Sequence
    • Fig. 130: Identifying Torque Wrench V.A.G. 1331
    • Fig. 131: Identifying Torque Wrench V.A.G. 1332
    • Fig. 132: Identifying Quick-Release Fasteners And Noise Insulation
    • Fig. 133: Identifying Line, Connector Terminal, Clamp, And Insulator
    • Fig. 134: Identifying Bolts And Starter
    • Fig. 135: Identifying Torque Wrench V.A.G. 1331
    • Fig. 136: Identifying Torque Wrench V.A.G. 1332
    • Fig. 137: Identifying Quick-Release Fasteners And Noise Insulation
    • Fig. 138: Removing Left/Right Heat Shields For Drive Axles
    • Fig. 139: Identifying Bolts And Starter
    • Fig. 140: Identifying Starter, Electrical Connector & Nuts
    • Fig. 141: Identifying Torque Wrench V.A.G. 1331
    • Fig. 142: Identifying Torque Wrench V.A.G. 1332
    • Fig. 143: Identifying Heat Shield For Right Drive Shaft
    • Fig. 144: Identifying Cable For Terminals, Heat Shield From Solenoid Switch, And Starter
    • Fig. 145: Identifying Torque Wrench V.A.G. 1331
    • Fig. 146: Identifying Torque Wrench V.A.G. 1332
    • Fig. 147: Identifying Quick-Release Fasteners And Noise Insulation
    • Fig. 148: Drive Axle Heat Shield
    • Fig. 149: Identifying Bolts, Starter Solenoid Terminal, And Connector
    • Fig. 150: Identifying 10-222A Engine Support Bridge With 10-222A/8 Bracket For Engine
    • Fig. 151: Identifying Special Tools - Shackle 10 - 222 A/12
    • Fig. 152: Identifying Torque Wrench V.A.G. 1331
    • Fig. 153: Identifying Torque Wrench V.A.G. 1332
    • Fig. 154: Removing/Installing Rear Engine Cover
    • Fig. 155: Securing Shackle 10-222 A/12 To Right Rear Engine Lifting Eyelet
    • Fig. 156: Engaging Shackle 10-222 A/12 On Spindle Of Engine Support Bridge 10-222 A
    • Fig. 157: Removing Quick-Release Fasteners, Screws And Noise Insulation
    • Fig. 158: Removing Nuts For Left/Right Stabilizer Mounts
    • Fig. 159: Removing Wiring Harness Bracket At Right Engine Mount Plate
    • Fig. 160: Identifying Nuts, Bolts, And Right Side Engine Mount Carrier
    • Fig. 161: Removing Refrigerant Line On Bracket
    • Fig. 162: Disconnecting Electrical Harness Connector At Right Engine Mount
    • Fig. 163: Drive Axle Heat Shield
    • Fig. 164: Identifying Ground (GND) Wire, Wires, Nuts, Bolts & Starter
    • Fig. 165: Removing Left/Right Heat Shields For Drive Axles
    • Fig. 166: Identifying Ground (GND) Wire, Starter Electrical Wires, Bolts & Starter
    • Fig. 167: Identifying 10-222A Engine Support Bridge With 10-222A/8 Bracket For Engine
    • Fig. 168: Insert Pad For Front Fender T40045
    • Fig. 169: Identifying Special Tools - Shackle 10 - 222 A/12
    • Fig. 170: Identifying Torque Wrench V.A.G. 1331
    • Fig. 171: Identifying Torque Wrench V.A.G. 1332
    • Fig. 172: Pulling Rear Engine Cover Off
    • Fig. 173: Removing Cover In Engine Compartment (Left Side)
    • Fig. 174: Identifying Bolts & Air Duct
    • Fig. 175: Inserting Insert Pad For Front Fender T40045 On Both Sides Between Fender Mounting Flange And Body Panel Underneath
    • Fig. 176: Locating Engine Support Spindles At Rear Of Crossbar
    • Fig. 177: Removing Quick-Release Fasteners, Screws And Noise Insulation
    • Fig. 178: Removing Nuts For Left/Right Stabilizer Mounts
    • Fig. 179: Removing Wiring Harness Bracket At Right Engine Mount Plate
    • Fig. 180: Identifying Nuts, Bolts, And Right Side Engine Mount Carrier
    • Fig. 181: Disconnecting Electrical Harness Connector At Right Engine Mount
    • Fig. 182: Identifying Engine Mount Nut
    • Fig. 183: Removing Left/Right Heat Shields For Drive Axles
    • Fig. 184: Identifying Screws, Nuts, And Starter Heat Shield
    • Fig. 185: Identifying Electrical Connection, Locking Mechanism, Nut, Ground Wire, And Cable Ties
    • Fig. 186: Identifying Special Hook 3370
    • Fig. 187: Pulling Off Bottom Cover Towards Rear
    • Fig. 188: Locating Screws
    • Fig. 189: Pulling Off Left Instrument Panel Cover Using Special Hook 3370
    • Fig. 190: Reaching Through Opening Above Fuse Panel And Pushing Out Instrument Cluster
    • Fig. 191: Identifying Securing Bracket Of Connectors
    • Fig. 192: Instrument Cluster, Rear View
    • Fig. 193: Identifying Multi-Pin Connector 32-Pin, Blue
    • Fig. 194: Identifying Green 32-Pin Multi-Pin Connector
    • Fig. 195: Unbolting Cover
    • Fig. 196: Identifying Electrical 4-pin Harness Connector
    • Fig. 197: Identifying Terminal Assignment Of The 4-Pin Connector On Fuel Gauge Sender
    • Fig. 198: Removing Cover Bolts For Locking Flange
    • Fig. 199: Identifying Electrical 4-pin Harness Connector
    • Fig. 200: Identifying Terminal Assignment Of The 4-Pin Connector On Fuel Gauge Sender
    • Fig. 201: Removing Cover Bolts For Locking Flange
    • Fig. 202: Disconnecting Electrical Harness Connector At Left Locking Flange
    • Fig. 203: Identifying Terminal Assignment Of The 4-Pin Connector On Fuel Gauge Sender
    • Fig. 204: Removing Engine Cover
    • Fig. 205: Disconnecting Connector At Coolant Temperature Sensor G2/G62
    • Fig. 206: Coolant Temperature Sensor Terminals
    • Fig. 207: Disconnecting Electrical Harness Connector From Engine Coolant Temperature (ECT) Sensor G62
    • Fig. 208: Identifying 2-Pin Electrical Harness Connector & Terminals
    • Fig. 209: Removing Rear Engine Cover
    • Fig. 210: Identifying Holding Plate, Intake Air Hose, Hose & Air Duct
    • Fig. 211: Removing Bolt And Disconnect Air Duct At Throttle Valve Control Module
    • Fig. 212: Disconnecting Electrical Harness Connector At Engine Coolant Temperature (ECT) Sensor -G2-/-G62-
    • Fig. 213: Coolant Temperature Sensor Terminals
    • Fig. 214: Identifying Front Engine Cover
    • Fig. 215: Disconnecting Electrical Connector, Retaining Clip And Engine Coolant Temperature (ECT) Sensor G62
