D3E8001FE7A-Suspension Wheels Steering

Service
Repair Manual
Audi A4 2001 ➤
Audi A4 Cabriolet 2003 ➤
Suspension, Wheels, Steering
Edition 10.2013
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
40 - Front Suspension
42 - Rear Suspension
43 - Self-Leveling Suspension
44 - Wheels, Tires, Wheel Alignment
48 - Steering
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Audi AG, Ingolstadt D3E8001FE7A

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
Suspension, Wheels, Steering - Edition 10.2013
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Repairing Damaged Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Thread in Longitudinal Member, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Front Gas-Filled Strut, Venting and Emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Rear Gas-Filled Strut, Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Power Steering Gear, Emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Shock Absorbers, Leaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Shock Absorber, Noises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Shock Absorbers, Removed, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Shock Absorbers, Checking on Shock Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
40 - Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Light Weight Wheel Hub Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Vehicle Level Sensor for Vehicles with Automatic Headlamp Vertical Aim Control . . . . . . 13
2.1 Wheel Bearing, Lifting to Curb Weight Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Front Suspension Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Vehicle Level Sensor Overview, Vehicles with Automatic Headlamp Vertical Aim Control
........................................................................ 20
2.4 Drive Axle with Triple Roller Joint AAR 2000 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 byDrive
Protected Axle
copyright. with
Copying Peened
for private Triple purposes,
or commercial Roller Joint
in part orAAR 2600
in whole, is noti or 3300 i Overview . . . . . . . . . . . . 23
2.6 unless
permitted Drive Axle with
authorised by AUDITriple
AG. AUDIRoller
AG does Joint AAR 2900
not guarantee or accept Overview
any liability ............................ 27
2.7 Drive Axle with Inner Constant Velocity Joint, 100 mm Overview . . . . . . . . . . . . . . . . . . . . 29
2.8 Drive Axle with Inner CV Joint, 108 mm, Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Outer Constant Velocity Joint with Triple Roller Joint AAR 2000, Checking . . . . . . . . . . . . 36
4.2 Outer Constant Velocity Joint with Inner Constant Velocity Joint, 100 mm, Checking . . . . 37
4.3 Outer Constant Velocity Joint with Inner CV Joint, 108 mm, Checking . . . . . . . . . . . . . . . . 38
4.4 Inner CV Joint with Inner Constant Velocity Joint, 100 mm, Checking . . . . . . . . . . . . . . . . 39
4.5 Inner CV Joint with Inner CV Joint, 108 mm, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1 Suspension Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 Wheel Bearing Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3 Wheel Bearing Housing with Bolted Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.4 Light Weight Wheel Hub Slide Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.5 Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.6 Upper Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.7 Front and Rear Upper Control Arm Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.8 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.9 Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.10 Subframe Bonded Rubber Bushing Stop Wedges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Contents i
5.11 Tunnel Crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.12 Control Arm, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.13 Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.14 Control Arm Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.15 Guide Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.16 Guide Link Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.17 Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.18 Crossbrace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.19 Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.1 Suspension Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.2 Drive Axle with Triple Roller Joint AAR 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.3 Drive Axle with Peened Triple Roller Joint AAR 2600 i or 3300 i . . . . . . . . . . . . . . . . . . . . 89
6.4 Drive Axle with Triple Roller Joint AAR 2900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.5 Drive Axle with Inner Constant Velocity Joint, 100 mm Diameter . . . . . . . . . . . . . . . . . . . . 99
6.6 Drive Axle with Inner CV Joint, 108 mm Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
42 - Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

1.1 Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.2 Light Weight Wheel Hub Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.3 Trapezoidal Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.4 Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.1 Wheel Bearing, Lifting to Curb Weight Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.2 Subframe Overview, FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.3 Subframe Overview, AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.4 Trapezoidal Control Arm, Transverse Link and Tie Rod Overview . . . . . . . . . . . . . . . . . . 124
2.5 Stub Axle Carrier Overview, FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.6 Wheel Bearing Housing Overview, Steel, AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.7 Stabilizer Bar Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.8 Wheel Bearing Housing Overview, Aluminum, AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.9 Level Control System Sensor with Automatic Headlamp Vertical Aim Control Overview . . 134
2.10 Subframe Mount Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.1 Outer Constant Velocity Joint, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.2 Inner CV Joint, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.1 Vehicle Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.2 Coil Spring . . . . . . . . . . . . . . . . . . . . . . . . Protected
. . . . . .by. copyright.
. . . . . .Copying
. . . . for
. .private
. . . .or. commercial
. . . . . . purposes,
. . . . . .in. part
. 142
or in whole, is not
5.3 Shock Absorber . . . . . . . . . . . . . . . . . . . . .permitted
. . . . .unless
. . . .authorised
. . . . . by
. .AUDI
. . .AG.
. . AUDI
. . . AG
. . does
. . . not
. . guarantee
. . . . . .or 143
accept any liability
5.4 Stub Axle Carrier/Wheel Bearing Housing, Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

5.5 Wheel Bearing, Steel Wheel Bearing Housing Installed, AWD . . . . . . . . . . . . . . . . . . . . . . 147
5.6 Bolted Wheel Bearing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.7 Wheel Bearing Housing, Aluminum, AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.8 Light Weight Wheel Hub Slide Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.9 Transverse Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.10 Transverse Link Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.11 Nut Securing Transverse Link to Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.12 Trapezoidal Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.13 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.14 Subframe Mount, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
ii Contents
5.15 Rear Differential Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

5.16 Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.17 Tie Rod Stone Deflector, Old Three-Part Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5.18 Tie Rod Stone Deflector, New One-Part Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
5.19 Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
5.20 Stabilizer Bar Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
5.21 Stabilizer Bar Coupling Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
5.22 Front or Rear Diagonal Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
5.23 Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.1 Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.2 Stub Axle Carrier, FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6.3 Wheel Bearing Housing, Steel, AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
6.4 Drive Axle with Inner CV Joint, 100 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
6.5 Drive Axle with Inner CV Joint, 108 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
43 - Self-Leveling Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

1.1 Dynamic Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2.1 Dynamic Ride Control Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
207
2.2 Central
with respect to the Valve
correctness and Bolted
of information Connections
in this document. toAUDI
Copyright by Suspension
AG. Struts . . . . . . . . . . . . . . . . . . . . . . 208
2.3 Dynamic Ride Control, Emptying and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.1 Dynamic Ride Control, Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
4.2 Dynamic Ride Control, Checking System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5.1 Central Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
44 - Wheels, Tires, Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

1.1 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.2 Tire Pressure Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.3 Tire Pressure Monitoring System Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.4 Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
2.1 Tire Pressure Monitoring System Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 231
2.2 Wheel Electronics Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2.3 Wheel Alignment Test Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2.4 Measurement Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2.5 Adapters, Allocating to Suspension for Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2.6 Initial Position for Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.7 Raising the Vehicle with Suspension 1BA, 1BB, 1BR, 1BE, 1BV, 1BD, 2MC, 2ME . . . . . . 237
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
3.2 Wheel Alignment Specified Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
4.1 Mechanical Center Position of Rack, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4.2 Front Axle Camber, Checking and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4.3 Rear Axle Camber, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Contents iii
4.4 Rear Axle Toe, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

4.5 Front Axle Toe, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4.6 Adjusting Toe Constant S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
4.7 Front Axle Toe, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
5.1 Tires, Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
5.2 Metal Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
5.3 Tire Pressure Monitoring Control Module J502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
5.4 Rear Tire Pressure Monitoring Antenna R96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.1 Steering Column Transport Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.2 Power Steering, Checking Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.3 Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.4 Steering System, Bleeding after Reconstructing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
2.1 Steering Wheel with Airbag Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2.2 Steering Column Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
2.3 Power Steering Gear Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
2.4 Power Steering Gear Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2.5 Heat Shield Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
2.6 Power Steering Gear, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
2.7 Servotronic Steering Gear Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2.8 Power Steering Pump, Reservoir and Hydraulic Lines Overview . . . . . . . . . . . . . . . . . . . . 263
2.11 by copyright.
Protected SuctionCopyingHose, Location
for private on Power
or commercial Steering
purposes, in part or inPump ................................
whole, is not 270
2.12 Suction Hose, Location on Power Steering Fluid
Reservoir ........................ 270
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
4.1 Steering Column, Checking for Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
4.2 Servotronic Steering Gear Fault Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
4.3 Voltage Supply for Servotronic, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4.4 Speed Signal, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4.5 Servotronic Control Module J236 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.6 Steering System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.7 Power Steering Pump, Checking Delivery Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
5.1 Steering Wheel with Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
5.2 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
5.3 Steering Lock with Ignition Switch, without Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 284
5.4 Power Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
5.5 Tie Rod End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
5.6 Tie Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
iv Contents
7 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Contents v
vi Contents
00 – General, Technical Data

1 General Information
(Edition 10.2013)
⇒ “1.1 Repairing Damaged Threads”, page 1
⇒ “1.2 Thread in Longitudinal Member, Servicing”, page 1
1.1 Repairing Damaged Threads

Damaged threads can be repaired using wire inserts (heli-coil).
Shavings that remain in the body must be imbedded in wax.
1.2 Thread in Longitudinal Member, Servic‐

ing
It is possible to service the threads of the weld nuts in the longi‐
tudinal member depending on certain conditions.
♦ Servicing work may only be performed once per thread.
WARNING
Wear protective goggles when drilling.
♦ Have the thread repair checked by the responsible foreman or

next person in charge.
♦ Thread insert must be same length as thread in body.
♦ Correct any damage to the underbody sealant layer. Refer to
⇒ General Information; Body Repairs, Body Collision Repair .
1. General Information 1
2 Description and Operation

⇒ “2.1 Front Gas-Filled Strut, Venting and Emptying”, page 2
⇒ “2.2 Rear Gas-Filled Strut, Venting”, page 3
⇒ “2.3 Power Steering Gear, Emptying”, page 4
2.1 Front Gas-Filled Strut, Venting and

Emptying
A - Venting through Drill Holes
– Secure
permittedgas-filled shock
unless authorised absorber
by AUDI AG. AUDI AG vertically in a vise,
does not guarantee with
or accept anypis‐
liability
ton rod facing down.
WARNING
Wear protective goggles while drilling.
– Drill a 3 mm hole -arrow A- through the outer shock absorber

tube.
Note
Gas escapes when drilling.
– Continue drilling until the tube inside is drilled through (ap‐

proximately 25 mm deep).
– Drill a second 6 mm hole -arrow B- through the outer and inner
shock absorber tubes.
– Hold shock absorber over appropriate container for catching
oil and move piston rod repeatedly through entire stroke until
no more oil flows out.
B - Open with Pipe Cutter
Special tools and workshop equipment required

♦ Pipe cutter, for example Stahlwille Express 150/3
WARNING
Wear protective goggles when drilling or sawing.
2 Rep. Gr.00 - General, Technical Data

– Drill a 3 mm diameter hole -arrow- through the outer shock

absorber tube or saw through tube wall.
Note
Gas escapes when drilling or sawing.
– Attach a pipe cutter as shown in illustration, and cut through

outer shock absorber tube.
– Pull the piston rod upward, hold the inner shock absorber tube
in place with pliers and push it downward so that it remains in
the outer shock absorber tube when the piston rod is slowly
raised.
– Remove the piston rod from the shock absorber inner tube.
– Empty the shock absorber tube.
2.2 Rear Gas-Filled Strut, Venting

A - Venting through Drill Holes
– Secure gas-filled shock absorber vertically in vise, with piston
rod facing down.
WARNING
Wear protective goggles while drilling.
– Drill a hole 3 mm hole -arrow A- through outer shock absorber

tube of strut.
Note
Gas escapes when drilling.
– Continue drilling until the tube inside is drilled through (ap‐

proximately 25 mm deep).
– Drill a second 6 mm hole -arrow B- through the outer and inner
shock absorber tubes.
– Hold shock absorber over appropriate container for catching
oil and move piston rod repeatedly through entire stroke until
no more oil flows out.
B - Open with Pipe Cutter

♦ Pipe cutter, for example Stahlwille Express 150/3
WARNING
Wear protective goggles when drilling or sawing.
2. Description and Operation 3

– Drill a 3 mm diameter hole -arrow- through the outer shock

absorber tube or saw through tube wall.
Note
Gas escapes when drilling or sawing.
– Attach a pipe cutter as shown in illustration, and cut through

outer shock absorber tube.
– Pull the piston rod upward, hold the inner shock absorber tube
in place with pliers and push it downward so that it remains in
the outer shock absorber tube when the piston rod is slowly
raised.
– Remove the piston rod from the shock absorber inner tube.
– Empty the shock absorber tube.
2.3 Power Steering Gear, Emptying
Note
Room temperature must be at least 20 °C (68 °F) when emptying

steering gear.
– Hold the power steering gear that will be opened over the oil
collecting container and let the hydraulic oil drain.
– Clamp the power steering gear horizontally in the vise with the
connections facing down.
– Place the oil collecting container under the power steering
gear.
– Move the steering rack over the tie rod approximately 6 times
over the from one end to the other.
– Dispose of the power steering gear.

3 Specifications
⇒ “3.1 Chassis”, page 5
⇒ “3.2 Steering”, page 6
3.1 Chassis
Front Suspension Four-link lightweight suspension with virtual steering axis, transverse stabilizer, twin
gas-filled struts and coil springs, control arm with hydraulic damping mounts
Rear Suspension Trapezoidal control arm - rear axle, independent suspension
Vehicles up to VIN 400 000

Front/All Wheel Drive
Model: Sedan/Avant Convertible
Standard Suspension Sport Suspension Comfort Heavy Du‐ Standard Sus‐
1BA 1BE Sport Suspen‐ ty Suspension 1BR pension 1BA
sion 1BV (quattro Sport Suspen‐
GmbH) Audi S4 1BD sion 1BE
Wheel‐ mm 2645 2651 2642 2650
base
Front track mm 1524 1 1528 1 1521 1 1522 2
Rear track mm 1
1517 by copyright. Copying for 1523
Protected
1
private or commercial purposes,1513
1
in part or in whole, is not 1517 2
maximum Degree 38 38 38
38
steering
angle at in‐
ner wheel
♦ 1These target values correspond to a wheel offset of ET 39

mm and a load condition of empty without driver
♦ 2These target values correspond to a wheel offset of ET 42
mm and a load condition of empty without driver.
Vehicles from VIN 400 001
Front/All Wheel Drive
Model: Sedan/Avant
Standard Sus‐ Sport Sus‐ Comfort Heavy Basic Suspen‐ Sport Suspen‐
pension 1BA pension 1BE Duty Suspen‐ sion 2MC sion 2ME
Sport suspen‐ sion 1BR (quattro GmbH (quattro GmbH
sion 1BV RS4) RS 4)
(quattro
GmbH) Audi
S4 1BD
Wheelbase mm 2644 2649 2640 2649 2652
Front track mm 15221 15241 15171 15231 15251
Rear track mm 15151 15211 15101 15331 15351
maximum Degree 38 38 38 38 38
steering an‐
gle at inner
wheel
1These specified values correspond to a wheel offset of ET 42
mm and a load condition “empty without driver”.
3. Specifications 5
Note
♦ The specified values apply to all engine versions.

