Audi A6 (C5) Repair Manual: 1998-2004 - Index

INDEX 1

WARNING

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

A

3-fold relay panel97-24

8-fold relay panel 97-29

13-fold relay panel 97-28

ABSsee Antilock brakes (ABS)

Acceleration sensorsABS 45-8

Accelerator pedal assembly02-14, 24-8

Accessory belt 03-34, 48-25, 48-35

Air-conditioning (A/C)accumulator 87-11air distribution 87-9blower motor 87-16capacities 87-4components 87-9

dashboard 87-13engine compartment 87-11

compressor with clutch 87-16with regulator valve 87-17

condenser 87-11controls and power supply 87-5dashboard vents 87-13dust and pollen filter 03-50evaporator housing 87-14evaporator housing drain 87-14flap motors 87-13housing 02-30, 87-14overview 02-30, 87-8pressure sensor 87-12rear vent and duct 70-7receiver-dryer 87-11refrigerant and refrigerant oil 87-4repairs 87-16service connection 87-11troubleshooting 87-2vents 87-13

Air filter03-43

Air quality sensor87-13

Air suspension02-22

Airbagscomponents 69-10control module 69-10driver’s 69-11inspection 03-49overview 02-29passenger 69-12rear side airbag 69-1

Alarm system96-13, 96-16radio 91-2

Alignment03-47, 44-5

allroad quattro02-4air suspension 02-22electrical components 97-22engine (V8) 02-9“jack mode” 03-7

Alternator (generator)belt 03-34removing and installing 27-14

Aluminumbody panels 55-1

Amplifier91-7

Antenna91-8amplifier 91-4, 91-5

Antifreeze03-26, 19-2

Antilock brakes (ABS)02-25, 45-3components

ABS / ASR 5.3 45-4ABS / ESP 5.7 45-5

electrical components 45-6hydraulic components 45-10impulse wheel

front 45-15rear (FWD) 45-18rear (quattro) 45-20

variants 45-3wheel speed sensors 45-14

Antislip regulation (ASR)02-25, 45-3, 45-4see also Antilock brakes (ABS)

Anti-theft 96-13radio 91-2

A-pillarconnector

left 97-18right 97-19

trim 70-14

Arm rest70-7

Ashtrayfront 70-7

ASR (antislip regulation)02-25, 45-3, 45-4see also Antilock brakes (ABS)

Automatic transmission 02-16ATF 37-2ATF screen 37-20codes 37-1CVT ATF 37-5identification 03-18selector mechanism 37-7shift lock 37-7oil pan 37-20rpm sensor 37-21

Auxiliary heater87-13

B

Back-up lights96-6

Balance shaft02-7

Battery27-5back-up (Telematics) 91-12charging 27-9reconnection notes 03-34, 27-2removing and installing 27-10service 03-33troubleshooting table 27-3

Beltaccessory 03-34, 48-25, 48-35timing 03-41, 13-2

Bleeding brakes47-3

Blower motor87-16

Bodyaluminum panels 55-1dimensions 02-3front fender 50-4grill 55-4overview 02-28wheel housing liner 66-1see also Trim

Bose® amplifier91-7

A604_index.fm Page 1 Friday, October 10, 2008 12:23 PM

965

2 INDEX

B-pillar trim70-15

Brake fluidbleeding 47-3level 03-28

Brake light switch46-19

Brakesantilock 45-3bleeding 47-3booster 47-8caliper

front 02-26, 46-2rear 02-27, 46-15

inspection 03-44master cylinder 47-8pads and discs

checking 03-44front 46-2rear 46-15

parking brake 46-17specifications

front 46-1rear 46-2

troubleshooting 47-1vacuum pump 47-12see also Antilock brakes (ABS)see also Brake fluid