    • Fig. 216: Identifying 2-Pin Electrical Harness Connector & Terminals
    • Fig. 217: Removing/Installing Rear Engine Cover
    • Fig. 218: Identifying Electrical Connection At Sensor
    • Fig. 219: Coolant Temperature Sensor Terminals
    • Fig. 220: Identifying 2-Pin Electrical Harness Connector & Terminals
    • Fig. 221: Removing Quick-Release Fasteners, Screws And Noise Insulation
    • Fig. 222: Disconnecting Electrical Connector On Engine Coolant Temperature (ECT) Sensor G62
    • Fig. 223: Identifying 2-Pin Electrical Harness Connector & Terminals
    • Fig. 224: Identifying Electrical Connection, Receiver, And Bolts
    • Fig. 225: Identifying Pry Lever 80-200
    • Fig. 226: Identifying Torque Wrench V.A.G. 1331
    • Fig. 227: Identifying Plenum Chamber Cover & Removing Rubber Seal
    • Fig. 228: Removing Securing Clips And Cowl
    • Fig. 229: Removing Screws And Cover From E-Box In Plenum Chamber
    • Fig. 230: Identifying Wiper Linkage And Wiper Frame
    • Fig. 231: Identifying Wiper Motor And Wiper Frame
    • Fig. 232: Identifying Wiper Motor And Wiper Frame
    • Fig. 233: Pressing Wiper Linkage In To Stop And Tightening Bolts In Sequence
    • Fig. 234: Identifying Crank, Wiper Frame, And Nut
    • Fig. 235: Checking Windshield Wiper Blade Tips Position
    • Fig. 236: Identifying Linkage, Wiper Blade, And Wiper Arm
    • Fig. 237: Identifying Wiper Blade And Arm
    • Fig. 238: Windshield Wiper Arm - Through 10.04, Assembly
    • Fig. 239: Identifying Linkage, Wiper Blade, And Wiper Arm
    • Fig. 240: Identifying Release Button, And Wiper Arm
    • Fig. 241: Pressing Sides Of Wiper Mounting Inwards And Removing Wiper Mounting
    • Fig. 242: Identifying Retaining Lugs, And Wiper Arm
    • Fig. 243: Identifying Retaining Clip, Wiper Arm, And Wiper Blade
    • Fig. 244: Identifying Wiper Blade And Retaining Clip
    • Fig. 245: Removing Cover In Engine Compartment (Left Side)
    • Fig. 246: Identifying Nut, Bolt, Overflow Hose, And Reservoir
    • Fig. 247: Removing Bottom Section Of Reservoir
    • Fig. 248: Identifying Electrical Connections, Hose Connector, And Fluid Pipe
    • Fig. 249: Identifying Bolt Tightening Sequence
    • Fig. 250: Removing Cover In Engine Compartment (Left Side)
    • Fig. 251: Identifying Nut, Bolt, Overflow Hose, And Reservoir
    • Fig. 252: Identifying Screws, Crossbar, Electrical Connection, Washer Fluid Line, And Washer Fluid Reservoir
    • Fig. 253: Identifying Hose, Clamp, And Electrical Connections
    • Fig. 254: Identifying Screw Tightening Sequence
    • Fig. 255: Unclipping Base Of Spray Jet From Bottom Of Hood
    • Fig. 256: Identifying Hose, And Electrical Connection
    • Fig. 257: Locating Oval Opening For Spray Individual Nozzles
    • Fig. 258: Identifying Adjustment Tool T10127 Equipped With Needle 3125/ 5 A
    • Fig. 259: Identifying Windshield Dimensions
    • Fig. 260: Rear Window Wiper/Washer, Assembly
    • Fig. 261: Identifying Wiper Arm, Spray Jet, And Cap
    • Fig. 262: Identifying Adjustment Tool T10127 Equipped With Needle 3125/ 5 A
    • Fig. 263: Identifying Windshield Wiper Dimensions
    • Fig. 264: Identifying Cover
    • Fig. 265: Identifying Spray Jets And Hex Head Nuts
    • Fig. 266: Identifying Dimensions For Wiper Blade On Rear Window
    • Fig. 267: Identifying Retaining Clips, Wiper Blade, And Wiper Arm
    • Fig. 268: Rear Window Wiper Motor, Assembly
    • Fig. 269: Identifying Electrical Connection, Washer Fluid Hose, And Nuts
    • Fig. 270: Pulling Up On Spray Jet Covers At Bumper And Carefully Disengaging Mounts
    • Fig. 271: Identifying Washer Fluid Hose, And Spray Jet Bolts
    • Fig. 272: Pulling Cover Of Spray Jet Upwards Away From Bumper Cover And Carefully Disengaging Retainers
    • Fig. 273: Identifying Hose, Spray Jet, And Screws
    • Fig. 274: Halogen Headlamps, Assembly
    • Fig. 275: Removing Cover In Engine Compartment (Left Side)
    • Fig. 276: Removing Cover In Engine Compartment (Right Side)
    • Fig. 277: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 278: Locating Screws And Electrical Connection
    • Fig. 279: Locating Vent Elements On Underside Of Headlamp
    • Fig. 280: Locating Screws And Electrical Connection
    • Fig. 281: Removing Cover In Engine Compartment (Right Side)
    • Fig. 282: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 283: Disconnect Wires/Unplug Connectors
    • Fig. 284: Removing Cover In Engine Compartment (Right Side)
    • Fig. 285: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 286: Identifying Lines And Air Cleaner Housing
    • Fig. 287: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp Housing
    • Fig. 288: Identifying Electrical Connection, Retaining Clip, And Bulb
    • Fig. 289: Removing Cover In Engine Compartment (Left Side)
    • Fig. 290: Disconnecting Electrical Connections From Retainer And Removing Retainer
    • Fig. 291: Releasing Retaining Clip And Detaching Housing Cover
    • Fig. 292: Disconnecting Electrical Connection, Releasing Retaining Clip, And Removing Bulb
    • Fig. 293: Identifying Bulb Holder
    • Fig. 294: Exploded View Of Headlamp Components
    • Fig. 295: Halogen Headlamps, Assembly
    • Fig. 296: Locating Screws
    • Fig. 297: Checking Adjusting Nut Of Adjuster For Freedom Of Movement
    • Fig. 298: Locating Screws
    • Fig. 299: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 300: Locating Retaining Tab
    • Fig. 301: Identifying Bulb, Spring Clips, And Electrical Connection
    • Fig. 302: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 303: Releasing Retaining Clip And Detaching Housing Cover
    • Fig. 304: Identifying Bulb, Spring Clips, And Electrical Connection