♦ Tracks change with use of wheels with different offset.
3.2 Steering
Steering Gear Servo assisted, maintenance-free rack-and-pinion steering
Turning diameter Approximately 11 ma

4 Diagnosis and Testing

⇒ “4.1 Shock Absorbers, Leaking”, page 7
⇒ “4.2 Shock Absorber, Noises”, page 7
⇒ “4.3 Shock Absorbers, Removed, Checking”, page 7
⇒ “4.4 Shock Absorbers, Checking on Shock Tester”, page 8
4.1 Shock Absorbers, Leaking

Shock absorbers are frequently rejected and exchanged because
of leaks. Examinations on the test stand and on the vehicle have
shown that the replacement of a large number of rejected shock
absorbers was not justified.
Slight leaking of oil (sweating) at piston rod seal is no reason to
replace a shock absorber. A shock absorber damp with oil is OK
under the following circumstances:

♦ Oil leak (shown screened in illustration) is visible, but dull,

matte and possibly dry from dust
♦ Oil excretion extends from upper shock absorber connection
(piston rod oil seal) no further than lower spring plate -arrow-
Note
Minor oil excretion is advantageous since piston rod oil seal gets
lubricated, which increases service life. This is true for front and
rear shock absorbers.
4.2 Shock Absorber, Noises

Shock absorbers are frequently rejected and exchanged because
of rumbling noises. Examinations on the test stand and vehicle
have shown that there was not complaint with approximately 70%
of the rejected shock absorbers and the replacement was not
justified.
With complaints that are interpreted as rumbling or knocking
sounds, proceed as follows.
– Determine on a road test with the customer - if possible on a
dry stretch of road with irregularities - where, when and how
these sounds change.
Note
Only in the rarest of cases shock absorbers are the fault for
noises.
4.3 Shock Absorbers, Removed, Checking

Defective shock absorbers are noticeable when driving due to
loud rumbling noises - a result of wheel hopping - especially on
4. Diagnosis and Testing 7

poor stretches of road. Moreover, they can be recognized by a

large loss of oil.
Note
Shock absorbers are maintenance-free, shock absorber oil can‐

not be topped off.
A removed shock absorber can be checked by hand as follows:

– Press shock absorber together by hand.
♦ Piston rods must move smoothly and with uniform difficulty
over the entire range.
– Release piston rods.
♦ On shock absorbers with sufficient gas pressure, piston rods
return to initial position by themselves.
Note
♦ If this is not the case, shock absorber must be replaced. As

long as oil loss is not large, the effectiveness represents that
of a conventional shock absorber.
♦ The damping function is also completely available without gas
pressure, as long as there is no large loss of oil. However,
noise may increase.
4.4
Shock Absorbers, Checking on Shock
Tester

♦ Boge Shock Tester or
♦ Sachs Shock Tester - VAG1975- or
♦ Maha Shock Absorber Tester - VAS 1990-
Shock absorbers can be checked while installed using the shock
tester (shock absorber testing device). The damping effect can
be evaluated based on the dial reading or print-out.
Note
♦ Temperature: 10 to 40 °C (104 °F)

♦ Driver in vehicle.
♦ Tire pressure OK.
♦ Drive vehicle straight onto center of wheel contact plates.
♦ Front wheels in straight position.
♦ Parking not engaged, foot brake not activated.
Threshold
Shock absorber condition can only be judged as follows:
♦ Sufficient damping effect.
or
♦ Insufficient damping effect.

Note
♦ Intermediate values for reduced damping performance cannot

be read out.
♦ A prognosis on service life is not permitted.
♦ Measured values that occur with the involvement of the sus‐
pension travel end stops are incorrect.
The following values apply only to the test stands named above.
If the specified values are exceeded, the shock absorber action
has weakened enough that a replacement is recommended.
Example:
Threshold = 70
♦ -a- = Greater than 70: Insufficient damping effect.
♦ -a- = Less than 70: Sufficient damping effect.
Shock absorber combination installed in vehicle is indicated by
corresponding PR number on vehicle data plate.
Explanation of numbers relevant for production weight (PR num‐
ber) ⇒ page 81
Threshold -a- in mm
Note
♦ If the readout value is greater than the limit value -a- (table
value): Damping effect insufficient, replace shock absorber.
♦ If the readout value is less than the limit value -a- (table value):
Damping effect sufficient, shock absorber does not need to be
replaced.
Vehicles up to VIN 400 000
Vehicle Type Front Suspen‐ Rear Suspen‐ Comment

sion sion
A4 standard front axle se‐ 44 / Up to and including support spring OJJ
dan/avant (up to front axle weight 918 Kg)
A4 standard front axle se‐ 46 / From support spring OJK
dan/avant (from front axle weight 919 Kg)
A4 standard rear axle se‐ / 66 Applies to FWD and AWD
dan/avant
A4 Standard front axle con‐ 44 / No weight difference
vertible
A4 Standard rear axle con‐ / 60 Applies to front
vertible
A4 Sport front axle sedan/ 43 / Up to and including support spring OJG

avant (up to front axle weight 923 kg)
A4 Sport front axle sedan/ 45 / From support spring OJH
avant (from front axle weight 924 Kg)
A4 Sport rear axle sedan/ / 65 Applies to FWD and AWD
avant
A4 Sport VA convertible 40 / Up to and including support spring OJG
(up to front axle weight 923 kg)

Vehicle Type Front Suspen‐ Rear Suspen‐ Comment

sion sion
A4 Sport VA convertible 42 / From support spring OJH
(from front axle weight 924 Kg)
A4 Sport HA convertible 65 Applies to FWD and AWD
A4 heavy duty suspension 48 / Up to and including support spring OJJ

front axle sedan/avant (up to front axle weight 918 Kg)
A4 heavy duty suspension 48 / From support spring OJK
front axle sedan/avant (from front axle weight 919 Kg)
A4 heavy duty suspension / 66 Applies to FWD and AWD
rear axle sedan/avant
A4 S4 VA sedan/Avant 42 / No weight difference

A4 S4 HA sedan/Avant / 55 Applies to AWD
Vehicles from VIN 400 001 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Vehicle type Front Suspen‐ Rear Suspen‐ Comment
sion sion
A4 standard front axle se‐ 42 / Up to and including support spring OJJ
dan/avant (up to front axle weight 918 Kg)
A4 standard front axle se‐ 44 / From support spring OJK
dan/avant (from front axle weight 919 Kg)
A4 standard rear axle se‐ / 47 Applies to FWD and AWD
dan/avant
A4 Sport front axle sedan/ 50 / Up to and including support spring OJG

avant (up to front axle weight 923 kg)
A4 Sport front axle sedan/ 52 / From support spring OJH
avant (from front axle weight 924 Kg)
A4 Sport rear axle sedan/ / 42 Applies to FWD and AWD
avant
A4 heavy duty suspension 48 / Up to and including support spring OJJ

front axle sedan/avant (up to front axle weight 918 Kg)
A4 heavy duty suspension 48 / From support spring OJK
front axle sedan/avant (from front axle weight 919 Kg)
A4 heavy duty suspension / 66 Applies to FWD and AWD
rear axle sedan/avant

5 Special Tools
♦ Boge Shock Tester or
♦ Sachs Shock Tester - VAG1975- or
♦ Maha Shock Absorber Tester - VAS 1990-
5. Special Tools 11
40 – Front Suspension
⇒ “1.1 Front Suspension”, page 12
⇒ “1.2 Light Weight Wheel Hub Characteristics”, page 13
⇒ “1.3 Vehicle Level Sensor for Vehicles with Automatic Head‐
lamp Vertical Aim Control”, page 13
1.1 Front Suspension

When installing waxed components, contact surfaces must be
cleaned. Contact surfaces must be free of wax and grease.
Tightening specifications for unoiled bolts and nuts are given.
Welding or straightening operations are not permitted on load-
bearing or wheel-controlling components.
Always avoid the following actions with coil springs: Hammer
strokes, welding beads, applying color identification later.
Do not perform any welding or grinding (separating work) in coil
spring or suspension strut area! Cover coil spring or suspension
struts if necessary.
Vehicles without drive axle must not be moved, otherwise wheel
bearing will be damaged. If vehicle does have to be moved, al‐
ways note the following points:
– Install an outer joint in place of the drive axle.
– Tighten outer joint to 115 Nm (M14 bolt) or 200 Nm (M16 bolt).
Bonded rubber bushings can only be turned to a limited extent.
Only tighten threaded connections at control arms if vehicle is in
curb weight position. Refer to
⇒ “2.1 Wheel Bearing, Lifting to Curb Weight Position”,
page 15 .
Note
If the vehicle axle must still be aligned, every bolt and nut that
must be loosened for adjustment is only tightened to tightening
specification. Tighten the bolts and nuts to the specified additional
tightening angleProtected
after the alignment/adjustment is complete.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
WARNING
All bolts and nuts must be tightened properly before driving the
vehicle!
12 Rep. Gr.40 - Front Suspension

1.2 Light Weight Wheel Hub Characteristics

Light construction wheel hub can be differentiated from traditional
wheel hub by -1- washer and by -2- sleeve.
The light weight wheel hub must only be used in conjunction with
the corresponding wheel bearing. Allocation, refer to the Parts
Catalog.
Slide washer -1- should be replaced if deformed or damage dur‐
ing wheel bearing removal.
1.3 Vehicle Level Sensor for Vehicles with

Automatic Headlamp Vertical Aim Con‐
trol
Vehicles with gas discharge headlamps come standard with au‐
tomatic headlamp range control.
To function properly, the automatic vertical aim control system
needs information about compression travel or rebound travel at
the front and rear axles.
For this, the position of the lower left control arm relative to the
body is transferred to the Left Front Level Control System Sensor
- G78- via a coupling rod. This transmits electrical signals to the
Headlamp Range Control Module - J431- .
Headlamp range control module removal and installation, refer to
⇒ Electrical Equipment; Rep. Gr. 94 ; Removal and Installation .
On the rear axle, the signals are transmitted to the Headlamp
Range Control Module from the Left Rear Level Control System
Sensor - G76- .
These signals are required for determining vehicle level.
The headlamp range control responds automatically to changes
in the vehicle level.
The vehicle level can change in the following situations:
♦ Trailer Mode.
♦ Different load conditions: Vehicle empty, vehicle partially or
fully loaded.
♦ Slow or fast driving habit.
WARNING
Adjustment of headlamps! Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
It is always necessary to check basic setting of headlamps when‐

ever:
♦ The track control arm has been removed and reinstalled or
replaced.
♦ Installation work has been performed on the level control sys‐
tem sensor.
♦ The level control system sensor has been replaced.
♦ The retaining clip for the coupling rod on the track control link
has been loosened.
Headlamp basic setting, refer to ⇒ Electrical Equipment; Rep.
Gr. 94 ; Diagnosis and Testing .


page 15
⇒ “2.2 Front Suspension Overview”, page 16
⇒ “2.3 Vehicle Level Sensor Overview, Vehicles with Automatic
Headlamp Vertical Aim Control”, page 20
⇒ “2.4 Drive Axle with Triple Roller Joint AAR 2000 Overview”,
page 21
⇒ “2.5 Drive Axle with Peened Triple Roller Joint AAR 2600 i or
3300 i Overview”, page 23
⇒ “2.6 Drive Axle with Triple Roller Joint AAR 2900 Overview”,
page 27
⇒ “2.7 Drive Axle with Inner Constant Velocity Joint, 100 mm
Overview”, page 29
⇒ “2.8 Drive Axle with Inner CV Joint, 108 mm, Overview”,
page 32
2.1 Wheel Bearing, Lifting to Curb Weight

Position
♦ Engine and Gearbox Jack - VAS6931-
♦ Tensioning Strap - T10038-
♦ Engine/Gearbox Jack Adapter - Wheel Hub Support - T10149-
Note
All bolts at suspension parts with bonded rubber bushings must

always be tightened in curb weight position (unloaded condition).

Parts with bonded rubber bushings must therefore be brought into
a position that corresponds to the position in driving mode before
being tightened (curb weight position).
Otherwise, bonded rubber bushing will be stressed resulting in a
shortened service life.
By raising appropriate suspension using Engine and Gearbox
Jack - VAS6931- and Engine/Gearbox Jack Adapter - Wheel Hub
Support - T10149- , this position can be simulated on the hoist.

– Before starting work, take measurement -a-, for example with

a tape measure, from center of wheel to lower edge of wheel‐
house.
Note
Measurement must be performed in curb weight position (unloa‐

ded condition).
– Note measured value. It will be required for tightening bolts/

nuts.
Before appropriate suspension is raised, vehicle must be strap‐
ped to lift arms of hoist using Tensioning Strap - T10038- .
WARNING
If a vehicle is not secured, there is danger that the vehicle could

slip off the lift!
– Turn wheel hub far enough until one of the holes for wheel
bolts is on top.
– Install Engine/Gearbox Jack Adapter - Wheel Hub Support -
T10149- with wheel bolt on wheel hub.
– Using Engine and Gearbox Jack - VAS6931- , lift wheel bear‐

ing housing until dimension -a- is reached.
Note
Tightening of the respective bolts/nuts must only occur if dimen‐

sion -a-, measured before installation between wheel hub center
and lower edge of wheel house, has been attained.
WARNING
♦ Do not lift or lower the vehicle with Engine and Gearbox

Jack - VAS6931- below vehicle.
♦ Do not leave Engine and Gearbox Jack - VAS6931- below
vehicle any longer than necessary.
– Tighten respective bolts/nuts.

– Lower wheel bearing housing.
– Move Engine and Gearbox Jack - VAS6931- away from under
vehicle.
– Remove Engine/Gearbox Jack Adapter - Wheel Hub Support

- T10149- .
2.2 Front Suspension Overview

1 - Bolt
❑ 75 Nm
2 - Washer
3 - Bolt
❑ Always replace after re‐
moval.
4 - Upper Rear Control Arm
❑ Removing and instal‐
ling, refer to
⇒ “5.6 Upper Control
Arm”, page 56 .
❑ Replace bearing. Refer
to
⇒ “5.7 Front and Rear
Upper Control Arm
Bearing”, page 57 .
5 - Bolt
❑ 5 Nm
moval.
❑ For adjusting track con‐
stants S.
6 - Bolt
7 - Nut
❑ Self-locking
❑ 45 Nm
moval
8 - Bolt
❑ 40 Nm
9 - Nut
❑ Self-locking
❑ Always replace after removal.
10 - Upper Front Control Arm
❑ Mounting bracket, removing and installing, refer to ⇒ “5.5 Mounting Bracket”, page 56 .
❑ Replace bearing, refer to ⇒ “5.7 Front and Rear Upper Control Arm Bearing”, page 57 .
11 - Suspension Strut
❑ Note different types of suspension versions, see vehicle data plate. Refer to ⇒ page 81 .
❑ On vehicles with Dynamic Ride Control (DRC), empty and fill the system. Refer to
⇒ “2.3 Dynamic Ride Control, Emptying and Filling”, page 209 .
❑ Removing and installing, refer to ⇒ “5.1 Suspension Strut”, page 43 .
❑ Servicing, refer to ⇒ “6.1 Suspension Strut”, page 80
❑ Mounting bracket, removing and installing, refer to ⇒ “5.5 Mounting Bracket”, page 56 .
12 - Bolt
❑ 70 + 180° turn
13 - Guide Link
❑ Guide link, removing and installing, refer to ⇒ “5.15 Guide Link”, page 73 .
If the hydro-mount leaks, it must be replaced, refer to ⇒ “5.16 Guide Link Bearing”, page 75 .