Bulbsapplications

exterior 94-2interior 96-2

Bumpersfront 63-1rear 63-3

Bus systems02-31, 9-2

C

Caliperfront 46-1rear 46-2

Camshaft sensor 28-5

CAN-bus02-31, 9-2

Catalytic converter26-1, 26-3

CD changer91-3

Center brake light94-13

Center console70-5switches 96-8

Central carrier relay panel97-30

Central locking96-14service notes 57-10

Chain, timing 02-8

Charging systemquick check 27-13troubleshooting table 27-3

Child seat anchor69-1

Children’s bench72-9

Climate controlsee Air-conditioning (A/C)

Clutchcomponents

5-speed 30-116-speed 30-13

hydraulics 30-4bleeding 30-10master cylinder 30-2, 30-5slave cylinder 30-2, 30-8

pedal 30-1pedal position switch 30-3repairs 30-15self-adjusting (SAC) 02-15, 30-1

resetting 30-16

Coilsee Ignition coil

Coil springfront 40-5rear 42-4

Component locations (electrical)97-3

Compressorsee Air-conditioning (A/C)

Condenser87-11

Console, center70-5

Constant velocity (CV) joint see CV joint

Continuity9-5

Continuously variable transmission (CVT)

02-17ATF

capacity 37-2level 37-5

identification 03-20

Coolantsee Engine cooling system

Coolant pumpafter-run 21-2removing and installing 19-16

Cooling systemsee Engine cooling system

C-pillar trim70-16

Crankshaft pulley 2.7 liter, 2.8 liter engine 13-63.0 liter engine 13-7V8 engine 13-8

Cruise control27-2pedal switches 24-8stalk switch 48-3

Curb weight position40-1

CV joint boot

checking 03- 48replacing 40-16

front 40-18, 40-19, 40-20, 45-14rear 45-19

CVT02-17ATF



Cylinder head coverV6 models 15-2V8 models 15-9

D

Dashboard02-32air outlets 87-9, 87-13end trim 70-4left side trim (driver’ storage compartment) 70-5

switches 96-9

Data labels02-13

Data link connector (DLC)03-8, 24-5, OBD-1

Diagnostic trouble code (DTC)access 03-8P-codes OBD-3

DifferentialTorsen® 02-18see also Final drive

Dimensions02-3

Disc brakessee Brakes


966

INDEX 3

WARNING


DLC03-8, 24-5, OBD-1

Dome light96-2

Doorcheck strap and hinge lubrication 03-49

component carrier 57-5courtesy light 96-5front 57-1handle 57-8rear 57-2removing and installing 57-3trim 70-9

Door lock57-7, 96-17service 03-50

Door panelfront 70-9rear 70-11

Door windowsee Window

D-pillar trim70-18

Drive axleboot

checking 03-48replacing 40-16

front 40-15rear 42-10

Drive belt03-34, 48-25, 48-35

Drive plate32-1

Driver information display90-3

Driveshaft39-4

DTC access 03-8P-codes OBD-3

Dual-mass flywheel30-13

Dust and pollen filter03-50

E

E-box (electronics box)97-24

EBC (electronic braking control)02-26

ECM (engine control module) 02-12, 24-7

EDL (electronic differential lock)02-25, 45-3

Electrical systemA-pillar connector stations

left 97-18right 97-19

component locations 97-3fuses 97-23grounds 97-30relays 97-23troubleshooting 9-3wiring

diagrams EWD-26index EWD-6

Electrolyte03-33, 27-5, 27-6

Electronic braking control (EBC)02-26

Electronic differential lock (EDL)02-25, 45-3

Electronic immobilizer90-2, 96-13

Electronic stabilization program (ESP)

02-25, 45-3, 45-5see also Antilock brakes (ABS)

Electronic throttle control (EPC) 02-14, 24-2

Electronics box (E-box)97-24

Emergency flasher switch96-9

Emergency sunroof closing 60-2

Engine02-5accessory belt 03-34applications table 03-15balance shaft 02-7compartment 03-21covers 03-22identification 03-14fluid leaks 03-20overview