    • Fig. 305: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 306: Releasing Retaining Clip And Detaching Housing Cover
    • Fig. 307: Identifying Bulb, Spring Clips, And Electrical Connection
    • Fig. 308: Pulling Bulb Holder From Housing
    • Fig. 309: Loosening Left/Right Wheelhousing Liners In Front Area
    • Fig. 310: Turning Bulb Holder Counter-Clockwise And Pulling From Housing
    • Fig. 311: Locating Lugs, And Screws For Headlamp Housing
    • Fig. 312: Headlamps With High Intensity Gas Discharge (Hid) Lamps, Assembly
    • Fig. 313: Removing Cover In Engine Compartment (Left Side)
    • Fig. 314: Removing Cover In Engine Compartment (Right Side)
    • Fig. 315: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 316: Locating Screws And Electrical Connection
    • Fig. 317: Locating Vent Elements On Underside Of Headlamp
    • Fig. 318: Locating Screws And Electrical Connection
    • Fig. 319: Removing Cover In Engine Compartment (Right Side)
    • Fig. 320: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 321: Disconnect Wires/Unplug Connectors
    • Fig. 322: Removing Cover In Engine Compartment (Right Side)
    • Fig. 323: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 324: Identifying Lines And Air Cleaner Housing
    • Fig. 325: Removing Cover In Engine Compartment (Right Side)
    • Fig. 326: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 327: Identifying Electrical Harness Connectors, Secondary Air Injection (AIR) Pump Hose, Air Guide Hose & Mass Air Flow (MAF) Sensor
    • Fig. 328: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp Housing
    • Fig. 329: Locating Connector And Retaining Clip
    • Fig. 330: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp Housing
    • Fig. 331: Identifying Retaining Clip, HID Headlamp Bulb, And Electrical Connection
    • Fig. 332: Removing Cover In Engine Compartment (Left Side)
    • Fig. 333: Disconnecting Electrical Connections From Retainer And Removing Retainer
    • Fig. 334: Releasing Retaining Clip And Detaching Housing Cover
    • Fig. 335: Identifying Electrical Connection, Retaining Clip, And Bulb
    • Fig. 336: Identifying Bulb Holder
    • Fig. 337: Removing Cover In Engine Compartment (Left Side)
    • Fig. 338: Disconnecting Electrical Connections From Retainer And Removing Retainer
    • Fig. 339: Releasing Retaining Clip And Detaching Housing Cover
    • Fig. 340: Releasing Headlamp Range Control Motor
    • Fig. 341: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp Housing
    • Fig. 342: Locating Connector And Retaining Clip
    • Fig. 343: Identifying Control Module Screws
    • Fig. 344: Releasing Retaining Clip And Detaching Housing Cover For Low Beam From Headlamp Housing
    • Fig. 345: Identifying Retaining Clip, HID Headlamp Bulb, And Electrical Connection
    • Fig. 346: Identifying Control Module Screws
    • Fig. 347: Exploded View Of Headlamp Components
    • Fig. 348: Headlamps With High Intensity Gas Discharge (HID) "Bi-Xenon" Lamps, Assembly
    • Fig. 349: Removing Cover In Engine Compartment (Left Side)
    • Fig. 350: Removing Cover In Engine Compartment (Right Side)
    • Fig. 351: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 352: Locating Screws And Electrical Connection
    • Fig. 353: Checking Whether Vent Element Has Been Inserted On Underside Of Headlamp
    • Fig. 354: Locating Screws And Electrical Connection
    • Fig. 355: Removing Screws And Retaining Clip
    • Fig. 356: Identifying Electrical Connection, Retaining Clip, And HID Headlamp Bulb
    • Fig. 357: Removing Screws And Retaining Clip
    • Fig. 358: Turning Bulb Clockwise And Removing From Housing/Disconnecting Electrical Connection
    • Fig. 359: Identifying Bulb Holder
    • Fig. 360: Removing Screws And Retaining Clip
    • Fig. 361: Locating Screw And Cover Cap
    • Fig. 362: Identifying Adjuster Rod, Electrical Connection, Control Motor, Swivel Ball Head, And Mounting
    • Fig. 363: Identifying Screws And Control Module
    • Fig. 364: Identifying Electrical Connections
    • Fig. 365: Removing Screws And Retaining Clip
    • Fig. 366: Identifying Screws And Control Module
    • Fig. 367: Identifying Electrical Connections
    • Fig. 368: Identifying Electrical Connection, Wiring, Adapter Cable, Retainer, And Housing Cover
    • Fig. 369: Exploded View Of Headlamp Components
    • Fig. 370: Headlamps With High Intensity Gas Discharge (HID) "Bi-Xenon" Lamps, Assembly
    • Fig. 371: Locating Screws
    • Fig. 372: Checking Adjusting Nut Of Adjuster For Freedom Of Movement
    • Fig. 373: Locating Screws
    • Fig. 374: Identifying Nut, Bolts, Breather Hose, And Washer Fluid Reservoir
    • Fig. 375: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 376: Disconnect Wires/Unplug Connectors
    • Fig. 377: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 378: Identifying Intake, Mass Air Flow (MAF) Sensor G70 Electrical Harness Connector & Air Filter Housing
    • Fig. 379: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 380: Identifying Lines And Air Cleaner Housing
    • Fig. 381: Identifying Bolts & Air Duct
    • Fig. 382: Locating Fastener
    • Fig. 383: Removing Cover In Engine Compartment (Right Side)
    • Fig. 384: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
    • Fig. 385: Identifying Electrical Harness Connectors, Secondary Air Injection (AIR) Pump Hose, Air Guide Hose & Mass Air Flow (MAF) Sensor
    • Fig. 386: Pulling Rear Engine Cover Off
    • Fig. 387: Identifying Bolts & Air Duct
    • Fig. 388: Identifying Mass Air Flow (MAF) Sensor G70 Electrical Harness Connector, Secondary Air Injection (Air) Pump Hose, Vacuum Lines & Air Guide Hose