14 - Nut
❑ 110 Nm
15 - Wheel Bearing Housing
❑ On vehicles with headlamp range control module, note sensor removal and installation. Refer to
⇒ “2.3 Vehicle Level Sensor Overview, Vehicles with Automatic Headlamp Vertical Aim Control”,
page 20 .
❑ Removing and installing, refer to ⇒ “5.2 Wheel Bearing Housing”, page 46 .
❑ Servicing, refer to ⇒ “5.3 Wheel Bearing Housing with Bolted Wheel Bearing”, page 50 .
16 - Collar Bolt
❑ Note work sequence. When loosening, refer to ⇒ page 78 . When tightening, refer to ⇒ page 79 .
❑ Tightening specification, refer to ⇒ page 79 .
17 - Bolt
❑ 10 Nm
18 - Cover Plate
19 - Nut
❑ Self-locking.
20 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 90 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
21 - Support for Subframe
❑ A tunnel crossmember can also be installed instead of subframe supports.
❑ Tunnel crossmember, removing and installing, refer to ⇒ “5.11 Tunnel Crossmember”, page 67 .
22 - Bolt
❑ 65 Nm
23 - Bolt
❑ 110 + 90° turn
❑ Always replace after removal
❑ Threads in body can be repaired according to DIN 8140 using wire thread inserts (Heli-Coil). Thread
insert must be same length as thread in body.
24 - Bolt
❑ 40 + 90° turn
25 - Coupling Rod
26 - Bolt
❑ 40 Nm + 90° turn
27 - Lower Control Arm
❑ On vehicles with headlamp range control module, note sensor removal and installation. Refer to
page 20 .
❑ Control arm, removing and installing, all engine versions except 3.2L FSI, refer to
⇒ “5.12 Control Arm,”, page 69 .
❑ Control arm, removing and installing on vehicles with 3.2L FSI, refer to
⇒ “5.13 Control Arm”, page 70 .
28 - Bolt
❑ 70 Nm + 180° turn

29 - Bolt
❑ 75 Nm
❑ Threads in body can be repaired according to DIN 8140 using wire thread inserts (Heli-Coil). Thread
insert must be same length as thread in body.
30 - Subframe
❑ With different versions of the subframe: Subframe with bonded rubber bushings in subframe/body
mounting points (all vehicles except convertible). The bonded rubber bushings is replaceable for the
subframe without the bonded rubber bushings in the subframe/body mounting points, but only with wel‐
ded steel bushings (convertible only). Steel bushings cannot be replaced, replace subframe if damaged.
Application, refer to the Parts Catalog.
❑ Short diagonal braces are installed in the subframe at the start of production (in each case, the diagonal
brace is connected once to the rear outer subframe and to the underbody). With running changes, the
subframe is repositioned with the diagonal brace lengthwise (in each case, the diagonal brace is con‐
nected once to the front and center subframe and to the underbody). There are no subframes for the first
version that are available as replacement parts. Therefore, the diagonal braces must be repositioned
lengthwise when exchanging subframes for the following version, refer to
⇒ “5.22 Front or Rear Diagonal Braces”, page 179 . The allocation for the respective replacement parts
may be found in the
Protected Parts Copying
by copyright. Catalog.for private or commercial purposes, in part or in whole, is not
❑ On vehicles withwithrespect
headlamp range control module, note sensor removal and installation. Refer to
to the correctness of information in this document. Copyright by AUDI AG.
page 20 .
❑ Removing and installing, refer to ⇒ “5.8 Subframe”, page 58 .
❑ Bonded rubber bushings for subframe, replacing, refer to ⇒ “5.9 Subframe Mount”, page 64
❑ Tunnel crossmember, removing and installing, refer to ⇒ “5.11 Tunnel Crossmember”, page 67 .
31 - Nut
❑ Self-locking
32 - Nut
❑ Self-locking
33 - Bolt
❑ Pre-tighten all bolts to 15 Nm, then tighten all bolts to specified torque.
❑ Tightening specifications:
M8 bolt: 40 Nm
M10 bolt: 70 Nm
34 - Backing Plate
35 - Drive Axle
❑ Removing and installing, refer to ⇒ “5.19 Drive Axle”, page 78 .
36 - Bolt
37 - Nut
❑ 50 Nm + 90° turn
❑ Self-locking
38 - Nut
❑ 50 Nm

2.3 Vehicle Level Sensor Overview, Vehicles with Automatic Headlamp Vertical
Aim Control
1 - Bolt
❑ 9 Nm
2 - Bracket
3 - Left Front Level Control
System Sensor - G78-
❑ Is checked electrically
through On Board Diag‐
nostics (OBD).
❑ In the event of com‐
plaints, perform Guided
Fault Finding using Ve‐
hicle Diagnosis, Testing
And Information System
- VAS5051A- .
ling, refer to
⇒ page 20
4 - Nut
❑ 10 Nm
❑ Self-locking
moval.
5 - Connecting Link from Left
Front Level Control System
Sensor
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Do not remove connecting link from
Left Front Level Control System
Sensor ball head!
6 - Retaining Clip
❑ Retaining clip closure
must face upward at
control arm and backward in direction of travel.
7 - Bolt
❑ 4 Nm
8 - Pop Rivet
Removing and Installing

♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Torque Wrench - VAG1410-
When removing and installing control arm, it is necessary to loos‐
en Left Front Level Control System Sensor - G78- retaining clip.

Note
To avoid damaging the seal, install the connecting link to the Left
Front Level Control System Sensor - G78- using a wrench
(wrench width 10) with the dimension -A- = 4 mm.
– Dimension -A- = 4 mm
– Mount wheel and tighten. Refer to ⇒ Wheel and Tire Guide;
Rep. Gr. 44 ; General Information .
– Left Front Level Control System Sensor connecting link re‐
taining clip is secured at control arm between stops with a
clamp.
When installing headlamp range control, ensure correct position
of crank and connecting link to each other.
Note
♦ Connecting link must face forward diagonally.

♦ Crank must face rearward.
2.4 Drive Axle with Triple Roller Joint AAR

2000 Overview
Grease Quantity and Type
Filling outer joint with grease G 000 603.
Filling triple roller joint with grease G 000 605.
Grease Quan‐ of Total:
tity
Outer joint Total quantity Joint Boot
[mm] [g] [g] [g]
88 90 50 40
Inner joint
72
permitted unless authorised by AUDI AG.110 80 or accept any liability
AUDI AG does not guarantee 30
Re-grease joint when replacing CV boot.

1 - Bolt
moval.
❑ Loosening, refer to
⇒ page 78 .
❑ Fastening, refer to
⇒ page 79 .
❑ Tightening specification
⇒ page 79 .
2 - Clamp Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Replace. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
3 - CV Boot
❑ Check for tears and
scuffing.
❑ Before clamping hose
clamp, raise protective
joint boot briefly to bal‐
ance pressure.
4 - Clamp
❑ Replace.
5 - Bolt
❑ Pre-tighten all bolts to
15 Nm, then tighten all
bolts to specified torque.
❑ Tightening specifica‐
tions:
M8 bolt: 40 Nm
M10 bolt: 70 Nm
❑ Application, refer to the

Parts Catalog.
6 - Joint Piece
7 - Triple Roller Star with Rollers
❑ The chamfer -arrow- points to drive axle splines.
❑ When installing triple roller star on axle shaft, splines on axle shaft must be lightly coated with grease
used in joint.
8 - Securing Ring
❑ Replace.
9 - O-Ring
❑ Replace.
10 - Cover
❑ Replace.
11 - Clamp
❑ For triple roller joint.
❑ Replace.
12 - Protective Joint Boot for Triple Roller Joint
❑ Check for tears and scuffing.
❑ Before clamping hose clamp, raise protective joint boot briefly to balance pressure. Joint must be in
center position for this.
13 - Drive Axle
14 - Securing Ring
❑ Replace.
❑ Insert in shaft groove.
15 - Outer Constant Velocity Joint
❑ Replace only as complete unit.
❑ Installing: Drive onto shaft using plastic hammer until compressed circlip seats.
❑ Greasing, refer to ⇒ page 21 .
❑ Checking, refer to
⇒ “4.1 Outer Constant Velocity Joint with Triple Roller Joint AAR 2000, Checking”, page 36 .
❑ When installing the joint on the profile shaft, the splines on the profile shaft must be lightly coated with
grease used in joint.
2.5 Drive Axle

Protected with Copying
by copyright. Peened Triple
for private Roller
or commercial purposes, in part or in whole, is not
Joint with
AAR 2600 i or 3300 i Overview
respect to the correctness of information in this document. Copyright by AUDI AG.
Filling Triple Roller Joint Shaft with Grease

Grease allocation, refer to the Replacement Parts Catalog.
Grease of Total:
Outer Joint Total Quantity Joint Boot
Diameter mm [g] [g] [g]
100 120 80 40
88 90 50 40
Inner joint
130 70 60

1 - Clamp
❑ Always replace.
❑ Different clamps possi‐
ble depending on mod‐
el. Allocation, refer to
the Replacement Parts
Catalog.
❑ Can also be installed
with Pliers - 3340- .
2 - Protective Joint Boot for Tri‐
ple Roller Joint
❑ Protective joint boot
must fit in groove and on
joint contour.
3 - Clamp
❑ Always replace.
4 - Securing Ring
❑ Only present on certain
versions.
Parts Catalog.
5 - Dished Washer
versions.
❑ Installed position, refer
to ⇒ page 26 .
Parts Catalog.
6 - Spacer Ring
❑ Plastic

versions.
to ⇒ page 26 .
❑ Application, refer to the Parts Catalog.
7 - Securing Ring
❑ Always replace.
❑ Insert before mounting in ring groove (not visible with joint installed).
❑ Pressing off, refer to ⇒ page 26 .
❑ Installing:
❑ Install the joint onto shaft with a plastic hammer until circlip engages
❑ Greasing, refer to
⇒ “2.5 Drive Axle with Peened Triple Roller Joint AAR 2600 i or 3300 i Overview”, page 23 .
9 - Bolt
❑ Loosen, refer to ⇒ page 78 .
❑ Fastening, refer to ⇒ page 79 .
10 - Clamp
❑ Replace
❑ Different versions for protective joint boot in rubber or Hytrel. Allocation, refer to the Parts Catalog.
11 - CV Boot for Outer Constant Velocity (CV) Joint
❑ Before clamping hose clamps, raise protective joint boot briefly to balance pressure. Refer to
⇒ page 26 .
❑ Different version in rubber or Hytrel. Allocation, refer to the Parts Catalog.
❑ Replace.
13 - Drive Axle
❑ Different versions. Allocation, refer to the Parts Catalog.
14 - Securing Ring
15 - Triple Roller Star
❑ The chamfer -arrow- points to drive axle splines.
used in joint.
16 - Securing Ring
❑ Replace.
17 - Bolt
M8 bolt: 40 Nm

M10 bolt: 70 Nm
18 - Joint Piece
Joint protective boots made from rubber are tightened with hose
clamp pliers - VAG1275- .
Tightening Clamp on Inner Joint
Driving Outer CV Joint Down

– Secure drive axle with protective covers in vise clamp.
– Remove largeProtected
clamping sleeve
by copyright. andforturn
Copying back
private protective
or commercial joint
purposes, in part or in whole, is not
boot. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Using a hammer, hit a copper or brass mandrel onto inner race
of CV joint.
Venting CV Boot
Only for joint protective boot of rubber.
A vacuum can form in the joint when installing the protective joint
boot.
This pressure pulls a fold in while driving -see arrow-.
Therefore, observe the following:
– Before clamping sleeves, balance pressure by raising protec‐
tive joint boot.
Installed Position of Spacer Ring and Dished Washer (wheel side)
Items 1 to 3 only present on certain versions. Allocation, refer to

the Parts Catalog.
1 - Securing ring
2 - Dished washer
3 - Spacer ring (plastic)
Note
Instructions only apply to stainless steel clamps.

Tightening Hose Clamp on Outer Joint

– Position CV Joint Boot Clamp Tool - VAG1682- as shown in
illustration. Make sure that edges of CV Joint Boot Clamp Tool
- VAG1682- are seated in corners -arrows B- of hose clamp.
– Tighten clamp by turning spindle with a torque wrench (do not
tilt clamp tool).
♦ Tightening specifications: 20 Nm.
♦ Use a torque wrench with an adjustment range of 5 to 50 Nm
(for example Torque Wrench 1331 5-50Nm - VAG1331- ).
♦ Make sure that the spindle thread is not tight. If necessary lu‐
bricate with MOS 2 grease.
♦ CV Joint Boot Clamp Tool - VAG1682-

2900 Overview
Grease Quantities and Grease Types for Tripod Drive Axle
Greasing CV joint diameter 98 using grease - G 000 633- .
Greasing triple roller joint using grease - G 000 605- .
Grease of Total:
Outer Joint Total Quantity Joint Boot
Diameter mm [g] [g] [g]
98 120 80 40
Inner joint Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
100 80 permitted 30 50AG. AUDI AG does not guarantee or accept any liability
unless authorised by AUDI

1 - Bolt
Tightening specification M16
bolt:
❑ 190 Nm + 180° turn
moval
Observe assembly notes when
removing. Refer to
⇒ “5.19 Drive Axle”,
page 78
Observe assembly notes when
installing. Refer to
⇒ page 79 .
2 - CV Boot for Outer Constant
Velocity (CV) Joint
scuffing.
⇒ page 27 .
❑ Before tightening hose
clamp, briefly raise CV
boot to allow pressure to
equalize. Refer to
⇒ page 99 .
❑ Different versions in
rubber or Hytrel.
❑ Different versions for permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
CV boot in rubber or Hy‐

trel.
❑ Replace
❑ Tensioning, refer to
⇒ page 98 .
4 - Drive Axle (Tube Shaft)
❑ Before installing outer or inner joint, splines on shaft must be greased.
5 - Clamp
❑ Replace
❑ Tensioning, refer to ⇒ page 98 .
6 - Joint Piece
7 - Bolt
❑ M 10 x 20: 70 Nm
8 - Triple Roller Star
The chamfer -arrow- points to drive axle splines.
❑ Installed position, refer to ⇒ page 96 .
used in joint.
9 - Securing Ring
❑ Always replace.
10 - O-Ring
Sealing must be replaced. New sealing is part of the repair kit.

11 - Cover
❑ Always replace.
❑ Destroyed during disassembly.
❑ A modified cover is included in the repair kit.
12 - Clamp
❑ Always replace.
❑ Different hose clamps are possible depending on construction. Also mountable using Pliers - 3340- .
Allocation, refer to the Parts Catalog.
13 - Protective Joint Boot for Triple Roller Joint
14 - Clamp
❑ Always replace.
15 - Dished Washer
16 - Spacer Ring
❑ Plastic.
17 - Securing Ring
❑ Always replace.
❑ Insert before mounting in ring groove (not visible with joint installed).
❑ Pressing off, refer to ⇒ page 99 .
❑ Installing:
❑ Install the joint onto shaft with a plastic hammer until circlip engages
2.7 Drive Axle with Inner Constant Velocity

Joint, 100 mm Overview
CV joints are packed with grease G 000 603:
tity
[mm] [g] [g] [g]
88 90 50 40
Inner joint Apply grease through ball
paths
100 80 30 50

1 - Bolt
moval.
❑ Loosen, refer to
⇒ page 78 .
❑ Fastening, refer to
⇒ page 79 .
tion, refer to
⇒ page 79 .
2 - Outer Constant Velocity
Joint
❑ Replace only as com‐
plete unit.
❑ Removing, refer to
⇒ page 103 .
❑ Installing, refer to
⇒ page 103 .
⇒ page 29
⇒ “4.2 Outer Constant
Velocity Joint with Inner
Constant Velocity Joint,
100 mm,
permitted Checking”,
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
page 37 . to the correctness of information in this document. Copyright by AUDI AG.
with respect
❑ When installing the joint

on the axle shaft, the
splines on the profile
shaft must be lightly
coated with grease used

in joint.
3 - Securing Ring
❑ Always replace.
❑ Insert before mounting
in ring groove (not visible with joint installed).
4 - Clamp
❑ Always replace.
❑ Check for tears and chafing, replace if necessary.
❑ In case of damage, check outer CV joint. Refer to
⇒ “4.2 Outer Constant Velocity Joint with Inner Constant Velocity Joint, 100 mm, Checking”,
page 37 .
❑ Before clamping hose clamps, raise protective joint boot briefly to balance pressure.
❑ Sealing surfaces must be free of grease when installing.
6 - Drive Axle
7 - Cover
❑ Always replace.
8 - Gasket
❑ Always replace.
9 - Securing Ring
❑ Always replace.
10 - Inner Constant Velocity Joint
❑ Exterior diameter: 100 mm.
❑ Removing, refer to ⇒ page 99 .
❑ Installing, refer to ⇒ page 101 .
❑ Adhesive surface must be free of oil and grease.
⇒ “4.4 Inner CV Joint with Inner Constant Velocity Joint, 100 mm, Checking”, page 39 .
❑ When installing the joint on the axle shaft, the splines on the profile shaft must be lightly coated with
11 - Backing Plate
12 - Bolt
M8 bolt: 40 Nm
M10 bolt: 70 Nm
13 - Protective Boot unless
permitted with authorised
Cap by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ In case of damage, check inner CV joint. Refer to
⇒ “4.4 Inner CV Joint with Inner Constant Velocity Joint, 100 mm, Checking”, page 39 .