V6 02-5V8 02-8

rear main seal 13-8technical data 03-15timing belt 03-41

Engine control module (ECM) 02-12, 24-7

Engine coolant temperature (ECT) sensor

2.7 liter engine 19-6, 24-92.8 liter engine 19-8, 24-133.0 liter engine 19-10, 24-15V8 engine 24-18, 24-20, 24-22

Engine cooling fan 2.7 liter engine 19-42.8 liter engine 19-7

Engine cooling systemafter-run coolant pump 21-2antifreeze concentration 03-27,19-2bleeding 19-12capacities 03-27, 19-1components

see Cooling system diagrams in 19 Engine–Cooling System

see also Engine compartment diagrams in 24 Fuel Injection

coolant level 03-27coolant pump 19-16draining, filling 19-12hoses, inspecting 03-28thermostat 19-17radiator 19-15

Engine lubrication components

see Lubrication system diagrams in 17 Engine–Lubrication System

oil pump 17-5oil service 03-24


967

4 INDEX

Engine managementaccelerator pedal sensors 24-8applications 24-2components

see Engine compartment diagrams in 24 Fuel Injection

diagnostics 24-5electronic throttle control (EPC) 20-8engine control module (ECM) 02-12, 24-7

engine coolant temperature (ECT) sensorsee Cooling system diagrams in 19 Engine–Cooling System

see also Engine compartment diagrams in 24 Fuel Injection

evaporative control (EVAP) 24-4overview

ME 7 02-12ME 7.1 24-3ME 7.1.1 02-13

power supply 24-7RS6 02-14secondary air injection 24-1, 26-10see also Ignition system

EPC (electronic throttle control)02-14, 24-2

ESP (electronic stabilization program)02-25, 45-3, 45-5see also Antilock brakes (ABS)

Evaporative control (EVAP)02-12, 24-4purge valve 24-22

Evaporatorsee Air-conditioning (A/C)

Exhaust manifold26-1

Exhaust systeminstallation details 26-9see also Exhaust system diagrams in 26 Exhaust System

Exhaust temperature sensor24-9, 24-11

F

Fasteners03-9

Fender, front50-4

Final driveoil 39-1Torsen® 02-18

Filterair 03-43dust and pollen 03-50fuel 03-30

RS6 03-32oil 03-25

Fluid leakengine compartment 03-20

Flywheel30-11dual-mass 30-13

Foglight94-10

Footwell light96-5

Front suspension02-19codes 42-3coil spring 40-5control arms 40-8curb weight position 40-1“jack mode”, allroad quattro 03-7stabilizer bar 40-13strut assembly 40-3wheel bearing 02-20

Fuel filter03-30RS6 03-32

Fuel flaplock 57-8, 96-15

Fuel injectionsee Engine management

Fuel injector24-4

Fuel level sender02-11, 20-1front-wheel drive 20-11quattro 20-13

Fuel pressure20-6relieving system pressure 20-5residual pressure 20-9

Fuel pump20-1components

front-wheel drive 20-11quattro 20-13

power supply 20-4testing 20-4volume 20-6wiring 20-5

Fuel systemcomponents 20-10diagnostics 20-2delivery 20-3evaporative emissions control 02-12fuel return system 02-12see also Engine management

Fuel tank02-11capacities 20-1filler flap lock 57-8, 96-15filler neck


Fuses97-23

G

Gear selectorautomatic transmission 37-7manual transmission 34-4

Generatorsee Alternator (generator)

Glasssee Window

Glove compartment70-4light 96-4

Grill55-4

Grounds97-30

H

Hand brakesee Parking brake

Headlight94-1adjusting 03-52automatic headlight beam adjustment 94-2

repairs 94-7suspension level sensor 94-2switch 96-8washer 92-10xenon 02-31, 94-2, 94-5, 94-8see also Lights, exterior

Heating and ventilationdust and pollen filter 03-50heater core 87-18see also Air-conditioning (A/C)