    • Fig. 389: Removing Screws And Cover For Low Beam From Headlamp Housing
    • Fig. 390: Identifying Retainers, Electrical Connection, Retaining Clips, And HID Headlamp Bulb
    • Fig. 391: Removing Bolts & Air Duct
    • Fig. 392: Releasing Retaining Tab And Detaching Housing Cover For Side Lights From Headlamp Housing
    • Fig. 393: Turning Bulb Holder Counter-Clockwise And Removing From Headlamp Housing
    • Fig. 394: Removing Bolts & Air Duct
    • Fig. 395: Releasing Retaining Tab And Detaching Housing Cover For Side Lights From Headlamp Housing
    • Fig. 396: Releasing Two Retainer Tabs And Pulling Bulb Holder Out Of Housing
    • Fig. 397: Loosening Left/Right Wheelhousing Liners In Front Area
    • Fig. 398: Turning Bulb Holder Counter-Clockwise And Pulling From Housing
    • Fig. 399: Identifying Screws, And Control Module
    • Fig. 400: Disconnecting Adapter Cable For HID Headlamp Bulb At Control Module
    • Fig. 401: Locating Lugs, And Screws For Headlamp Housing
    • Fig. 402: Releasing Catches Using Screwdriver And Removing Air Intake Grille On Left/Right On Bottom Part Of Bumper
    • Fig. 403: Identifying Screw, Air Intake Grille, And Retaining Clip
    • Fig. 404: Identifying Screws For Fog Lamp Housing
    • Fig. 405: Disconnecting Electrical Connection At Bulb And Turning Bulb Counter-Clockwise To Remove From Housing
    • Fig. 406: Identifying Quick-Release Fasteners And Noise Insulation
    • Fig. 407: Identifying Screws, Electrical Connection, And Fog Lamp Housing
    • Fig. 408: Removing Air Intake Grille From Fog Lamp Housing
    • Fig. 409: Locating Screws For Housing
    • Fig. 410: Pulling Off Air Inlet Grille In Lower Section Of Bumper Cover
    • Fig. 411: Identifying Screws For Fog Lamp Housing
    • Fig. 412: Identifying Quick-Release Fasteners And Noise Insulation
    • Fig. 413: Disconnecting Electrical Connection And Turning Bulb Counter Clockwise To Remove
    • Fig. 414: Disconnecting Electrical Connection At Bulb And Turning Bulb Counter-Clockwise To Remove From Housing
    • Fig. 415: Disconnecting Electrical Connection At Bulb And Turning Bulb Counter-Clockwise To Remove From Housing
    • Fig. 416: Pushing Turn Signal Light/Housing Against Retainer
    • Fig. 417: Rear Lights - Sedan, Assembly
    • Fig. 418: Folding Pre-Punched Area Of Luggage Compartment And Removing Screw
    • Fig. 419: Pressing Retaining Clips Together To Take Bulb Carrier Out Of Rear Light
    • Fig. 420: Folding Pre-Punched Area Of Luggage Compartment And Removing Screw
    • Fig. 421: Rear Lights - Avant, Assembly
    • Fig. 422: Removing Plug From Luggage Compartment Lining
    • Fig. 423: Locating Screw
    • Fig. 424: Pressing Apart Retaining Clips And Taking Bulb Carrier Out Of Rear Light
    • Fig. 425: Locating Screw
    • Fig. 426: Rear Lights In Rear Fender - Sedan, Assembly
    • Fig. 427: Identifying Pre-punched Area Of Luggage Compartment Lining, Fastener, And Rear Light
    • Fig. 428: Pressing Together Retaining Tabs And Removing Bulb Carrier From Rear Light
    • Fig. 429: Rear Lights In Rear Lid - Sedan, Assembly
    • Fig. 430: Unclipping Plug From Luggage Compartment Trim Using A Small Screwdriver
    • Fig. 431: Identifying Nut, Retainer, And Inner Rear Light
    • Fig. 432: Unclipping Plug From Luggage Compartment Trim Using A Small Screwdriver
    • Fig. 433: Releasing Retaining Tab To Remove Bulb Holder
    • Fig. 434: Rear Lights In Rear Fender - Avant, Assembly
    • Fig. 435: Unclipping Plug From Luggage Compartment Trim Using A Screwdriver
    • Fig. 436: Identifying Screw And Rear Light
    • Fig. 437: Pressing Apart Retaining Tabs And Removing Bulb Carrier From Rear Light
    • Fig. 438: Rear Lights In Rear Lid - Avant, Assembly
    • Fig. 439: Unclipping Plug From Luggage Compartment Trim
    • Fig. 440: Identifying Nuts, Bulb Holder, And Rear Light
    • Fig. 441: Unclipping Plug From Luggage Compartment Trim
    • Fig. 442: Identifying Nut, Bulb Holder, And Retaining Tabs
    • Fig. 443: Identifying Electrical Connection, High-Mount Brake Lamp, And Retaining Clips
    • Fig. 444: Identifying Special Hook 3370
    • Fig. 445: Releasing Retaining Rail Of Spring Tabs Towards Right By Pressing Screwdriver Handle Left
    • Fig. 446: Identifying High-Mount Brake Lamp And Electrical Connection
    • Fig. 447: Identifying Lug, Spring Clip, Catches, Housing Guides, And Retaining Rail
    • Fig. 448: Identifying Electrical Connection, High-Mount Brake Lamp, And Retaining Clips
    • Fig. 449: Identifying Special Hook 3370
    • Fig. 450: Releasing Retaining Rail Of Spring Tabs Towards Right By Pressing Screwdriver Handle Left
    • Fig. 451: Identifying High-Mount Brake Lamp And Electrical Connection
    • Fig. 452: Identifying Lug, Spring Clip, Catches, Housing Guides, And Retaining Rail
    • Fig. 453: Identifying Bolt In Handle Recess
    • Fig. 454: Steering Column Switch Module (SCSM), Assembly Overview
    • Fig. 455: Torx Screwdriver T8 T 40056
    • Fig. 456: Identifying Ground Down Torx Screwdriver T8 T40056 Shoulder
    • Fig. 457: Identifying Screws, Hex Socket Head Bolt, Trim Cover, And Upper Steering Column Trim
    • Fig. 458: Identifying Screw And Electrical Connection
    • Fig. 459: Disengage Connector Lock To Release Connector
    • Fig. 460: Torx Screwdriver T8 T 40056
    • Fig. 461: Identifying Ground Down Torx Screwdriver T8 T40056 Shoulder
    • Fig. 462: Identifying Screws, Hex Socket Head Bolt, Trim Cover, And Upper Steering Column Trim
    • Fig. 463: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module
    • Fig. 464: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control Module J527
    • Fig. 465: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module