❑ Protective boot-drive axle sealing surfaces and cap must be free of grease when installing.
2.8 Drive Axle with Inner CV Joint, 108 mm,

Overview
CV joints are packed with grease G 000 603:
tity
[mm] [g] [g] [g]
100 120 80 40
paths
with 108 120
respect to the correctness of information in this 35
document. Copyright by 85
AUDI AG.
1 - Cover
❑ Always replace.
2 - Locking Ring
❑ Remove and install us‐
ing commercially availa‐
ble locking ring pliers.
3 - Inner Constant Velocity
Joint
❑ Exterior diameter: 108
mm.
plete unit.
⇒ page 104 .
⇒ page 105 .
⇒ page 32 .
❑ Adhesive surface must
be free of oil and grease.
⇒ “4.5 Inner CV Joint
with Inner CV Joint, 108
mm, Checking”,
page 40 .
on the axcle shaft, the
splines on the profile
shaft must be lightly
coated with grease used
in joint.
4 - Protective Boot with Cap
❑ In case of damage,
check inner CV joint.

Refer to
⇒ “4.5 Inner CV Joint with Inner CV Joint, 108 mm, Checking”, page 40 .
❑ Protective boot-drive axle sealing surfaces and cap must be free of grease when installing.
5 - Backing Plate
6 - Bolt
M8 bolt: 40 Nm
M10 bolt: 70 Nm
7 - Drive Axle
❑ Application,
Protected byrefer to the
copyright. Parts
Copying Catalog.
for private or commercial purposes, in part or in whole, is not
8 - Clamp with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Always replace.
❑ Without ventilation bore.
❑ Check for tears and chafing; replace if necessary.
⇒ “4.3 Outer Constant Velocity Joint with Inner CV Joint, 108 mm, Checking”, page 38 .
❑ Sealing surfaces must be free of grease when installing.
10 - Clamp
❑ Always replace.
11 - Securing ring
❑ Always replace.
12 - Dished Washer
13 - Spacer Ring (Plastic)
14 - Securing Ring
❑ Always replace.
❑ Servicing, refer to ⇒ “6.6 Drive Axle with Inner CV Joint, 108 mm Diameter”, page 104 .
❑ Circlip must lie in joint chamfer when guiding in, guide with pliers if necessary.
⇒ “4.3 Outer Constant Velocity Joint with Inner CV Joint, 108 mm, Checking”, page 38 .
❑ When installing the joint on the axle shaft, the splines on the profile shaft must be lightly coated with
16 - Bolt
❑ Always replace.

❑ Loosen, refer to ⇒ page 78 .

❑ Fastening, refer to ⇒ page 79 .

3 Specifications
⇒ “3.1 Fastener Tightening Specifications”, page 35
3.1 Fastener Tightening Specifications

Component Fastener Size Nm
Coupling Rod to Lower Control Arm Bolt 1 - 40 + 90°
Coupling Rod to Stabilizer Bar Bolt 1 - 40 + 90°
CV Joint Boot Clamp - 20
Drive Axle to Transmission Bolt 2 M8 40
M10 70
Drive Axle to Wheel Bearing Bolt - Refer to
⇒ page 79 .
Cover Plate to Wheel bearing Housing Bolt - 10
Guide Link to Subframe Bolt 1 - 70 + 180°
Guide Link to Wheel Bearing Housing Nut 1 - 110
Lower Control Arm to Subframe Bolt 1 - 70 + 180°
Mounting Bracket to Body Bolt - 75
Strut to lower Control Arm Bolt - 90
Strut to Strut Mounting Bracket Nut 1 - 50
Subframe to Body Bolt 1 - 110 + 90°
- 75
Support to Subframe Bolt - 55
Tie Rod End to Wheel Bearing Housing Bolt - 5
Tie Rod End to Wheel bearing Housing Lock Nut 1 - 45
Upper Control Arm to Mounting Bracket Nut 1 - 50 + 90°
Upper Control Arm to Wheel Bearing Housing Lock Bolt -
40
Vehicle Level Sensor to Subframe Bolt
with respect to the correctness of information in this document. Copyright by AUDI -AG. 9
• 1 Always replace after removal.

• 2 Pre-tighten all bolts to 15 Nm, then tighten all bolts to speci‐
fied torque.
3. Specifications 35

⇒ “4.1 Outer Constant Velocity Joint with Triple Roller Joint AAR
2000, Checking”, page 36
⇒ “4.2 Outer Constant Velocity Joint with Inner Constant Velocity
Joint, 100 mm, Checking”, page 37
⇒ “4.3 Outer Constant Velocity Joint with Inner CV Joint, 108 mm,
Checking”, page 38
⇒ “4.4 Inner CV Joint with Inner Constant Velocity Joint, 100 mm,
Checking”, page 39
⇒ “4.5 Inner CV Joint with Inner CV Joint, 108 mm, Checking”,
page 40
4.1 Outer Constant Velocity Joint with Triple

Roller Joint AAR 2000, Checking
It is necessary to disassemble the joint whenever replacing the
grease or if the ball surfaces show wear or damage.
Removing
– Mark position of the ball hub to ball cage and to housing before
disassembling, using electro-writer or grindstone.
– Swing ball hub and ball cage.
– Remove balls in sequence.
– Turn cage, until two rectangular windows -arrow- contact joint

body.
– Lift out cage with hub.
– Swing segment of hub into rectangular window of cage.

– Fold hub out from cage.
6 balls for each joint belong to a tolerance group. Check stub axle,
hub, cage and balls for small depressions (pitting buildup) and
chafing. Excessive circumferential backlash in joint makes itself
noticed via tip-in shock, in such cases joint should be replaced.
Flattening and running marks of balls are no reason to replace
joint.
Installing
– Insert cage with hub into joint body.
– Press in opposing balls in sequence, during this, previous po‐
sition of ball hub to ball cage and to joint body must be
established again.

4.2 Outer Constant Velocity Joint with Inner

Constant Velocity Joint, 100 mm,
Checking
Disassembling
– Mark position of ball hub to ball cage and to housing before
disassembling, using electro-writer or grindstone.
– Turn cage, until two rectangular windows -arrow- contact joint

body.
– Swing segment of hub into rectangular window of cage.

Checking
hub, cage and balls for small depressions (pitting build-up) and
joint.
Assembling
Note
Cage must be installed laterally correct.

established again.
– Press grease quantity into joint body, grease quantity and
type. Refer to ⇒ page 29 .

4.3 Outer Constant Velocity Joint with Inner

CV Joint, 108 mm, Checking
Disassembling
– Before disassembling mark ball hub position in relation to the
ball cage and housing with an electric scriber or oil stone
-see arrow-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Swing ball hub and ball cage. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Turn cage until two cage windows -arrow- rest on joint body.
– Swing a hub segment in a cage window.

Checking
hub, cage and balls for small depressions (pitting build-up) and
joint.
Assembling
Note

established again.
– Press grease quantity into joint body, grease quantity and
type. Refer to ⇒ page 32 .

4.4 Inner CV Joint with Inner Constant Ve‐

locity Joint, 100 mm, Checking
The joint must be disassembled to replace dirty grease or for
checking the balls and ball tracks for wear and damage.
Disassembling
Note
Ball hub and joint are paired and should be identified before re‐
moval. Do not interchange cage allocation.

– Press out ball joint housing in direction of -arrow-.
– Press balls out of cage.
– Flip out ball hub from ball cage via running path of ball
-arrows-.
– Check joint piece, ball hub, ball cage and balls for small broken
off depressions (pitting build-up) and chafing.
Note
Excessive circumferential backlash in joint makes itself noticed

via tip-in shock. Joint must be replaced in such cases. Flattening
and running marks of balls are no reason to replace joint.
Assembling
– Insert ball hub into ball cage via two chamfers. The installation
position is at random. Press balls into cage.
– Insert hub with cage and balls upright into joint piece.
♦ When inserting, make sure that in each case the wide gap
-a- at joint piece contacts narrow gap -b- at hub after swinging
in.
♦ Chamfer on inner diameter of wheel hub (splines) must face
toward drive axle.

– Swing in ball hub, to do so swing out hub far enough from cage
-arrows- so that the balls have the distance of the running
paths.
– Swing in hub with balls by pressing forcefully onto cage

-arrow-.
Constant Velocity Joint, Checking for Function
CV joint is properly assembled, if ball hub can be slid back and
forth by hand over whole compensation length.
4.5 Inner CV Joint with Inner CV Joint, 108

mm, Checking
Disassembling
Note
– Swing ball hub and ball cage and pull out of joint in direction
of -arrow-.

-arrows-.
Checking
Note
Excessive circumferential backlash in joint makesProtected

itself by
noticed
copyright. Copying for private or commercial purposes, in part or in whole, is not
and running marks of balls are no reason to replacewithjoint.
Assembling
Note
When inserting, make sure that in each case the wide gap -a- at
joint piece contacts narrow gap -b- at hub after swinging in.
paths.


-arrow-.

5 Removal and Installation

⇒ “5.1 Suspension Strut”, page 43
⇒ “5.2 Wheel Bearing Housing”, page 46
⇒ “5.3 Wheel Bearing Housing with Bolted Wheel Bearing”, page
50
⇒ “5.4 Light Weight Wheel Hub Slide Washer”, page 55
⇒ “5.5 Mounting Bracket”, page 56
⇒ “5.6 Upper Control Arm”, page 56
⇒ “5.7 Front and Rear Upper Control Arm Bearing”, page 57
⇒ “5.8 Subframe”, page 58
⇒ “5.9 Subframe Mount”, page 64
⇒ “5.10 Subframe Bonded Rubber Bushing Stop Wedges”, page
67
⇒ “5.11 Tunnel Crossmember”, page 67
All Engines Except 3.2L FSI ⇒ “5.12 Control Arm,”, page 69
3.2L FSI ⇒ “5.13 Control Arm”, page 70
⇒ “5.14 Control Arm Bearing”, page 72
⇒ “5.15 Guide Link”, page 73
⇒ “5.16 Guide Link Bearing”, page 75
⇒ “5.17 Stabilizer Bar”, page 76
⇒ “5.18 Crossbrace”, page 77
⇒ “5.19 Drive Axle”, page 78
5.1 Suspension Strut

Removing
On vehicles with Dynamic Ride Control (DRC II), empty the sys‐
tem. Refer to
– Remove wheel trim cap, remove cover cap on light-alloy
wheels (removal hook in vehicle tool kit).
– Remove wheel.
– Secure the brake disc with a wheel bolt.
– Before removing left suspension strut, level control system
sensor link must be loosened from control arm on vehicles with
headlamp range control module by opening retaining clip. Re‐
fer to
⇒ “2.3 Vehicle Level Sensor Overview, Vehicles with Auto‐
matic Headlamp Vertical Aim Control”, page 20 .
– Unclip ABS lineunless
permitted from bracket
authorised at brake
by AUDI caliper.
AG. AUDI AG does not guarantee or accept any liability
5. Removal and Installation 43

Vehicles with Brake Caliper HP-2

– Remove bolt -2- and remove brake line bracket.
– Remove bolts -1- for brake caliper and take off brake caliper.
– Reinstall brake line holder. Install and tighten bolt -2-.
– Secure brake caliper to body so that the weight of the brake
caliper does not stress or damage the brake line.
Continuation for All Vehicles
– Remove brake caliper and secure to body so weight of caliper
does not stress or damage brake hose or brake line.
– Remove clip -1- with a pair of pliers.

This clip does not need to be inserted again.
– Remove nut -2-, remove bolt and remove both control arms
upward.
Caution
The slits in the wheel bearing housing must not be widened

using a chisel or similar tool!
– Protect steering gear boot from damage with a protective

sleeve.
Note
♦ For clarity the illustration shows a steering gear that has been
removed.
♦ Protective sleeve -1- can be ordered under part number 893
512 137.
– A 20 to 25 mm strip -dimension A- must be cut out of protective

sleeve -1-.
– Carefully deburr the cut surfaces.
– Slide protective sleeve over the steering gear boot. The open
side of the sleeve must point downward.
To protect the joints of the lowerProtected
control arms from
by copyright. Copyingdamage,
for private oritcommercial
is purposes, in part or in whole, is not
necessary to use Engine and Gearbox Jack - VAS6931- to brace
against excessive rebound.


– Remove hex head bolt -arrow- from suspension strut/control

link.
– Swing wheel bearing housing to side.
– Loosen the coolant reservoir mount.
– Remove plenum chamber cover.
– Remove cover -arrow- of bolt.
– Remove the bolts -1- in the plenum chamber.

– Take out suspension strut with mounting bracket.
Caution
Be careful not to damage CV boot in the process!
Installing
– Insert suspension strut with mounting bracket into suspension
turret. Tighten hex bolts -1- ⇒ Item 1 (page 17) .
Note
Make sure that washers are seated correctly.
– Bonded rubber bushings can only be turned to a limited extent.

Only tighten threaded connections at control arms if vehicle is
in curb weight position. Refer to
page 15 .

– Insert suspension strut forked head into the control arm and
tighten the threaded connection -1- (90 Nm).
Note
Bolt must be inserted opposite direction of travel.
– Insert both upper control arm joint pins in wheel bearing hous‐
ing and bend downward as much as possible using Pre-
Tensioning Pliers - T40067- .
– Insert new bolt -2- and self-locking nut and tighten (40 Nm).
– Insert ABS wiring into retainer on brake caliper.
– Install brake disc, install and tighten brake caliper. Refer to ⇒
Brake System; Rep. Gr. 46 ; Removal and Installation .
– On vehicles with headlamp range control, install vehicle level
sensor link atwithcontrol
respect toarm. Refer to
the correctness of information in this document. Copyright by AUDI AG.
On vehicles with Dynamic Ride Control (DRC II), fill the system.
Refer to
5.2 Wheel Bearing Housing

♦ Ball Joint Puller - T40010-
♦ Pre-Tensioning Pliers - T40067-


Removing
WARNING
Loosen drive axle bolt only when the vehicle is standing on its
wheels!
– Remove the drive axle bolt. Refer to ⇒ page 78 .

– Remove ABS speed sensor wiring from wheel bearing hous‐
ing bracket.
– Remove ABS speed sensor bolt -5-.

– Disengage ABS cable at wheel bearing housing.
– Remove disc brake.
– Remove the bolts -arrows- and removepermitted
the heat shield.