HID headlightsee Xenon headlight

High intensity headlightsee Xenon headlight

Hoodengine hood 55-2

Hornacoustic 96-12alarm 96-16


968

INDEX 5

WARNING


I

Ignition coil28-4

Ignition shift lock37-18

Ignition switchelectrical 96-11key cylinder 96-10

Ignition system28-1coil 28-4disabling 28-2firing order 28-2knock sensor 28-6spark plug wires 28-5

Immobilizer90-2, 96-13

Instrument cluster02-31, 02-32, 90-1details 90-5diagnostics 90-3dimmer 96-9removing and installing 90-4

Intake manifoldsee Engine management diagrams in 24 Fuel Injection

Intercooler02-5, 02-10, 21-1

Interior lightssee Lights, interior

Interior motion detector03-52, 96-14

J

“Jack mode”allroad quattro 03-7

Jacking vehicle03-7

K

Key96-14

Keyless entry 96-16

Knock sensor28-6

L

License plate light94-14

Lid, trunk55-5

Lifting vehicle03-4allroad quattro “jack mode” 03-7

Lights, exteriorback-up 96-6bulb applications 94-2controls and power supply 94-4foglights 94-10switch 96-8taillights 94-12see also Headlightsee also Turn signal

Lights, interior96-2bulb applications 96-2dome 96-3power supply 96-2reading 96-3

Lock carrier, frontservice position 02-28, 50-2

M

Maintenanceaccessory belt 03-34air filter 03-44ATF 37-2battery 03-33, 27-5body and interior 03-50brake fluid 03-28brake system 03-45cooling 03-26CV joint boot 03-49, 40-16diagnostic trouble codes (DTCs) access 03-8

dust and pollen filter 03-51engine covers 03-22engine oil 03-24exhaust system 03-49fuel filter 03-30headlight adjustment 03-53parking brake 46-17schedules 03-53spark plugs 03-42timing belt 03-42, 13-1tires and wheels 03-46transmission fluid 03-45

automatic 37-2manual 34-2

underbody sealant 03-49under car maintenance 03-45windshield wipers and washers 03-52

Manifoldexhaust 26-1intake

see Engine management diagrams in 24 Fuel Injection

Manual transmission02-15gear selector

5-speed 34-56-speed 34-9

identification 03-18oil 34-2removing and installing

5-speed 34-156-speed 34-22

Master cylinderbrakes 47-8clutch 30-2, 30-5

ME 702-12

Micro central relay panel97-28

Mirrorinterior 70-2memory 02-29outside 66-3switch 96-9

Motion detector, interior03-52, 96-14


969

6 INDEX

Motronicsee Engine management

Mufflersee Exhaust system diagrams in 26 Exhaust System

Multifunction steering wheel91-13

Multitronic® transmission (CVT)02-17ATF



N

Navigation91-11

O

OBD IIOBD-1

Oil03-24capacities 17-1cooler 17-5level sensor 17-6pressure switch 17-2pump 17-5specifications 17-1see also Engine lubrication

Oil filter03-25, 17-5

On-board diagnosticsOBD-1

Outside air temperature sensor87-11

Oxygen sensor26-2replacing 26-10

P

Parking aid94-3

Parking brake46-17

Parts03-10

P-codeOBD-3

Plenum chambercover 92-5

Pollen filter03-51

Power steeringsee Steering

Power windowsee Window

Q

quattrosee allroad quattro

R

Radiator 19-16

Radiator grill55-4

Radio91-3antenna connections 91-8power supply 91-3removing and installing 91-9satellite 91-8see also Sound systems

Raising vehicle03-4allroad quattro “jack mode” 03-7

Rear main seal2.8 liter engine 13-92.7 liter, 3.0 liter, V8 engine not allroad quattro 13-10

V8 engine allroad quattro 13-13

Rear shelf70-18

Rear suspension02-20codes 42-3coil spring 42-4curb weight position 40-1“jack mode”, allroad quattro 03-7overview 42-4shock absorber


stabilizer bar 42-8wheel bearing 02-21, 42-4

Rear window defoggercontrol 87-5

Refrigerantsee Air-conditioning (A/C)