    • Fig. 466: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control Module J527
    • Fig. 467: Removing Screws, And Steering Column Electronics Systems Control Module J527 From Steering Column Switch Module
    • Fig. 468: Steering Column Electronics Systems Control Module J527 , Front Multi-Pin Connector Assignments
    • Fig. 469: Steering Column Electronic Systems Control Module (Rear) Assembly Overview
    • Fig. 470: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module
    • Fig. 471: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control Module J527
    • Fig. 472: Identifying Screws, Steering Column Electronics Systems Control Module, Windshield Wiper/Washer Switch, And Retaining Clip
    • Fig. 473: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module
    • Fig. 474: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control Module J527
    • Fig. 475: Identifying Screws, Steering Column Electronics Systems Control Module, And Cruise Control Switch
    • Fig. 476: Releasing Clip Fasteners To Remove Spiral Spring From Steering Column Switch Module
    • Fig. 477: Removing Steering Angle Sensor G85 From Steering Column Electronic Systems Control Module J527
    • Fig. 478: Identifying Screws And Windshield Wiper/Washer Switch
    • Fig. 479: Turn Ignition Key To "Ignition On" Position
    • Fig. 480: Aligning Recess In Trim
    • Fig. 481: Identifying Steel Wire In Hole, Lock Cylinder And Reader Coil Out Of Steering Lock Housing
    • Fig. 482: Identifying Steel Wire In Hole, Lock Cylinder And Reader Coil Out Of Steering Lock Housing
    • Fig. 483: Locating Screws , Ignition/Starter Switch And Steering Lock Housing
    • Fig. 484: Connection Assignment At Ignition/Starter Switch
    • Fig. 485: Parking Aid System, Component Overview
    • Fig. 486: Removing Screws And Base Mount
    • Fig. 487: Disconnecting Electrical Connections And Antenna Wiring At Rear Of Navigation Interface
    • Fig. 488: Removing Screws And Base Mount
    • Fig. 489: Identifying Electrical Connections, Screws, And Parking Aid Control Module
    • Fig. 490: Removing Warning Buzzer
    • Fig. 491: Removing Warning Buzzer
    • Fig. 492: Locating Parking Aid Sensors In Rear Bumper Cover
    • Fig. 493: Identifying Electrical Connection, Catches, And Sensor
    • Fig. 494: Automatic Headlamp Range Control, Component Overview
    • Fig. 495: Identifying Connector, Bolts, And Headlight Range Control Module
    • Fig. 496: Pressing Light Switch And Turning It Clockwise
    • Fig. 497: Pulling Off Light Switch From Switch Housing
    • Fig. 498: Pressing Headlamp Range Control Adjuster Out Of Switch Housing
    • Fig. 499: Pressing Headlamp Range Control Adjuster Out Of Switch Housing
    • Fig. 500: Identifying Special Hook 3370
    • Fig. 501: Removing Trim Using Hook For Front End 3370
    • Fig. 502: Levering Out Emergency Flasher Button E229 From Switch Mounting Using Flat Screwdriver
    • Fig. 503: Identifying Special Hook 3370
    • Fig. 504: Removing Trim Using Hook For Front End 3370
    • Fig. 505: Prying Switch Out Of Mounting Using Flat Screwdriver
    • Fig. 506: Switch Mount Remove/Install Components
    • Fig. 507: Identifying Cigarette Lighter Cover And Start System Button E378
    • Fig. 508: Identifying Special Hook 3370
    • Fig. 509: Removing Right Instrument Panel Cover
    • Fig. 510: Identifying Connector, Joint Pin, And Switch
    • Fig. 511: Identifying Electrical Connection, Mirror Adjustment Switch, And Fasteners
    • Fig. 512: Identifying Fasteners, Electrical Connection, And Window Switch
    • Fig. 513: Identifying Retaining Element, Retaining Hooks, Window Switches, And Electrical Connection
    • Fig. 514: Identifying Fasteners, Electrical Connection, And Window Switch
    • Fig. 515: Locating Screws
    • Fig. 516: Pulling Switch Mounting From Armrest
    • Fig. 517: Using Small Screwdriver To Carefully Release Fasteners
    • Fig. 518: Identifying Electrical Connection, Screws, And Sunroof Switch
    • Fig. 519: Identifying Connector, Central Locking Switch, And Driver Side Door Trim
    • Fig. 520: Pressing Retaining Hooks And Swiveling Switch Mounting To Rear
    • Fig. 521: Locating Switch For Interior Monitoring And Towing Protection Or Trunk Release Switch
    • Fig. 522: Identifying Catches, Interior Monitoring And Towing Protection, And Trunk Release Switch
    • Fig. 523: Identifying Trim Removal Wedge 3409
    • Fig. 524: Removing Switch Using Removal Wedge 3409
    • Fig. 525: Identifying Fasteners, Switch, And Mounting
    • Fig. 526: Identifying Catch, Retaining Bolts, And Contact Switch
    • Fig. 527: Identifying Rear Lid Contact And Rear Lid Lock
    • Fig. 528: Identifying Special Hook 3370
    • Fig. 529: Rear Power Outlet Remove/Install Components
    • Fig. 530: Identifying Nut And 12 V Socket
    • Fig. 531: Identifying Nut, Electrical Connection, Horn, Bolt, And Horn Bracket
    • Fig. 532: Prying Out Light At Recess Using Flat-Head Screwdriver
    • Fig. 533: Bulb Holder And Cover
    • Fig. 534: Identifying Special Hook 3370
    • Fig. 535: Removing Interior Lamp Module Trim Using Hook 3370
    • Fig. 536: Disconnection Microphone Electrical Connection
    • Fig. 537: Locating Screws
    • Fig. 538: Identifying Electrical Connections, Retaining Clips, And LED
    • Fig. 539: Identifying Special Hook 3370
    • Fig. 540: Removing Interior Lamp Lens Using Hook 3370
    • Fig. 541: Removing Bulb From Holder
    • Fig. 542: Identifying Special Hook 3370
    • Fig. 543: Removing Interior Lamp Module Trim Using Hook 3370
    • Fig. 544: Remove Bulb From Holder
    • Fig. 545: Identifying Special Hook 3370
    • Fig. 546: Removing Trim Using Hook For Front End 3370