– Remove combi-bolt -3- and bolt -4-.
Note
♦ An axle alignment may be required. Refer to

⇒ “2.3 Wheel Alignment Test Prerequisites”, page 232 .
♦ Do not use a chisel or similar tool between steering arm -1-
and tie rod ball joint sealing washer -2- when removing tie rod,
otherwise sealing washer could be damaged.
♦ Tie rod may only be pressed off steering arm over tie rod ball
joint pin ends or driven with a wooden or rubber hammer.
– Press or pull tie rod downward to remove.

– Remove the nut from the guide link joint pins enough so it is
flush with the joint pin threads. Use 4 mm socket wrench to
hold joint pin, if necessary.
– Press linkage stub of guide control arm off conical seating us‐
ing Puller - Ball Joint - T40010A- .
Note
♦ Be careful not to damage CV boot in the process!

♦ Make sure that both puller lever arms are parallel to each other
when using greatest force.
– On vehicles with headlamp range control, remove the left front

level control system sensor from the control arm. Refer to
– Remove the nut from the control armbyjust
Protected enough
copyright. Copyingsoforitprivate
is flush
or commercial purposes, in part or in whole, is not
with the joint pin threads. Use 4permitted
mm socket wrenchbytoAUDI
unless authorised hold AG.joint
AUDI AG does not guarantee or accept any liability
pin, if necessary. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Press linkage stub of track control arm off conical seating us‐
ing Puller - Ball Joint - T40010A- .
Note
Make sure that both puller lever arms are parallel to each other

– Remove nut -1-, remove bolt and lift out both control arms
-2- upward.
The slits in the wheel bearing housing must not be widened using
a chisel or similar tool!
– Tilt the wheel bearing housing to the side while pulling the drive
axle pins out of the wheel hub.
– Secure drive axle to body, for example with wire.
– Remove the nut from linkage stub of track control arm.
– Take off wheel bearing housing.
Installing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Install wheel bearing housing.
– Install outer drive axle joint into the hub and tighten with a new
hex bolt by hand.
– Insert control arm and guide link joint pins in wheel bearing
housing.
– Install new self-locking nuts and tighten (110 Nm) counter hold
joint pins, for example with 4 mm hex socket head wrench.
– Insert new bolt -1- and self-locking nut and tighten. Specifica‐
tion: 40 Nm.

Note
Tie rod (tie rod ball joint) must only be inserted in steering arm
-1- by hand. Sealing washer -2- must not be stressed under any
circumstances.
– Install the tie rod.
– Screw on new self-locking nut -4- and tighten to 45 Nm.

– Tighten hex head bolt -3-. Specification: 5 Nm.
– Install ABS speed sensor. Refer to ⇒ Brake System; Rep. Gr.
45 ; Removal and Installation .
sensor link at control arm. Refer to
– Screw on cover plate and tighten (10 Nm).

– Install brake disc and attach the brake caliper. Refer to ⇒
WARNING
Tighten drive axle bolt only when the vehicle is standing on its
wheels!
– Tighten drive axle bolt. Refer to ⇒ page 79 .

– An axle alignment may be required. Refer to
Check the axle alignment for the front axle. The alignment must
take place on a VW/Audi recommended alignment stand.
5.3 Wheel Bearing Housing with Bolted Wheel Bearing

Assembly Overview


2 - Bolt
❑ 80 Nm + 90° turn
3 - Sockets
4 - Ball Bearing
❑ Pressing out diameter
82, refer to
⇒ page 53 .
❑ Pressing in diameter 82,
refer to ⇒ page 54 .
❑ Pressing off bearing in‐
ner race, refer to
⇒ page 53 .
ling, refer to
⇒ page 52 .
❑ Installation position:
❑ The larger
permitted diameter
unless ofAUDI AG. AUDI AG does not guarantee or accept any liability
authorised by
the wheel bearing faces
the hub.
5 - Wheel Hub
❑ Pressing out, refer to
⇒ page 53 .
❑ Removing bearing inner
race, refer to
⇒ page 53 .
❑ Tiered version.
❑ Wheel hub/brake disc
contact surfaces and
threaded holes are to be
free of paint and dirt.
❑ Light construction wheel
hub, refer to
⇒ “1.2 Light Weight
Wheel Hub Characteristics”, page 13 .

♦ Thrust Plate - VW 401-
♦ Punch - VW 407-
♦ Thrust Disc - VW 412-
♦ Thrust Pad - VW 511-
♦ Press Tube - 30 - 100-
♦ Tube 37 mm Dia. - VW 416 B-
♦ Sleeve - VW 519-
♦ Puller - Kukko Separating Tool - Diameter 22-115mm - 15-2-
or Puller - Kukko Quick Action Separating Tool - 22-115mm -
17-2-

Removing
WARNING
Loosen drive axle bolt only when the vehicle is standing on its
wheels!
– Remove drive axle bolts. Refer to ⇒ page 78 .

– Remove wheel.
ing bracket.

– Remove bolts -arrows-.

– Remove backing plate.

– Loosen nut -1-, remove hex bolt and lift out both control arms
-2- upward.
– Swing wheel bearing housing in direction of arrow away to
side, when doing this remove drive axle pin from wheel hub.
– Secure drive axle to body, for example with wire.
– Remove bolts -1-.

– Remove wheel bearing unit.
Pressing Wheel Hub Out of 82 mm Diameter Wheel Bearing

Housing
Remove the Bearing Inner Race from the Hub

– Insert a separating tool for example the Puller - Kukko Sepa‐
rating Tool - Diameter 22-115mm - 15-2- or Puller - Kukko
Quick Action Separating Tool - 22-115mm - 17-2- into the
bearing inner race ring groove -arrow- and pretension with the
spindle.

– Press bearing inner race off from wheel hub.

Light construction wheel hub. Refer to
⇒ “1.2 Light Weight Wheel Hub Characteristics”, page 13 .
Pressing Wheel Hub into 82 mm Diameter Wheel Bearing

– When pressing in, -VW 511- may only lie against bearing inner
race.
Installing
– Insert wheel bearing unit in wheel bearing housing.
– Install bolts -1- and tighten (80 Nm + 90° turn).
– Install outer drive axle joint into the hub and tighten with a new
hex bolt by hand.
Note
Remove any adhesive residue on joint pin threads.

– Insert new bolt -1- and self-locking nut and tighten. Specifica‐
tion: 40 Nm.
– Install ABS speed sensor.
– Install brake disc, fasten brake caliper. Refer to ⇒ Brake Sys‐
tem; Rep. Gr. 46 ; Removal and Installation .
WARNING
Tighten drive axle bolt only when the vehicle is standing on its
wheels!
– Tighten drive axle bolt. Refer to ⇒ page 79 .

Why an axle alignment is necessary, refer to ⇒ page 233 .
5.4 Light Weight Wheel Hub Slide Washer

♦ Assembly Tool - T40089/1-
♦ Thrust Piece - VW 473-
Replacing
– Carefully pry off slide washer -1-, for example with a screw‐
driver.
– Position slide washer on wheel hub.

– Install special tools as shown in illustration.

1- -VW 473-
2- -T40089/1-
3- Slide washer
4- Wheel hub
5- -VW 401-
– Press slide washer off using -T40089/1- as shown in illustra‐
tion up to wheel bearing hub radius.
Note
Slide washer must be pressed on up to wheel bearing hub radius.
5.5 Mounting Bracket

Removing
– Remove suspension strut. Refer to
⇒ “5.1 Suspension Strut”, page 43 .
– Remove mounting bracket from suspension strut. Refer to
Installing
– Fasten mounting bracket to suspension strut. Refer to
– Install suspension strut. Refer to
5.6 Upper Control Arm

Removing
– Remove suspension strut. Refer to
– Loosen nuts -1- and remove bolts -2-.
– Remove control arms -3 and 4-.
Installing
– Secure upper control arms -3 and 4- using new bolts -2- and
new nuts -1- just enough so that control arms cannot move in
their positions.

Upper Front Control Arm

– Adjust height -A-.
-A- = 81 mm ± 2 mm
Upper Rear Control Arm

– Adjust height -A-.
-A- = 70 mm ± 2 mm
Continuation for Upper Front and Rear Control Arms

– Tighten the nuts -1- (50 Nm + 90° turn).
– Check position of upper control arms.
– Repeat adjustment, if necessary.
– Reinstall mounting bracket. Refer to
5.7 Front and Rear Upper Control Arm

Bearing
♦ Assembly Tool - 3301-
♦ Assembly Tool - 3301/1-
Note
Use protective covers when clamping aluminum control arms.

Pulling Out Bushing
Mounting Installation Location Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
A = ~ 90° ± 5° with respect to the correctness of information in this document. Copyright by AUDI AG.
Pulling In Bushing
A - Rubber mount
5.8 Subframe
♦ Engine Support Bridge - 10 - 222 A-
♦ Bracket for Engine - 10 - 222 A /1-
♦ Testing Mandrel - 3393-
Removing
– Support engine entirely with engine support bridge.
– Remove wheels.

– Remove noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

50 ; Description and Operation .
Convertible Only
– Remove front diagonal brace. Refer to
⇒ “5.22 Front or Rear Diagonal Braces”, page 179 .
– Before removing subframe, check whether holes -1- and -2-
are aligned using -3393- .
Note
If this is not the case, an axle alignment must be performed after
the carrier is installed.
– Remove nuts -arrows- at transmission mounts if necessary.
– Remove the nuts -1-.

– On vehicles with headlamp range control, remove the left front

ing bracket.


– Remove hex head bolt -2- and remove brake line bracket.
– Reinstall brake line holder. Reinstall bolt -2- and tighten.
To avoid damaging upper control arm joints, wheel bearing hous‐
ing must be braced against a rebound that is too strong, for
example using Engine and Gearbox Jack - VAS6931-
– Remove bolt -1-.

– Loosen guide link/subframe connection.
– Remove tunnel crossmember if necessary. Refer to

⇒ “5.11 Tunnel Crossmember”, page 67 .
– Place Engine and Gearbox Jack - VAS6931- with wooden
block under subframe and press lightly against.

– Remove bolts -2- and lower rear subframe.
– Remove guide link bolts.
– Remove guide links from subframe.
Note
In order not to over bend the joints of track control arm and guide
control arm, they must be fastened to the body with a tie wire or
something like it.
– Remove power steering line -arrow- from console.


– Loosen the bolts -2- just enough until it is possible to remove
the subframe.
Installing
– Insert subframe and install bolts -5 and 6-.
– Insert suspension strut bolts at control arm.
– Guide the track control arms and guide links into subframe.
Before tightening the subframe, it must be fixed to the body using
-3393- .
– Holes -1 and 2- of the subframe and hole -3- of the aluminum

bracket must line up on both sides.
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Fixing the carrier in this way is a substitute for a subsequent

axle alignment only when:
♦ The subframe is removed completely and installed.
♦ Holes -1 and 2- lined up before the repair.
– Position bolts -1 and 2-.

– Protect holes in body for -3393- against corrosion.

– Install nut -1-.
– Install transmission mount nuts -arrows- if necessary.
– Clip cable -arrow- into bracket.

Tightening Sequence
Note
♦ Thread in body can be repaired with thread insert made of wire

according to DIN 8140 (heli-coil). Thread insert must be same
length as thread in body.
♦ Bonded rubber bushings can only be turned to a limited extent.
Only tighten threaded connections at control arms if vehicle is
in curb weight position. Refer to
page 15 .
– Tighten bolts -2 and 5- (110 + 90° turn). with respect to the correctness of information in this document. Copyright by AUDI AG.
– Tighten bolts -1- (55 Nm).

– Tighten transmission mount nuts -arrows-. Refer to ⇒ Manual

Transmission; Rep. Gr. 34 ; Removal and Installation or ⇒
Automatic Transmission; Rep. Gr. 37 ; Removal and Instal‐
lation .
– Tighten bolt -2- (75 Nm).

– Tighten engine mount nuts -1-. Refer to ⇒ Engine Mechanical;
Rep. Gr. 10 ; Removal and Installation .
– Tighten control arm bolts -3- (70 Nm + 180° turn).

– Tighten guide link bolts (70 + 180° turn).
– Tighten coupling rod to the stabilizer bar -4- (40 + 90° turn).
– Suspension strut to control arm (90 Nm).
– Install tunnel crossmember if necessary. Refer to

– Tighten ABS speed sensor bolt -5-. Refer to ⇒ Brake System;

– On vehicles with headlamp range control, install the left front
– Tighten brake caliper to wheel bearing housing. Refer to ⇒
– Mount wheels and tighten. Refer to ⇒ Wheel and Tire Guide;
Note
♦ If the -3393- was attached to the body before subframe re‐

moval and installation (before tightening bolts), axle alignment
does not have to be done.
♦ If fixation was not performed, axle alignment must be done.

Convertible Only
– Install front diagonal brace. Refer to
The axle alignment must be performed on a VW/Audi approved
alignment stand.
5.9 Subframe Mount
Note
♦ Various subframe versions are installed. Allocation, refer to

the Parts Catalog.
♦ Subframe with bonded rubber bushings in subframe/body
mounting points (all vehicles except convertible). Bonded rub‐
ber bushings cannot be replaced.
♦ Subframe without bonded rubber bushings in subframe/body
mounting points, rather with welded steel bushings (converti‐
ble only). Steel bushings cannot be replaced, replace sub‐
frame if damaged.

♦ Assembly Device - 3291-
♦ Puller - 3351/1-
♦ Puller - 3351/4-
♦ Installation Device - 3372-
♦ Installation Device - 3372/1-
♦ Thrust Pad - 30 - 205-

To replace subframe mount, subframe must be removed. Refer

to ⇒ “5.8 Subframe”, page 58
Pulling Out Bonded Rubber Bushing
– Saw or cut rubber shoulder off subframe mount up to outer
mount bushing.
Note
If the paint on the surface of the subframe should be damaged,

the surface should be protected against corrosion.
Pulling Out Rear Bonded Rubber Bushing

Make sure that -3372- is seated correctly and cannot tilt.

All bonded rubber bushings on subframe are pulled out using
same special tool.
Preparing to Pull-In Subframe Mounting

– Position Front Subframe Mount Kit - 3372- and insert seg‐
ments -3372/2- .

Aligning Bonded Rubber Bushing

The bonded rubber bushings must be aligned with a long square
tube or straightedge.
-A- = 90° ± 5°
Only tension subframe in a vise using protective clamps!
Pulling in Rear Bonded Rubber Bushing

To press on bonded rubber bushing, use installation lubricant G
294 421 A1.
– Pull in mount -A- until -3372/1- is flush with upper edge of Front
Subframe Mount Kit - 3372- .
– Remove Front Subframe Mount Kit - 3372- and -3372/2- up‐
ward.
Pulling in Rear Bonded Rubber Mounting

– Insert -3372/2- between -3351/4- and subframe.
– Pull mounting in onto stop.
Pulling in Front Bonded Rubber Bushing

To press on bonded rubber bushing, use installation lubricant G
294 421 A1.
– Insert -3372/2- in -3372- .
– Pull in the mount -A- until -3372/1- is flush with upper edge of
-3372- .

Pulling in Front Bonded Rubber Bushing

– Raise -3372- and remove -3372/2- .
– Replace -3351/41- with -3351/1- and then push mounting in
onto stop.
5.10 Subframe Bonded Rubber Bushing

Stop Wedges
Removing
– Remove subframe supports.
– Pull stop wedges downward out of bonded rubber bushings.
Installing
– Push stop wedges -1- positioned in bonded rubber bushing as
shown in illustration in to stop.
Illustration shows subframe from below.
– Install subframe supports.
5.11 Tunnel Crossmember


Removing
– Remove bolts -arrows-
– Support transmission with Engine and Gearbox Jack -
VAS6931- and a wooden block.
– Remove bolts -1 and 2-.