Relays97-23

Remote control (locking)96-14

Ribbed beltsee Accessory belt

S

SAC (self-adjusting clutch)30-1

Safetypassenger 02-29working under car 03-8

Satellite radio91-8

Scan toolOBD-2suppliers OBD-3

Seat beltchild seat anchors 69-1front 69-5inspection 69-2overview 69-5rear 69-7

Seatsadjusting 02-29children’s bench 72-9front 72-1headrest 72-3memory 02-29memory control module 72-3rear 72-4

backrest 72-4headrest 72-8side padding 72-8

switch 02-29, 72-4

Secondary air injection system24-1, 26-10power supply 26-11pump 26-11schematic 26-10

Self-adjusting clutch (SAC)30-1

ServiceAudi 03-11

Service positionlock carrier 02-28, 50-2

Service reminder indicator (SRI)03-8

Shift lockautomatic transmission 37-7

Shock absorberFWD 42-5quattro 42-7

Short circuit9-5

Sill panel trim70-15


970

INDEX 7

WARNING


Slave cylinder, clutch30-2, 30-8

Sound absorber panels03-22

Sound systemcomponents 91-4see also Radio

Spark plugs03-42applications 03-44

Speakersee Sound system diagrams in 91 Radio and Communication

Special tools suppliers03-12

SRI (service reminder indicator)03-8

Stabilizer barfront 40-13rear 42-8

Starter27-10removing and installing

V6 engine 27-11V8 engine 27-12

troubleshooting 27-3, 27-10

Steeringangle sensor 45-6column 02-27, 48-3column switches

ignition 96-10stalk 48-4

column trim 70-3fluid 03-29, 48-1pump

see Steering pump procedures in 48 Steering

rack 48-9wheel 48-3

multifunction 91-13removing and installing 48-3sport 48-3

Strut front 40-3

Sunlight photo sensor02-30, 87-13

Sunroofdrain hoses 60-7drive motor 60-6emergency closing 60-2function 60-1motor and switch 60-1service 03-51, 60-2wind deflector 60-2

Suspension02-19air suspension 02-22checking 03-49codes 42-2curb weight position 40-1“jack mode”, allroad quattro 03-7RS6 02-24see also Front suspensionsee also Rear suspension

Switchesdashboard 96-9emergency flasher 96-9exterior lights 96-8ignition and steering lock 96-10instrument cluster dimmer 96-9mirror 96-9steering column stalk 48-4window 96-11

T

Tailgate55-9lock 55-13, 57-9, 96-15trim 70-23

Taillight94-2, 94-12

Telematics91-12

Telephone91-10

Thermostat19-17

Throttle control02-14, 24-2

Tie-rod48-10

Tightening torquesgeneral 03-10

Timing belt03-42removing and installing 13-1

Timing chain (camshaft drive chain)02-8

TiptronicRS6 02-18switch 37-10

Tires03-46, 44-1pressure monitoring system 44-3

Toothed beltsee Timing belt

Tools03-11, OBD-3

Torque converter32-1service 32-2

Torsen® differential02-18see also Final drive

Towing03-3

Transmissionidentification 03-18oil 03-45see also Automatic transmissionsee also Manual transmission

Trimdashboard end 70-4door inner trim

front 70-9rear 70-11

driver storage compartment 70-5pillar and side trim 70-14rear vent and duct 70-7sill panel trim 70-15steering column trim 70-3tailgate trim 70-23trunk trim 70-21

Triple roller joint40-19, 40-20

Trunk lid 55-5light 96-6lock 55-8, 57-9, 96-15trim 70-21

Turbocharger21-1cooling circuit 21-2

Turn signalfront 94-9side 94-9switch 48-4

U

Ultrasound sensor96-14


971

8 INDEX

V

Vacuum pumpbrake booster 47-12

Vehicle identification number (VIN)01-1, 03-13

Vehicle level sensor 42-3

Vehicle speed sensor 37-21

Ventilationdust and pollen filter 03-51see also Air conditioning (A/C)see also Heating and ventilation