    • Fig. 547: Prying Out Indicator Lamp From Switch Mounting
    • Fig. 548: Identifying Special Hook 3370
    • Fig. 549: Removing Rear Interior Lamp Module From Headliner Opening Using Hook 3370
    • Fig. 550: Interior/Reading Light Bulbs
    • Fig. 551: Identifying Retaining Tab, Glove Box Light, And Electrical Connection
    • Fig. 552: Identifying Ashtray Insert And Gear Lever Cover
    • Fig. 553: Locating Screws For Ashtray
    • Fig. 554: Releasing Retaining Clips And Swivel Light For Front Ashtray Out Of Retainer
    • Fig. 555: Identifying Bulb For Socket At Door Trim And Connector For Socket
    • Fig. 556: Identifying Door Safety/Entry Light And Components
    • Fig. 557: Prying Off Cover On Door Safety Light
    • Fig. 558: Identifying Retaining Tab, Footwell Light, And Electrical Connection
    • Fig. 559: Slide Footwell And Disengage
    • Fig. 560: Prying Off Cap
    • Fig. 561: Identifying Retaining Tab, Luggage Compartment Light, And Electrical Connection
    • Fig. 562: Identifying Special Hook 3370
    • Fig. 563: Removing Luggage Compartment Light From Headliner Opening Using Hook 3370
    • Fig. 564: Prying Off Lens With Screwdriver
    • Fig. 565: Identifying Special Hook 3370
    • Fig. 566: Pulling Rear Lid Light Using Hook 3370
    • Fig. 567: Pulling Reflector Out Of Rear Lid Light
    • Fig. 568: Identifying Connector, Nut, And Horn
    • Fig. 569: Identifying Quick-Release Fasteners And Noise Insulation
    • Fig. 570: Disconnecting Left/Right Electrical Connectors Of Horns
    • Fig. 571: Prying Control Head Out Of Windshield Frame
    • Fig. 572: Identifying Bolt And Module For Removal
    • Fig. 573: Identifying Hose, Spray Jet, And Screws
    • Fig. 574: Identifying Retaining Clips, Retainer, Module, And Electrical Connection
    • Fig. 575: Identifying Bolts For Fuse Box
    • Fig. 576: Fuse Panel Cover And Cable Tie
    • Fig. 577: Removing Retaining Strip For Connectors
    • Fig. 578: Identifying Main Fuse Panel
    • Fig. 579: Identifying Nuts And Vehicle Electrical System Control Module
    • Fig. 580: Identifying Fuse Carrier And Connectors
    • Fig. 581: Identifying Nuts, And Relay Carrier
    • Fig. 582: Identifying 9-Way Relay Carrier
    • Fig. 583: Identifying Nuts, And Relay Carrier
    • Fig. 584: Identifying 3-Position Relay Carrier
    • Fig. 585: Identifying Bolts For Fuse Box
    • Fig. 586: Identifying Nuts And Vehicle Electrical System Control Module
    • Fig. 587: Identifying Screw Connections, Bolts, And Nuts, For Fuse Carrier
    • Fig. 588: Identifying 4-Way Relay Carrier
    • Fig. 589: Identifying Screw Connections, Bolts, And Nuts, For Fuse Carrier
    • Fig. 590: Locating Left Connection Point
    • Fig. 591: Identifying Connection Point
    • Fig. 592: Identifying Cover For Drivers Side Electronics Box
    • Fig. 593: Identifying Retaining Clips, Comfort System Central Control Module J393, And Electrical Connections
    • Fig. 594: Locating Right Connection Point
    • Fig. 595: Identifying Connection Point
    • Fig. 596: Identifying Quick-Release Fasteners, Main Fuse Box Cover, And Luggage Compartment
    • Fig. 597: Removing Nuts And Main Fuse
    • Fig. 598: Identifying Main Fuse
    • Fig. 599: Identifying Plenum Chamber Cover & Removing Rubber Seal
    • Fig. 600: Removing Securing Clips And Cowl
    • Fig. 601: Removing Screws And Cover From E-Box In Plenum Chamber
    • Fig. 602: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623
    • Fig. 603: Releasing Connector Latches And Pulling Off Connectors On Engine Control Module
    • Fig. 604: Releasing Connector Lock And Disconnecting From Transmission Control Module
    • Fig. 605: Identifying Electrical Connections And Wire
    • Fig. 606: Releasing Retaining Clips And Lifting Auxiliary Relay Carrier Out Of Electronics Box
    • Fig. 607: Identifying Securing Nuts
    • Fig. 608: Identifying Bolts, Fan, And Air Duct
    • Fig. 609: Identifying Plenum Chamber Cover & Removing Rubber Seal
    • Fig. 610: Removing Securing Clips And Cowl
    • Fig. 611: Removing Screws And Cover From E-Box In Plenum Chamber
    • Fig. 612: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623
    • Fig. 613: Releasing Retaining Clips And Lifting Auxiliary Relay Carrier Out Of Electronics Box
    • Fig. 614: Removing Motronic Engine Control Module (ECM) Power Supply Relay J271 From E-Box
    • Fig. 615: Identifying Plenum Chamber Cover & Removing Rubber Seal
    • Fig. 616: Removing Securing Clips And Cowl
    • Fig. 617: Removing Screws And Cover From E-Box In Plenum Chamber
    • Fig. 618: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623
    • Fig. 619: Identifying Wire Connection And Bolts
    • Fig. 620: Identifying Connection Point E-Box Plenum Chamber
    • Fig. 621: Identifying Electrical Wire, Screws, And Socket
    • Fig. 622: Identifying Electronics Box
    • Fig. 623: Identifying Plenum Chamber Cover & Removing Rubber Seal
    • Fig. 624: Identifying Cap, Nut At Electric Cable, And Nut For Carrier Fuse On Positive Post
    • Fig. 625: Identifying Plenum Chamber Cover & Removing Rubber Seal
    • Fig. 626: Removing Screw, Retaining Clip, And Positive Terminal
    • Fig. 627: Releasing Retaining Clip And Opening Cover Over Positive Terminal Pick-Off
    • Fig. 628: Removing Terminal Nuts, Cables, And Positive Terminal
    • Fig. 629: Wiring Harness Repair Kit V.A.S 1978
    • Fig. 630: Opened Wiring Harness Repair Kit VAS 1978
    • Fig. 631: Repairing Twisted Wire Pairs
    • Fig. 632: Stripping Insulation At Wiring Using Stripping Pliers
    • Fig. 633: Crimping On Both Sides With Crimping Pliers
    • Fig. 634: Heating Crimp Connection Using Hot Air Gun
    • Fig. 635: Assembly Overview Of Antenna Wire
  • TABLES