– Remove tunnel crossmember
Installing
Installation is the reverse of removal, with special attention to the

following:
– Tighten the new combi bolt -1- to 110 Nm +90°.
– Tighten bolt -2- to 65 Nm.

– Tighten bolts -arrows- to 23 Nm.

– Install noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
5.12 Control Arm,

♦ Puller - Ball Joint - T40010A-
Removing
– Remove wheel cap, remove cover cap on light-alloy wheels
(removal hook in vehicle tool kit).
– Remove wheel.
– On vehicles with headlamp range control, remove Left Front
Level Control System Sensor - G78- from control arm. Refer
to
– Remove the nut from the control arm just enough so it is flush
with the joint Protected
pin threads. Use
by copyright. 4 mm
Copying socket
for private wrenchpurposes,
or commercial to coun‐
in part or in whole, is not
terhold the joint pin, unless
permitted if necessary.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Separate the lower control arm joint pin from the tapered seat
using the Puller - Ball Joint - T40010A- .
Note
when using greatest force, adjust if necessary.
♦ In order not to damage the joints of the upper control arms, it
is necessary to use Engine and Gearbox Jack - VAS6931- ,
for example, to brace wheel bearing housing against too
strong rebound.


– Remove bolts -2 and 4- and the coupling rod.
– Remove track control arm.
Installing
Note
♦ Always replace bolts and nuts.

♦ Bonded rubber bushings have a limited range of motion. Only
tighten threaded connections at control arms if vehicle is in
page 15 .
– Insert new bolt -3- and new nut and tighten (70 Nm + 180°
turn).
– Remove the adhesive residue from control arm at joint pins.
– Tight the nut on the joint pins (control arm) (110 Nm).
– Tighten the threaded connection -1- (90 Nm)
– Tighten the bolt -2- (40 + 90° turn).
50 ; Description and Operation
5.13 Control Arm


♦ Engine Support Bridge - 10 - 222 A-
Removing
Removal of right control arm with 3.0L TDI engine is performed
as already described for all engine versions. Refer to
⇒ “5.12 Control Arm,”, page 69 .
– Support engine entirely with engine support bridge.
– Remove wheel.

– On vehicles with headlamp range control, remove Left Front

Level Control System Sensor - G78- from control arm. Refer
to
– Remove the nut from the control arm just enough so it is flush
with the joint pin threads. Use 4 mm socket wrench to coun‐
terhold the joint pin, if necessary.
– Separate the lower control arm joint pin from the tapered seat
using the Puller - Ball Joint - T40010A- . copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected by
Note
when using greatest force, adjust if necessary.
♦ In order not to damage the joints of the upper control arms, it
is necessary to use Engine and Gearbox Jack - VAS6931- ,
for example, to brace wheel bearing housing against too
strong rebound.
– Remove hex bolt -1-.

– Remove the bolts -2 and 4- and the coupling rod.
– Remove nut from threaded connection -3-.
– Remove nut -1-.


– Pull engine mount and stabilizer bar bracket -3- downward and
remove bolts -2-.
– Remove control arm -1-.
Installing
following:
Note
♦ Always replace bolts and nuts.

♦ Bonded rubber bushings have a limited range of motion.Protected
Only by copyright. Copying for private or commercial purposes, in part or in whole, is not
tighten threaded connections at control arms if vehicle is inwith respect to the correctness of information in this document. Copyright by AUDI AG.

page 15 .
– Remove the adhesive residue from control arm at joint pins.

Tightening specifications, refer to
⇒ “2.2 Front Suspension Overview”, page 16 .
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
Rep. Gr. 44. ; General Information .
5.14 Control Arm Bearing

Note
Inner Mounting, Removing

– Mark location of old mounting.

Mounting Installation Location

– Transfer installation mark for old mounting to new mounting.
Inner Mounting, Pulling In

– Insert bearing -A- in -3346/1- to a depth of 3.2 mm.
– Pull mounting in onto stop.
Pull Out Outer Mounting
Pull In Outer Mounting

To press in, use installation lubricant G 294 421 A1 thinned with
water at a ratio of 1:100.
– Pull in mounting in center.
Chamfers on mounting and control arm must align.
5.15 Guide Link


Removing
– Remove wheel.
– Remove brake caliper and secure to body if Puller - Ball Joint
- T40010A- cannot be installed.
Note
♦ Install brake line bracket on brake caliper HP-2 before secur‐

ing to body to avoid damaging brake lines.
♦ Secure brake caliper to body so that caliper weight does not
stress or damage brake hose or brake line.
– Remove the nut from the guide link joint pins enough so it is
flush with the joint pin threads. Use 4 mm socket wrench to
counterhold the joint pin, if necessary.
– Press the guide link joint pin off the conical seat using the
Puller - Ball Joint - T40010A- .
Note
♦ Be careful not to damage CV boot in the process!

– Place Engine and Gearbox Jack - VAS6931- with a wooden

block under subframe and press lightly against.
– Remove bolts -2 and 3- on both sides.
– Disconnect with
therespect
tunnel crossmember and move it slightly to the
rear, where applicable. Refer to

– Lower subframe slightly using Engine and Gearbox Jack -
VAS6931- .
Caution
Be careful not to damage surface of brake lines and underbody

guard!
– Remove the bolt -1-.

– Remove guide link.
Installing
Note
Bonded rubber bushings have a limited range of motion. Only

tighten threaded connections at control arms if vehicle is in curb
weight position. Refer to
⇒ “2.1 Wheel Bearing, Lifting to Curb Weight Position”, page 15 .

– Tighten nut on joint pin (110 Nm).

– Tighten bolt -2- (110 + 90° turn).
– Tighten bolt -3- (55 Nm).
– Install the tunnel crossmember and tighten the bolts, where
applicable. Refer to ⇒ “5.11 Tunnel Crossmember”, page 67 .
– Install brake caliper, if necessary. ⇒ Brake System; Repair
Group 46
Rep. Gr. 44. ; General Information .
5.16 Guide Link Bearing

Remove Hydraulic Mount at Control Arm
Note with respect to the correctness of information in this document. Copyright by AUDI AG.
Installation Position of Hydro-Mount

Arrow applied to hydraulic mount -1- points in joint pin direction.
The permissible deviation is ± 5°.
A = View -arrow A-

Pull in Hydro-Mount
– Insert hydro-mount -A- into -3347/2- .
– Tighten together with -3348- , -3346/2- and nut.
– Pull in hydro-mount -A- until it stops.
5.17 Stabilizer Bar

Removing
– Remove noise insulation.
– Remove
permittedbolt
unless-2-.
– Remove hex nut -2-.

– Remove the stabilizer bar.
Installing
Note
♦ If you replace stabilizer, note chassis version.

♦ Stabilizer and mounting must be free of grease.
– Install nut -2- but do not tighten.

– Tighten nuts -2- to 25 Nm.

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
50. ; General Information .
5.18 Crossbrace
Note
Crossbrace is only installed on certain vehicle versions. It is lo‐

cated on front plenum chamber cross panel.
Crossbrace allocation, refer to the Parts Catalog.

Removing
– Remove plenum chamber cover rubber seal in direction of
-arrow-.

– Remove plenum chamber cover -1- forward.

Bolt allocation, refer to the Parts Catalog.
– Remove crossbrace -1- upward out of plenum chamber -5-.
3 - Left mounting bracket welded to body
6 - Right mounting bracket welded to body
Arrow points in direction of travel
Installing
Installation is performed in the reverse order of removal.
Bolt tightening specification: 25 Nm
5.19 Drive Axle

Remove Drive Axle
WARNING
Loosen drive axle bolt with vehicle resting on wheels!
– Loosen outer drive axle joint bolt a maximum of 90°.

– Remove wheel.
– Tighten all five wheel bolts by hand.
– Remove drive axle outer joint bolt.
– Disconnect drive axle from transmission axle flange.
If there is not enough room available to remove drive bolt, perform
following steps:

– Remove nut -1-, remove bolt and lift out both control arms
-2- upward.
Caution

Note
Do not loosen bolts -3 and 4-, otherwise the adjustment of the

front axle will change!
– Swing wheel bearing housing to side.

– Remove drive axle. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Install Drive Axle permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Insert drive axle in wheel bearing housing.

– Insert both upper control arms, insert new bolt and tighten new
nut -8- ⇒ Item 8 (page 17) ; while tightening, press control arm
as far as possible toward wheel bearing housing.
– Fasten drive axle to flange shaft/transmission -33-
⇒ Item 33 (page 19) .
– Fasten drive axle outer joint
Note
When tightening drive axle outer joint to pre-tightening specifica‐

tion, vehicle must not come in contact with floor; otherwise wheel
bearing can be damaged.
A second technician is needed for the next step:

– 1. Technician: Sit in vehicle and operate foot brake
– 2. Technician: Tighten drive axle bolt to pre-tightening speci‐
fication
M14 bolt: 115 Nm
M16 bolt: 200 Nm
– Install wheel and place vehicle on floor.
WARNING
Only turn drive axle bolt additional turn with vehicle resting on
wheels!
– Turn drive axle bolt an additional 180°.

6 Disassembly and Assembly

⇒ “6.1 Suspension Strut”, page 80
⇒ “6.2 Drive Axle with Triple Roller Joint AAR 2000”, page 85
⇒ “6.3 Drive Axle with Peened Triple Roller Joint AAR 2600 i or
3300 i”, page 89
⇒ “6.4 Drive Axle with Triple Roller Joint AAR 2900”, page 94
⇒ “6.5 Drive Axle with Inner Constant Velocity Joint, 100 mm Di‐
ameter”, page 99
⇒ “6.6 Drive Axle with Inner CV Joint, 108 mm Diameter”,
page 104
6.1 Suspension Strut

Assembly Overview
1 - Nut
❑ 50 Nm
❑ Always replace.
2 - Shock Absorber Mounting
3 - Washer
4 - Mounting Bracket
to ⇒ page 84
5 - Coil Spring
⇒ page 82 and
⇒ page 82 .
⇒ page 83 .
❑ Note different vehicle
versions, see vehicle
data plate. Refer to
⇒ page 81 .
Parts Catalog. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Additional Spring with respect to the correctness of information in this document. Copyright by AUDI AG.
7 - Protective Sleeve
8 - Protective Cap
9 - Lower Spring Support
10 - Lower Spring Plate
to ⇒ page 83 .
11 - Shock Absorbers
❑ Replace, refer to
⇒ page 83 .
❑ Note different vehicle versions, see vehicle data plate. Refer to ⇒ page 81 .
❑ Faulty shock absorbers must be vented and emptied before disposal. Refer to
⇒ “2.1 Front Gas-Filled Strut, Venting and Emptying”, page 2 .

Explanations of the Production Control Numbers (PR Number)

Shock absorber combination installed in vehicle is indicated by
corresponding PR number on vehicle data plate.
Sample Vehicle Data Label
– Front suspension PR no. is item -A-.
– Rear suspension PR no. is item -B-.
There is a vehicle data label in the spare wheel well and also one
in the customer Maintenance booklet.
The correct shock absorber combination is found in the electronic
parts catalog using the PR number.
You can find the suspension version PR no. in illustration -see

arrow-.
1BA = Standard suspension
1BB = heavy duty suspension, China
1BE = sport suspension (20 mm lower than 1BA)
1BD = Sport suspension S4
1BR = comfort heavy duty suspension (13 mm higher than 1BA)
1BV = sport suspension (quattro GmbH)
2MC = basic suspension (quattro GmbH RS 4)
2ME = sport suspension (quattro GmbH RS 4)

♦ Spring Compressor Kit - Spring Tensioner - VAG1752/1-
♦ Spring Mounting Tool - VAG1752/2-
♦ Spring Holder - VAG1752/4-
♦ Spring Holder - VAG1752/6-
♦ Shock Absorber Set - T10001/3-
6. Disassembly and Assembly 81

Coil Spring, Removing

– Clamp the suspension strut in a vise.
– Pretension coil spring using Spring Compressor Kit - Spring
Tensioner - VAG1752/1- and -VAG1752/4- until upper sus‐
pension strut is free.

– When doing this, make sure the coil spring fits correctly in the
-VAG1752/4- -arrows-.

– Remove collar nut from piston rod with -T10001/3- , -
T10001/11- and -T10001/7- .
– Remove individual components of suspension strut and pre‐
tensioned coil spring with Spring Compressor Kit - Spring
Tensioner - VAG1752/1- .

Shock Absorber, Replacing

– Remove the cap -1- and the lower spring support -2-.
– Mark installation position of lower suspension strut to shock
absorber.
– Loosen suspension strut -3- using plastic hammer and remove
upward.
Lower Suspension Strut Installation Location

A - Shock absorber/control arm bolt axis
I = Left, B = 65° ± 2°
II = Right, C = 87° ± 2°
– Drive suspension strut downward using plastic hammer ac‐
cording to self-provided marking.
With a new damper, transfer marking from old damper.
Note different installation locations on left and right sides.
Suspension strut trimming -arrow- must result in clearance to
body.
Coil Spring, Installing

– Install suspension strut, lower spring support and protective
cap.
– Position pretensioned coil spring on lower spring support us‐
ing Spring Compressor Kit - Spring Retainer w/Inserts -
VAG1752/4- . End of spring coil must rest against stop
-arrow-.
Permissible deviation: ± 2°.
Installed Position of the Upper Spring Support

Position the mounting bracket with the spring support on the pre‐
tensioned spring so that the spring supports rests against the end
of the coil spring -arrow-.

Coil Spring, Installing

– Tension suspension strut with spring compressor vertically in
Spring Compressor Kit - Strut Holder - VAG1752/2- .
– Position individual suspension strut components. Make sure
the end of the spring touches the upper spring support.
– Tighten collar nut using special tools.
– Do not yet release tension on spring.
Mounting Bracket Installation Location
– Loosen lower locking lever and turn upper suspension strut

until -VAG1752/2- scale is at 7°.
– Make sure the ends of the spring touch the spring seat at the
top and at the bottom.
– Lock locking lever.

Seen in direction of travel

I = left
II = right
A - Shock absorber/control arm bolt axis
– Adjust angle B.
B = 7°
– The -VAG1752/2- arm -arrow- must align with the center of the
mounting bracket.
– Now release tension on -VAG1752/1- and remove.
– Check adjustment, repeat procedure if necessary.

2000
♦ Tube Trans. Drive Shaft - VW 426-
♦ Assembly Tool - T10065-
♦ Punch - VW 408 A-
♦ Pressure Spindle - 3207-
♦ Hose Clamp Pliers - VAG1275-
♦ Use the Puller - Kukko 3 Jaw - 100x100mm - 12/1- (commer‐
cially available)

Disassembling
– Drive axle, clamping in vise
Note
Use the protective backing!
– Open clamp on joint and slide back protective boot.

– Bend open metal tabs with flat-head screwdriver and pry off
cover.
– Mark installation position of parts 1 through 3 with dashes.

If they are not marked and are not reinstalled in their previously
installed positions, noises may occur later during driving opera‐
tion.
A waterproof felt pen is well-suited for marking.
– Remove the O-ring -arrow- out of the groove.
1 - Joint piece
2 - Triple roller star
3 - Drive axle
– Remove circlip.
1 - Pliers (commercially available)

– Pull triple roller star off driveshaft. To do this used for example
the Puller - Kukko 3 Jaw - 100x100mm - Kukko 12/1- (com‐
mercially available).
– Remove grease in groove for sealing ring.
– Check the roller body and ball cage for wear.
– Clean shaft and housing.
– If protective boot is damaged, remove, for example with
shears. Otherwise, carefully turn back.
– Insert drive axle in vise.
– Secure drive axle then press off triple roller star from drive
axle.
Make sure that roller bodies are free when pressing off.
– Remove triple roller star with rollers and set aside on a clean
surface.
– Remove joint from drive axle.
– Pull joint protective boot off from drive axle.
– Clean drive axle, joint piece and groove for oil seal.
Assembling
– Slide joint protective boot onto drive axle.
– Slide joint piece onto drive axle.
Mount Triple Roller Star
The chamfer on star faces toward shaft, this is used as an as‐
sembly aid.
– Before installing joint or triple roller star, splines -A- must be

lightly coated with grease used in joint.