Voltage9-4

W

Washersfluid 03-52headlight 92-10nozzles 92-9rear 92-7reservoir and motor 92-8

Water pumpafter-run 21-2removing and installing 19-16

Wheel alignment44-5

Wheel bearing02-20, 02-21

Wheel housing liner66-1

Wheel speed sensor45-14see also Antilock brakes (ABS)

Wheels03-46, 44-1alignment 44-5

Windowglass service 64-2motor reinitializing 64-1motor service 64-4switch 96-11

Windshield defroster87-5, 87-13

Wipersarms and blades 92-3blades 03-52controls and power supply 92-2repairs

front 92-5rear 92-7

Wiring diagrams EWD-26index EWD-6

Working under vehicle safely03-8

X

Xenon headlight02-31, 94-2, 94-5, 94-8control 94-4see also Headlight


972

established 1950Automotive Reference™

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

Audi A6Service Manual: 1998-2004includes A6, allroad quattro, S6, RS6

Price: $99.95Bentley Stock Number: A604Publication Date: 2006.oct.13ISBN-10: 0-8376-1499-6ISBN-13: 978-0-8376-1499-1Audi of America Lit. No. W42 AUDIA69804SMSoftcover, 8 3/8 in. x 11 in.Case quantity: 5964 pages, 1772 photos, illustrations and diagramsIncludes a 32 page color Audi A6 Familiarization sectionBentley Publishers is proud to announce the publication of the

Audi A6 Service Manual: 1998–2004. This repair manual covers the 1998 through 2004 model year A6 and S6 models built on the Audi “C5” platform.

The do-it-yourself Audi owner will find this manual indispensable as a source of detailed maintenance and repair information. Even if you have no intention of working on your car, you will find that reading and owning this manual makes it possible to discuss repairs more intelligently with a professional technician.

Features:• Maintenance procedures from changing the oil to replacing the dust and pollen filter. This manual tells you what to do and how and

when to do it.• Step-by-step engine timing belt service.• Cylinder head cover and crankshaft seal replacement.• Cooling system filling and bleeding, coolant pump replacement and engine cooling fan and radiator service.• Fuel injection and ignition system diagrams and explanations, including three different Bosch Motronic engine management systems.• Clutch, flywheel and rear main seal service.• Suspension component replacement, including front struts, rear

shocks, coil springs, wheel bearings and wheels.• Multi-link front suspension repair procedures, including stabilizer

bar link, control arm and axle boot replacement.• Brakes, steering and ABS maintenance, troubleshooting, and repair.• Heating and air-conditioning repair, including A/C component replacement.• Body, hood and sunroof repairs and adjustments.• Electrical system service, with an easy-to-use illustrated component locator section.• Wiring schematics for selected models, including power distribution and grounds.

Bentley repair manuals provide the highest level of clarity and comprehensiveness for service and repair procedures. If you’re looking for better understanding of your C5 platform Audi A6 or S6, look no further than Bentley.

Engines covered:

• 1998 - 2001 2.8 liter V6 (AHA, ATQ)• 1999 - 2004 4.2 liter V8 (ART, AWN, BBD)• 2000 - 2004 2.7 liter V6 biturbo (APB, BEL)• 2002 - 2004 3.0 liter V6 (AVK)• 2003 - 2004 4.2 liter V8 (BAS)• 2003 - 2004 4.2 liter V8 biturbo (BCY)

Transmissions covered:

• 5-speed manual AWD (01A)• 6-speed manual AWD (01E)• 5-speed automatic AWD (1L)• 5-speed automatic FWD or AWD (1V)• Continuously variable transmission (CVT) FWD (01J)

Bentley technical editorsphotographing axle bootreplacement.

Step-by-step frontsuspension componentreplacement.40 Front Suspension

BentleyPublishers.com

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Audi A6 (C5) Repair Manual: 1998-2004 - Index