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

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.
  • 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.
  • 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.
  • 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

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, .
  • 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

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 applicable engine repair information, .
  • 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:

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

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.

  • 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 -.
  • 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.

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:

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:

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

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.
  • 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.
  • 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.

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, .
  • 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.

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 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:

  • 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

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.

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.
Black
  • Not charged or inadequately charged.
Colorless or yellow

Electrolyte level - batteries with sealing plugs, checking

CAUTION:
  • 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

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.

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.

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 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).

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.

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.
  • 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).

NOTE:
  • Use print function of MCR 340V where test results are required for warranty claims.

Battery test results:

Battery Tester Display / Printout Required action
Good Battery None
Good - Recharge Charge battery where necessary --> Battery, charging
Use inCHARGE Charge battery --> Battery, charging
Replace Battery Replace battery --> Battery in engine compartment, removing and installing
Bad Cell - Replace Replace battery --> Battery in engine compartment, removing and installing

Battery, charging

CAUTION:

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:
  • 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:

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.

  • 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:

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.

CAUTION:

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.

Generator (GEN)

Generator (GEN) - 4-cylinder 1.8L Turbo engine, removing and installing

Special tools, testers and auxiliary items required

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.

  • VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Removing

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.
  • 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.

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.

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.

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 - .
  • 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

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

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.

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.

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.
  • Top up coolant --> 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection Ignition, Engine Code(s): BPG - .
  • 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.

  • 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

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.

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.

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.

  • 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
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

Fig. 62: Identifying Front Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove front engine cover - arrows -.

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.

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.
  • 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

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

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

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. 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.

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
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 -.

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.

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 -.

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.

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!

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.

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.

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
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 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 .
  • Top up coolant --> 4.2 Liter V8 5V Engine Mechanical, Engine Code(s): BHF - .

CAUTION: Power steering pump must NOT be allowed to run dry. Damage will result.

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

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.

  • 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

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
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.
  • 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.

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.

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 -.

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)
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 -.

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 -.

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.

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.

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.

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.

  • 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 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
  • 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 - .
  • Reconnect battery. Required steps Connecting
  • Start engine and check belt routing.

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

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

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.

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:

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

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

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.

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.

  • 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:

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)

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

Fig. 143: Identifying Heat Shield For Right Drive Shaft
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove heat shield for right drive shaft - arrows -.

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:

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

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

NOTE:
  • Secure brake disc with a wheel bolt.

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:

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

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

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

Fig. 154: Removing/Installing Rear Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Unclip engine cover - arrows -.

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.

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.

  • 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 -.

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 -.

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).

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:

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

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.

  • 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:

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 -.

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.

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.

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
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.

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.

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:

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.

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"
  • 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.

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.

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 -.

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 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

  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)

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)
  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.

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

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).

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.

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

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.

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.

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.
  • 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 -.

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 -.

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

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.

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

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.

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

Fig. 224: Identifying Electrical Connection, Receiver, And Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Disconnect electrical connection - 3 - at receiver - 2 -.
  • Remove bolts - 1 - and remove receiver.

Installing

Install in reverse order of removal, noting the following:

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

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

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

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.

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 α = 2 degrees
  • 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 - α - is attained; re-align if necessary.

NOTE:

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.
  • 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

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

Fig. 238: Windshield Wiper Arm - Through 10.04, Assembly
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Wiper blade mount

2 - Release button

3 - Spacer

4 - Wiper arm

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 -.

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

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

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

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 -.
  • 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.
  • 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.

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.

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.

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

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.

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

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

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

4 - Cap for rear wiper

5 - Wiper arm

6 - Wiper blade

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

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.

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:

Tightening torque

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.

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

Fig. 268: Rear Window Wiper Motor, Assembly
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Nut, 8 Nm

2 - Wiper motor

3 - Rubber grommet

4 - Washer fluid hose

Rear window wiper motor, removing and installing

Removing

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.

Component - fastener Nm
Wiper motor to rear lid - nut 8

Washer fluid reservoir, removing and installing

NOTE:

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

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 -.

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:

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:

Headlamp Washer System - from 11.04

Headlamp washer spray jets, removing and installing

Removing

NOTE:
  • To protect the bumper cover, place a cloth under pliers before taking hold of the spray jet.

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:

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:

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.

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

5 - Bulb holder

  • 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

8 - Housing cover

  • For high beam headlamps

9 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb

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

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 -.

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:

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 .

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 -.

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.

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.
  • 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:

Right headlamp - vehicles with 1.8L 4-cylinder Turbo engine:

  • Preparation.

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 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 -.

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.

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

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

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

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

2 - Screw - 4.5 Nm

3 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb

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

7 - Screw - 4.5 Nm

8 - Housing cover

  • For low beam headlamps

9 - Left Low Beam Headlamp M29 , Right Low Beam Headlamp M31 - bulb

10 - Bulb holder

  • For turn signal lamp bulb

11 - Left Front Turn Signal Lamp M5 , Right Front Turn Signal Lamp M7 - bulb

12 - Trim cover

Headlamps, removing and installing

Removing

  • Turn light switch to position "0".

CAUTION:
  • Switch off all electrical consumers.
  • Switch ignition off and remove ignition key.

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:

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 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 -.

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.

  • 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 -.

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

  • 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.

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 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

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 -.
  • 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

Right headlamp

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

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 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

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

3 - Headlamp housing

4 - Vent element

  • 2x

5 - Turn signal/parking lamp bulb

6 - Bulb holder

  • For turn signal

7 - High intensity gas discharge (HID) low beam headlamp bulb

8 - Housing cover

  • For low beam headlamps

9 - High intensity gas discharge (HID) low beam headlamp lamp bulb

10 - Housing cover

  • For high beam headlamps

11 - Left High Beam Headlamp M30 , Right High Beam Headlamp M32 - bulb

12 - Headlamp beam adjustment motor

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

18 - High intensity gas discharge (HID) lamp control module

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

Left headlamp

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 -.

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:

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.
  • 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 -.

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.

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.
  • 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

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 -.

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

Left headlamp

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.
  • 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 (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

Left headlamp

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.

  • 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.
  • 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.

  • 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.

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

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

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

  • 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.
  • 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

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.

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

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

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 -.

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).
  • Different repair sets are available for left and right headlight.

Procedure

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.
  • 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.

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

3 - Turn signal/parking lamp bulb

4 - Bulb holder

  • For turn signal

5 - Headlamp beam adjustment motor

6 - High intensity gas discharge (HID) low beam headlamp bulb

7 - Screw - 1.5 Nm

8 - Adapter lead

9 - High intensity gas discharge (HID) lamp control module

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

16 - Vent element

  • 1x

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

Fig. 349: Removing Cover In Engine Compartment (Left Side)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove left engine cover - 1 -.

Right headlamp

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.

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.

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.
  • 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

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.

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 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

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.

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.

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.

Turn signal/parking lamp 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.

Removing

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!
  • Always disconnect negative ( - ) battery terminal prior to working on parts of HID headlamp components marked with yellow "HIGH VOLTAGE" warning symbols.

Removing

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.

  • 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.

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

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.

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

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.

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

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

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
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.