– Install triple roller star onto shaft as per markings and drive in
to stop.
A second technician is needed to slide protective boot back.
Use -VW 426- as shown in illustration.
– Insert securing ring, be sure to fit properly.
– Press 80 grams of joint grease from repair set, into triple roller
joint.
– Slide joint piece over rollers and secure.
– Press 30 grams of joint grease, from repair set, into the reverse
side of the triple roller joint.
– Install CV boot. The bead in the CV boot must engage in the
joint piece groove.
– Remove drive axle from vise and clamp in joint piece.
– Insert newProtected
sealingbyring -arrow-
copyright. Copyingfrom repair
for private kit intopurposes,
or commercial the groove.
– Install new cover on joint. The holes of the cover and joint must
align.
– Install clamp.
Observe note. Refer to ⇒ page 94 .
Outer CV Joint, Servicing
Disassembling Outer CV Joint
– Secure drive axle with protective covers in vise clamp.
– Remove clamp and slide boot back.

– Screw Pressure Spindle - 3207- with M16/M14 thread version

into joint pins until CV joint is press off of drive axle.
– Remove circlip
Outer CV Joint, Installing
Protective boot and boot seat on drive axle must be free of grease.
– Install new circlip
Circlip (snap ring) must be replaced.
– Apply 50 g joint grease in inside of joint.

– Screw old drive axle screw into joint as shown in illustration.

– Drive joint onto drive axle with plastic hammer until circlip en‐
gages.
– Apply 40 g joint grease in boot side of joint.
Grease quantities, see table ⇒ page 21
– Bleed protective joint boot.
– Close clamp.
6.3 Drive Axle with Peened Triple Roller

Joint AAR 2600 i or 3300 i
♦ Thrust Plate - VW 401- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Thrust Plate - VW 402- with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Punch - VW 411-
♦ Thrust Pad - VW 447 H-

♦ Slide Hammer - Complete Set - VW 771-

♦ Assembly/Removal Tool - T40018- for triple roller joint AAR
3300 i
♦ Or Assembly Device - T40084- for triple roller joint AAR 2600
I
Disassembling
Removal
– Clamp drive axle horizontally in vise.
Note
♦ Use protective backings.

♦ Make sure that drive axle is not damaged.
– Mark location of joint to drive axle

If they are not marked and are not reinstalled in their previously
tion.
– Open clamps -arrows-.
– Slide back protective boot.
Distinguishing Characteristic of Drive Axle AAR 2600 i to AAR

3300 i
– Determine dimension -A- as shown in illustration.
♦ Dimension -A- 74 mm = drive axle AAR 2600 i
♦ Dimension -A- 77 mm = drive axle AAR 3300 i
Caution
Make sure that correct special tool allocation for each drive
axle.
– Guide triple roller joint AAR 3300 i -T40018- or triple roller joint
AAR 2600 i -T40084- behind joint.

Guide pins -1- must contact joint.

– Bring installation device into contact with joint by turning
knurled thumb screws -2-.
Note
♦ Joint must be secured without play in -T40018- or -T40084- .

♦ Tighten the bolts -2- by hand only.
– Screw - VW 771- into -T40018- or -T40084- .

Drive axle AAR 3300 i -T40018- is shown in illustration.
Use -T40084- with drive axle AAR 2600 i.
– Pull joint out horizontally with impact tool.
Leave joint in -T40018- or -T40084- .
– Mark installationProtected
position of parts
by copyright. 1 and
Copying 2 with
for private lines. purposes, in part or in whole, is not
or commercial
If they are not marked and
with areto the
respect notcorrectness
reinstalled in their
of information previously
in this document. Copyright by AUDI AG.
tion.
1 - Drive axle
– Remove grease with lint-free cloth.
– Remove securing ring.


– Press triple roller star off of drive axle.

-T10065/4- must not be applied to roller body.
– Remove protective boot
– Remove grease on shaft splines
– Check roller body and ball cage for wear
– Clean drive axle and housing.
Assembling
Assembly
– Slide new protective boot onto drive axle.
– Press on circlip -1- to center of splines
– Use special tool shown in illustration.
Depending on drive axle version, -T10065/3- must be used in‐
stead of -T10065/2- .
Triple Roller Star, Pressing onto Drive Axle
The chamfer on the triple roller star faces the drive axle. This is
used as an assembly aid.

– Place triple roller star on shaft according to marking and drive
on until impact.

This illustration only applies to conical drive axle -arrow-.

Caution
-T10065/2- must not come in contact with roller body.
This illustration only applies to cylindrical drive axle -arrow-.

Caution
-T10065/3- must not come in contact with roller body.
– Press triple roller joint onto drive axle.

– Circlip must engage audibly, triple roller star must lie against
circlip with no gap.
– Install circlip.
– Press 70 grams of joint grease, from repair set, into the reverse
side of the triple roller joint.
– Lightly lubricate roller body
Caution
Make sure roller body does not tilt!

– Press joint over triple roller start with plastic hammer.

Drive axle AAR 3300 i -T40018- is shown in illustration.
– Press remaining quantity of grease in protective boot.
– Make sure that correct seating of boot on joint.
– Boot must fit in groove and on joint contour
– Position joint in center position. See min - max position
Note
While positioning joint in center position, it is necessary to bleed

protective boot, for example with a screwdriver -arrow-.
– Install clamp.
Note
For a better alignment of multipoint bolts when installing drive

axle, clamping sleeve connecting tube -2- must be between joint
connecting flanges -1-.
– Tension small clamp using -VAG1275- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

2900
⇒ “6.4.1 Outer CV Joint, Replacing”, page 98
♦ Sleeve - VW 416 B-
♦ Punch - VW 412-

♦ Sleeve - 3110-
♦ Kukko Puller No. 12/1 100 X 100 mm - 12/1-
♦ Thrust Plate - 2050-
♦ Circlip Pliers - VW 161 A-
Disassembling
– Knock out cap.
Note
♦ Use old bolt to knock out.

♦ Hold shaft at approximately 20° for this.
Use plastic hammer and -3110- .

– Remove any shavings in area of cover.
– Open the large clamping sleeve.
– Open the small clamping sleeve on the shaft and slide the
protective joint boot back.
– Mark installation position of parts -1 to 3- with lines.

If they are not marked and are not reinstalled
Protected in their
by copyright. Copying previously
for private or commercial purposes, in part or in whole, is not
installed positions, noises may occurunless
permitted laterauthorised
duringbydriving
AUDI AG.opera‐
AUDI AG does not guarantee or accept any liability
tion. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove the O-ring -arrow- out from the groove.
1 - Joint piece
3 - Drive axle

– Remove securing ring.

– Pull triple roller star off drive axle. For this, use -12/1- (com‐
mercially available).
– Remove grease in groove for sealing ring.
– Check the roller body and ball cage forProtected
wear. by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Clean shaft and housing. with respect to the correctness of information in this document. Copyright by AUDI AG.
Assembling
– Slide small clamp for joint protective boot onto shaft.
– Slide the protective joint boot onto the shaft.
– Slide joint piece onto shaft.
– Slide the protective boot onto the joint.
Mounting Triple Roller Star

The chamfer -arrow- on the triple roller star faces toward the shaft,
this is used as an assembly aid.
– Place triple roller star on shaft according to marking and drive
on until impact.
– Insert securing ring, be sure to fit properly.
– Press 70 grams of grease - G 000 605- from repair set into
triple roller joint.
– Slide the joint over the rollers.
Note
Make sure CV boot does not get twisted during this.
– Press 70 grams of grease - G 000 605- from repair set into

rear side of triple roller joint.

– Thoroughly clean groove -4- for sealing ring.

– Insert O-ring -3- into the groove -4-.
The individual parts are shown disassembled for the sake of a
better illustration.
1 - Securing ring
2 - Cover from repair kit
3 - O-ring
4 - Groove in triple roller joint
– Insert drive axle in a vise.

– Lightly press on cover -1- from repair kit so that circlip from the
repair kit can be inserted.
– Insert circlip from repair kit all around below engaging groove.
Note
Make sure circlip engages audibly.
– Position joint in center position. See min - max position.
Note
It is necessary to vent CV boot -arrow-, for example using a

screwdriver, while positioning joint piece in center position.
– Install clamp -2-.
For a better alignment of multipoint bolts when installing drive

axle, clamping sleeve connecting tube -2- must be between joint

connecting flanges -1-.

Tightening Clamp on Inner Joint
– Tension small clamp using -VAG1275- .
6.4.1 Outer CV Joint, Replacing

Rubber CV Boots are Clamped on Using -VAG1275- .
Note
Instructions only apply to stainless steel clamps.
Tightening Hose Clamp on Outer Joint

– Position Clamping Pliers - VAG1682- as shown in illustration.
When doing this, make sure that edges of clamping pliers are
seated in corners -arrows B- of clamp.
– Tension clamp by turning spindle with a torque wrench (do not
tilt clamp tool).
♦ Tightening Specifications: 20 Nm.
♦ Use torque wrench with 5 to 50 Nm range (for example Torque
Wrench 1331 5-50Nm - VAG1331- ).
♦ Be sure thread of spindle in clamping pliers moves freely.
Grease with MOS2 grease, if necessary.
♦ If it does not move freely, for example due to dirt in thread, the
required clamp tension will not be achieved at the specified
torque.

Pressing Off Outer CV Joint

– Secure drive axle with protective covers in a vise clamp.
– Remove large clamping sleeve and turn back protective joint
boot.
– Screw Pressure Spindle - 3207- into joint bolt until CV joint can
be removed.
Venting CV Boot
Applies to rubber CV boots only:
A vacuum can form in the joint when installing the protective joint
boot.
This vacuum pulls a fold inward when the car is driven -arrow-.
Therefore, note the following:
– Before clamping, clamping sleeves, balance pressure by rais‐
ing protective joint boot.
Installed Position of Spacer Ring and Dished Washer (Wheel

Side)
1 - Dished washer
2 - Spacer ring (plastic).
6.5 Drive Axle with Inner Constant Velocity

Joint, 100 mm Protected
Diameter by copyright. Copying for private or commercial purposes, in part or in whole, is not

♦ Punch - VW 412-
♦ Press Block - 40 - 204 A-
♦ Sleeve-Press Tool - VW 522-
♦ Punch - VW 411-
♦ Arbor - VW 434-
♦ Press Appliance - VW 459-
Inner CV Joint, Removing
– Drive axle, clamping in a vise
Use protective vise covers for this.

– Pry off cap, for example with a screwdriver.
– Remove seal -arrow-.
– Drive protective joint boot cap under with a brass or copper

drift.
Clamping sleeves must not be loosened.
– Remove circlip.

– Press inner CV joint off of drive axle with special tool shown
in illustration.
– Remove inner CV joint protective boot from drive axle.
Inner CV Joint, Installing
– Apply sealant -hatched surface- to clean surface on inner side

of protective joint boot cap. Sealant bead: unbroken, diameter
2 - 3 mm. Skirt area around inner holes -arrow-.
– Use sealant D 454 300 A2 for this
– Slide joint protective bootunless
permitted ontoauthorised
drive axle.
by AUDI AG. AUDI AG does not guarantee or accept any liability

Caution
Protective boot and cap contact surfaces must be free of

grease!
– Press on joint until stop.

Chamfer on inner diameter of ball hub (splines) must face the
contact shoulder on the drive axle.
Use special tool shown in illustration.
Press block - 40 - 204 A- and clamping surfaces on drive axle
must be free of grease.

– Install circlip.
– Check circlip for correct seating.
Circlip must be replaced
– Apply 50 g joint grease in boot.
Make sure you do not damage the sealant bead.
– Using bolts -arrows-, align protective boot and cap with bolt
holes.
It must be aligned exactly because it cannot be aligned after driv‐
ing on.
– Drive off protective boot with cap using plastic hammer.
– Clear away leaking sealing immediately.
– Apply 30 g joint grease in CV joint through ball paths.
– Grease seal contact surface -arrow-.

– Remove adhesive foil from seal and adhere to CV joint.
– Align new cover with the screw holes.
It must be aligned exactly because it cannot be aligned after
pressing on.
– Press cover on with special tool shown in illustration.

– Position protective joint boot -between arrows-.

Outer CV Joint, Removing
– Drive axle, clamping in vise.
– Open clamps.
– Slide back protective boot.
– Using a hammer, hit a copper or brass mandrel onto inner race

of CV joint.permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove joint.

– Insert new circlip.
Circlip (snap ring) must be replaced.

– Insert sealing ring in groove on shaft.
– Slide on CV joint up to sealing ring.

– Align sealing ring at center with opening upward
-see arrows-.

– Screw old drive axle bolt into joint as shown in illustration.

gages.
– Close clamp.
6.6 Drive Axle with Inner CV Joint, 108 mm

Diameter
♦ Punch - VW 412-
♦ Tube 42 mm Dia. - VW 516-
♦ Punch - VW 409-
Inner CV Joint, Removing
– Drive axle, clamping in vise Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
– Drive cover down with copper or brass drift.
– Remove circlip.
– Remove joint grease and mark location of CV joint to drive
axle.

– Clamp drive axle in vise at CV joint, as shown in illustration.

– A 2nd work must hold drive axle horizontally so that CV joint
is not damaged.
– Bend edge -arrow- of cap up slightly with small flat chisel.
– Drive cap down with copper or brass drift
– Press CV joint off of drive axle.

– Remove protective boot with cap.
Inner CV Joint, Installing

– Apply sealant D 454 300 A2 -hatched surface- to clean surface
on inner side of protective boot cover or cap, -item 1-
⇒ Item 1 (page 32) and -item 4- ⇒ Item 4 (page 32) . Sealant
bead: unbroken, diameter 2 to 3 mm, skirt area around inner
holes -arrow-.
Caution
Protective boot and cap contact surfaces must be free of

grease!
– Slide new protective booth with cap onto drive axle.

– Press 85 g joint grease into boot.


– Secure CV joint from coming apart, for example with adhesive

tape -arrow-.
– Press off CV joint.
Note
Position ball hub with chamfer on inner diameter (splines) on drive

axle.
Use special tool shown in illustration.

Press block - 40 - 204 A- and clamping surfaces on drive axle
must be free of grease.
– Install circlip
– Press 35 g joint grease into joint through ball races.
– Using bolts -arrows-, align protective boot and cap with bolt
holes.
ing on.
– Drive off protective boot with cap using plastic hammer.
– Align new cover with bolts -arrows- to bolt holes.

ing on.
– Drive cover on with a plastic hammer.
Outer CV Joint, Removing

– Drive axle, clamping in vise Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Use protective vise covers for this. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Open clamps.
– Slide back protective boot
– Using a hammer, hit a copper or brass mandrel onto inner ring
of CV joint.
– Remove joint


– Insert new circlip
Note
Circlip (snap ring) must be replaced

– Screw old drive axle bolt into joint as shown in illustration.
gages.
– Close clamp.