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
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Screw - 1.5 Nm

2 - High intensity gas discharge (HID) lamp control module

3 - Headlamp housing

4 - Screw - 4.5 Nm

5 - Housing cover

  • For parking/daytime running lamps

6 - Daytime running lamp (DRL) bulb

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

10 - Screw - 4.5 Nm

11 - Housing cover

  • For low beam headlamps

12 - Screw - 1.5 Nm

13 - High intensity gas discharge (HID) lamp

14 - Bulb holder

  • For turn signal bulb

15 - Left Front Turn Signal Lamp M5 , Right Front Turn Signal Lamp M7 - bulb

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

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 -.
  • 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

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

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:
  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 -.

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 -.

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 -.
  • 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 -.

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.

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 -.

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.
  • 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

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.

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 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

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.

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

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.

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.

Front Turn Signal Lamp M5 / M7 - bulb, replacing

Removing

CAUTION:
  • Switch off all electrical consumers.
  • Switch ignition off and remove ignition key.

Left headlamp

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.

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

Right headlamp

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.

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:

  • 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

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

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.

  • 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:

Tightening torque

Component - fastener Nm
Fog lamp housing to bumper - screw 5

Fog lamp bulb, replacing

Removing

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".

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:

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 -.

Installing

Install in reverse order of removal, noting the following:

Vehicles with charge air cooler:

All models:

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 -.

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:

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

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 .

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:

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:

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:

All models:

Fog lamp bulb - Audi A4 with "S-line" equipment Audi S4, replacing

Removing

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

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".

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

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

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.

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.

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

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

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.

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:
  • 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

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

5 - Bolt - 3.5 Nm

  • With hex socket (17 mm)

6 - Bulb holder

7 - Taillamp bulb

  • 12 V, 21 W

8 - Backup lamp bulb

  • 12 V, 21 W

9 - Housing

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 ).
  • 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

Fig. 429: Rear Lights In Rear Lid - Sedan, Assembly
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Housing

2 - Taillamp/rear fog lamp bulb

  • 12 V, 21 W

3 - Bulb holder

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.

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

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.

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

  • With hex socket (17 mm)

5 - Bulb holder

6 - Brake/taillamp bulb

  • 12 V, 21 W

7 - Backup lamp bulb

  • 12 V, 21 W

8 - Housing

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.

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.

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

2 - Taillamp bulb

  • 12 V, 21 W

3 - Electrical connector

4 - Nut - 3.5 Nm

5 - Retainer

  • For securing housing to rear lid

6 - Bulb holder

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.

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.

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

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

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 -.

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 -.
  • 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.

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

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:

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.

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 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.

2 - Steering Angle Sensor G85

3 - Socket head bolt

4 - Cruise Control Switch E45

5 - Socket head bolt

6 - Turn Signal Switch E2

7 - Retaining clip

8 - Steering Column Electronic Systems Control Module J527

9 - Clamping bolt - 3 Nm

10 - Windshield Wiper/Washer Switch E22

11 - Socket head bolt

Steering column switch module, removing and installing

Special tools, testers and auxiliary items required

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

Fig. 456: 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. 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.

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.
  • 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

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 -.
  • 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

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

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.
  • 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 -.

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.

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"

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

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
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

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. 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 -.

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

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 -.

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

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. 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 -.

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 J527 0.6

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

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.

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:

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.
  • 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

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.

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

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

2 - Not applicable to USA/Canada

3 - Not applicable to USA/Canada

4 - Rear Parking Aid Warning Buzzer H15

Sedan:

Avant:

5 - Rear Parking Aid Sensors

6 - Parking Aid Control Module J446

Parking Aid Control Module J446 , removing and installing

Removing

  • Location: At left rear or luggage compartment below side trim/taillamp.

Sedan:

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:

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

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.

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

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:

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.

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

3 - Left Rear Level Control System Sensor G76

4 - Left Front Level Control System Sensor G78

Headlamp Range Control Module J431 , removing and installing

Removing

  • Location: at instrument panel carrier behind glove box

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
Control module to body - screw 3

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:

  • 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

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:

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

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:

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

  • 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

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.

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.

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.

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.

  • 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

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

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

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

Fig. 513: Identifying Retaining Element, Retaining Hooks, Window Switches, And Electrical Connection
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • 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

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

Removing

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 -.

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

Fig. 518: Identifying Electrical Connection, Screws, And Sunroof Switch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Disconnect electrical connection - 2 -.
  • Remove screws - arrows -.
  • Take sunroof switch E8 - 1 - out of interior light/reading light.

Installing

Install in reverse order of removal, noting the following:

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.

Drivers Interior Locking Switch E150 , removing and installing

Removing

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 -.

Installing

Install in reverse order of removal, noting the following:

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

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

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:

Drivers Seat Memory Program Control E97 , removing and installing

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.

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

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.
  • 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.

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.

12 V Socket U5 - in luggage compartment through 10.04, removing and installing

Special tools, testers and auxiliary items required

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

  • 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:

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

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".

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.

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

Install in reverse order of removal, noting the following:

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
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.

  • 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 -.
  • 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

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:

Front Interior Light W1 - bulbs, replacing

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.

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

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

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.

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

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

Fig. 550: Interior/Reading Light Bulbs
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Screw applicable bulb 12 V, 5 W - arrow - from holder.

Installing

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

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.

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:

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:

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

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

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.
  • 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

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

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.

  • 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 -.
  • 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.
  • 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:

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.

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:

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:

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:

Vehicles with charge air cooler or additional radiator:

Tightening torque

Component - fastener Nm
Horn to bracket - nut 5

Heated Steering Wheel

Heated steering wheel, servicing

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.

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

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:

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

Vehicles with headlamp washers

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:

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

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 -.

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:

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.

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:

Tightening torque

Component - fastener Nm
Control module to central tube for instrument panel - nut 2.4

9-position relay carrier, removing and installing

Removing

CAUTION:
  • Switch off all electrical consumers.
  • Switch ignition off and remove ignition key.

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.

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:

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.

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.

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:

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

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.

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:

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.

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:

Comfort System Central Control Module J393 , removing and installing

Removing

NOTE:
  • Safety belts at seat frame do not have to be unfastened.
  • Fold back floor covering.

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:

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.

Installing

Install in reverse order of removal, noting the following:

Main fuse panel in left rear luggage compartment - Audi RS4, removing and installing

Removing

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 -.

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:

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.

  • 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 -.

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.

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

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

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.
  • 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 -.

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.

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

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 -.

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:

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:

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:

Tightening torques

Component Nm
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

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

Install in reverse order of removal, noting the following:

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

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.

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.

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 -.

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:

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.
  • 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.

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

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.
  • 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.

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; 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:

  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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