7 Special Tools
Special tools and workshop

equipment required
♦ Engine Support Bridge - 10
- 222 A-
♦ Bracket for Engine - 10 -
222 A /1-
♦ Testing Mandrel - 3393-


equipment required
♦ Tube 37 mm Dia. - VW 416
B-
♦ Tube Trans. Drive Shaft -
VW 426-
♦ Press Support - 3110-
♦ Kukko Puller No. 12/1 100
X 100 mm - 12/1-
7. Special Tools 109


equipment required
♦ Assembly Tool 3 - 3301/3-
♦ Support Arm Bearing Inst.
Tool - 3346-
♦ Component Part for 3346
Tool - 3346/2-
♦ Guide Bearing Inst. Tool -
3347-
♦ Front And Rear Bearing
Tool - 3348-

♦ CV Joint Boot Clamp Tool -

VAG1682-
♦ Hose Clamp Pliers -
VAG1275-
♦ Torque Wrench 1331
5-50Nm - VAG1331-
40-200Nm - VAG1332-


equipment required
♦ Engine and Gearbox Jack -
VAS6931-
♦ Engine/Gearbox Jack
Adapter - Wheel Hub Sup‐
port - T10149-

♦ Assembly Tool 3 - 3301/3-
♦ Socket - T10001/3-
♦ Socket - T10001/4-
♦ Replacement Component for T10001 - T10001/7-

♦ Replacement Component for T10001 - T10001/11-
♦ Assembly/Removal Tool - T40018- for triple roller joint AAR

3300 i
♦ Spring Compressor Kit - Spring Tensioner - VAG1752/1-

♦ Spring Mounting Tool - VAG1752/2-
♦ 2 Spring Holders (80-165 mm) - VAG1752/4-

♦ Spring Holder for A8 - VAG1752/6-
♦ Arbor - VW 434-
♦ Press Appliance - VW 459-

♦ Slide Hammer
permitted - Complete
unless authorised by AUDISet - VW
AG. AUDI AG771-
does not guarantee or accept any liability
♦ Not illustrated:
♦ Separating Tool - 5-17-
17-2-
♦ Press Tube - 30 - 100-
♦ Thrust Pad - 30 - 205-
♦ Assembly Device - 3291-
♦ Puller - 3351/1-
♦ Puller - 3351/4-
♦ Installation Device - 3372-


♦ Removal & Assembly Tool - T40084- for triple roller joint AAR
2600 i
♦ Circlip Pliers - VW 161 A-
♦ Punch - VW 407-
♦ Punch - VW 409-
♦ Punch - VW 411-
♦ Tube Trans. Drive Shaft - VW 426-
♦ Thrust Pad - VW 447 H-
♦ Thrust Pad - VW 511-
♦ Tube 42 mm Dia. - VW 516-
♦ Sleeve-Press Tool - VW 522- Use the Puller - Kukko 3 Jaw -
100x100mm - 12/1- (commercially available)

42 – Rear Suspension
⇒ “1.1 Rear Suspension”, page 117
⇒ “1.2 Light Weight Wheel Hub Characteristics”, page 118
⇒ “1.3 Trapezoidal Control Arm”, page 118
⇒ “1.4 Tie Rod”, page 118
1.1 Rear Suspension

When installing waxed components, contact surfaces must be
cleaned. Contact surfaces must be free of wax and grease.
Tightening specifications for unoiled bolts and nuts are given.
Welding or straightening operations are not permitted on load-
bearing or wheel-controlling components.
Always avoid the following actions with coil springs: Hammer
stroke, welding beads, applying color identification later.
Do not perform any welding or grinding (separating work)unless
permitted in coil
spring or suspension strut area! Cover coil spring orwith
suspension
struts if necessary.
Vehicles without drive axle must not be moved, otherwise wheel
bearing will be damaged. If vehicle must be moved, observe the
following:
– Install an outer joint in place of the drive axle.
– Tighten outer joint to 115 Nm (M14 bolt) or 200 Nm (M16 bolt).
⇒ “2.1 Wheel Bearing, Lifting to Curb Weight Position”, page 15 .
Note
If the vehicle must still be aligned, every bolt and nut that must be
loosened for adjustment is only tightened to tightening specifica‐
tion. Tighten the bolts and nuts to the specified additional tight‐
ening angle after the alignment/adjustment is complete.
WARNING
All bolts and nuts must be tightened properly before driving the
vehicle!

1.2 Light Weight Wheel Hub Characteristics

Light construction wheel hub can be differentiated from traditional
wheel hub by -1- washer and by -2- sleeve.
The light weight wheel hub must only be used in conjunction with
the corresponding wheel bearing. Allocation, refer to the Parts
Catalog.
Slide washer -1- should be replaced if deformed or damage dur‐
ing wheel bearing removal.
1.3 Trapezoidal Control Arm

♦ Modified trapezoidal control arms are installed in Audi A4 with
Front Wheel Drive (FWD) or All Wheel Drive (AWD). Alloca‐
tion, refer to the Parts Catalog.
♦ A mixed installation between old and new trapezoidal control
arms in a vehicle is not permitted.
Old Trapezoidal Control Arm Version
8E0 505 311 S
8E0 505,312 S
New Trapezoidal Control Arm Version
8E0 505 311 S/ also identified with yellow dot (∅ approxi‐
8E0 505 312 S mately 15 mm)
8E0 505 311 T
8E0 505,312 T
Note
An axle alignment may be required. Refer to

1.4 Tie Rod

The three-part tie rod (old version) is replaced by a one-part tie
rod (new version) with or without stone impact protection. Alloca‐
tion, refer to the Parts Catalog.
A mixed installation of a three-part and a one-part tie rod on one
vehicle is not permitted.
A mixed installation of tie rod (new version) with old stone impact
protection (old version) or vice versa is not possible.
Stone impact protection 8E0 501 561 (old version) is now offered
as a replacement part on finished vehicles with heavy duty sus‐
pension. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
118 Rep. Gr.42 - Rear Suspension


page 119
⇒ “2.2 Subframe Overview, FWD”, page 120
⇒ “2.3 Subframe Overview, AWD”, page 122
⇒ “2.4 Trapezoidal Control Arm, Transverse Link and Tie Rod
⇒ “2.5 Stub Axle Carrier Overview, FWD”, page 127
⇒ “2.6 Wheel Bearing Housing Overview, Steel, AWD”,
page 129
⇒ “2.7 Stabilizer Bar Overview”, page 132
⇒ “2.8 Wheel Bearing Housing Overview, Aluminum, AWD”, page
133
⇒ “2.9 Level Control System Sensor with Automatic Headlamp
Vertical Aim Control Overview”, page 134
⇒ “2.10 Subframe Mount Overview”, page 136
2.1 Wheel Bearing, Lifting to Curb Weight

Position
♦ Protected
Tensioning Strap - T10038-
♦ Engine/Gearbox Jack Adapter - Wheel Hub Support - T10149-
Note
All bolts at suspension parts with bonded rubber bushings must

always be tightened in curb weight position (unloaded condition).
Bonded rubber bushings have a limited range of motion.

Parts with bonded rubber bushings must therefore be brought into
a position that corresponds to the position in driving mode before
being tightened (curb weight position)
Otherwise, bonded rubber bushing will be stressed resulting in a
shortened service life.
By raising appropriate suspension using Engine and Gearbox
Jack - VAS6931- and Engine/Gearbox Jack Adapter - Wheel Hub
Support - T10149- , this position can be simulated on the hoist.

– Before starting work, take measurement -a-, for example with

tape measure, from center of wheel to lower edge of wheel‐
house.
Note
Measurement must be performed in curb weight position (unloa‐

ded condition).
– Note measured value. It will be required for tightening bolts/

nuts.
Caution
Before appropriate suspension is raised, vehicle must be

strapped to lift arms of hoist using -T10038- .
If a vehicle is not secured, there is danger that the vehicle could
slip off the lift!
– Turn wheel hub far enough until one of the holes for wheel
bolts is on top.
– Install Engine/Gearbox Jack Adapter - Wheel Hub Support -
T10149- with wheel bolt on wheel hub.
– Using Engine and Gearbox Jack - VAS6931- , lift wheel bear‐

ing housing until dimension -a- is reached.
Note
Tightening of the respective bolts/nuts must then only occur after

dimension -a-, which was measured before installation between
the wheel hub center and the lower edge of wheel housing, has
been attained
WARNING
♦ Do not lift or lower vehicle with Engine and Gearbox Jack

- VAS6931- below vehicle.
♦ Do not leave Engine and Gearbox Jack - VAS6931- below
vehicle any longer than necessary.
– Tighten respective bolts/nuts.

– Lower wheel bearing housing.
– Move Engine and Gearbox Jack - VAS6931- away from under
vehicle.
– Remove Engine/Gearbox Jack Adapter - Wheel Hub Support
- T10149- .
2.2 Subframe Overview, FWD

1 - Subframe
ling, refer to
⇒ “5.13 Subframe”,
page 162 .
❑ Subframe mountings,
replacing, refer to
⇒ “5.14 Subframe
Mount, Replacing”,
page 168 .
2 - Plastic Insert
❑ Part of purchased
mounting assembly.
3 - permitted
Washer unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Always replace.
4 - Bolt
❑ 110 Nm + 90° turn
❑ Always replace.
❑ Threads in body can be
repaired according to
DIN 8140 using wire
thread inserts (Heli-
Coil). Thread insert
must be same length as
thread in body.
5 - Washer
❑ Front only.
❑ Corrugation face toward
body.
❑ Installed only with a hy‐
draulic mounting.
❑ Discontinued from cal‐
endar week 48/2000
with introduction of new
hydraulic mounting. Allocation, refer to the Electronic Part Catalog.

2.3 Subframe Overview, AWD
1 - Subframe
ling, refer to
⇒ “5.13 Subframe”,
page 162 .
❑ Subframe mountings,
replacing, refer to
⇒ “5.14 Subframe
Mount, Replacing”,
page 168 .
❑ Rear differential mount,
replacing, refer to
⇒ “5.15 Rear Differential
Mount”, page 172 .
2 - Bolt
❑ 55 Nm
3 - Washer
4 - Nut
5 - Plastic Insert
❑ Part of purchased
mounting assembly.
6 - Washer
❑ Always replace.
7 - Bolt
❑ 110 Nm + 90° turn
❑ Always replace.
❑ Threads in body can be
repaired according to
DIN 8140 using wire
thread inserts (Heli-
Coil). Thread insert
must be same length as

thread in body.
8 - Washer
❑ Front only.
❑ Corrugation face toward body.
❑ Installed only with a hydraulic mounting.
❑ Discontinued from calendar week 48/2000 with introduction of new hydraulic mounting. Allocation, refer
to the Part Catalog.
9 - Front Transmission Support
10 - Bolt
with❑ 40toNm
respect the correctness of information in this document. Copyright by AUDI AG.
11 - Cover
12 - Bolt
❑ 25 Nm
13 - Rear Final Drive
14 - Rear Crossmember
15 - Bolt
❑ 40 Nm
16 - Nut
❑ 40 Nm
17 - Washer
18 - Bolt

2.4 Trapezoidal Control Arm, Transverse Link and Tie Rod Overview
1 - Trapezoidal Control Arm

❑ Various versions. Refer
to
⇒ “1.3 Trapezoidal Con‐
trol Arm”, page 118 .
❑ Mixed installation not
permissible.
ling, refer to
⇒ “5.12 Trapezoidal
Control Arm”,
page 159 .
❑ Trapezoidal control arm
mountings must not be
replaced, if mounting is
damaged, replace tra‐
pezoidal control arm.
2 - Eccentric Bolt
– An axle alignment may
be required. Refer to
⇒ “2.3 Wheel Alignment
Test Prerequisites”,
page 232 .
❑ Do not turn more than
90° left or right (that is,
smallest to largest pos‐

sible adjustment).
3 - Eccentric Washer
❑ Inner bore with tab.
4 - Nut
❑ 95 Nm
❑ Always replace.
❑ Self-locking
❑ Tighten nuts only in curb
weight position.
5 - Bolt
❑ 85 Nm + 90° turn
❑ Always replace.
6 - Lower Spring Support
❑ Spring end rotated up to stop.
7 - Coil Spring
❑ Note different vehicle versions, see vehicle data plate. Refer to ⇒ page 81 .
❑ Removing and installing,
Protected by copyright. Copying for refer tocommercial
private or ⇒ “5.2 Coil Spring”,
purposes, in part or page
in whole,142
is not.
8 - Upper Spring Support
9 - Upper Spring Support

❑ Only for heavy duty suspension in conjunction with -item 8- ⇒ Item 8 (page 125) .
10 - Bolt
❑ 85 Nm + 90° turn
❑ Always replace.
11 - Transverse Link
❑ Removing and installing, refer to ⇒ “5.9 Transverse Link”, page 156 .
❑ Replace bearing, refer to ⇒ “5.10 Transverse Link Bracket”, page 157 .
12 - Eccentric Bolt
– An axle alignment may be required. Refer to ⇒ “2.3 Wheel Alignment Test Prerequisites”, page 232 .
❑ Do not turn more than 90° left or right (that is, smallest to largest possible adjustment).
13 - Washer
14 - Nut
❑ 85 Nm + 90° turn
❑ Always replace.
❑ Self-locking
❑ Tighten nuts only in curb weight position.
15 - Tie Rod
❑ Various versions.
❑ Removing and installing, refer to ⇒ “5.16 Tie Rod”, page 173 .
– An axle alignment may be required. Refer to ⇒ “2.3 Wheel Alignment Test Prerequisites”, page 232 .

16 - Stone Protection Plate

❑ Only for heavy duty suspension.
❑ Removing and installing (old version), refer to
⇒ “5.17 Tie Rod Stone Deflector, Old Three-Part Version”, page 174 .
❑ Removing and installing (new version), refer to
⇒ “5.18 Tie Rod Stone Deflector, New One-Part Version”, page 175 .
17 - Nut
❑ Self-locking.
❑ Always replace.
❑ Tighten nuts only in curb weight position.
18 - Stone Deflector for Trapezium Control Arm
❑ Only for heavy duty suspension.
19 - Bolt
❑ 25 Nm
20 - Bracket
❑ For parking cable.

2.5 Stub Axle Carrier Overview, FWD
1 - Stub Axle Carrier

❑ With FWD
ling, refer to
⇒ “5.4 Stub Axle Carrier/
Wheel Bearing Hous‐
ing, Steel”, page 144 .
❑ Servicing, refer to
⇒ “6.2 Stub Axle Carrier,
FWD”,bypage
Protected 186
copyright. . for private or commercial purposes, in part or in whole, is not
Copying
2 - Wheel
with Bearing
respect to theUnit
correctness of information in this document. Copyright by AUDI AG.

ling, refer to
❑ The wheel bearing and
wheel hub are installed
together in a housing.
❑ This wheel bearing/
wheel bearing unit is
maintenance and ad‐
justment free. Adjusting
or servicing is not possi‐
ble!
❑ Does not need to be re‐
placed.
❑ If wheel bearing unit can
be removed from stub
axle carrier by hand,
wheel bearing unit is OK
and can be reinstalled.
❑ If it cannot be removed
by hand, wheel bearing
unit must be replaced.

plete unit.
3 - Bolt
❑ 200 Nm + 180° turn
❑ Always replace.
❑ Tighten to 200 Nm, if vehicle is raised, only tighten with additional turn when vehicle is on floor.
❑ If vehicle is resting on floor, do not loosen more than 90°.
4 - Dust Cap
❑ An appropriate seal can only be achieved with a new dust cap.
❑ Only then is an optimum function and long service life guaranteed.
5 - Wheel Speed Sensor
❑ Wire routing, refer to ⇒ page 129 .
6 - Bolt
❑ 10 Nm
7 - Nut
❑ Always replace.
❑ Self-locking
8 - Washer
9 - Shock Absorbers
❑ On vehicles with Dynamic Ride Control (DRC II), empty and fill system. Refer to
❑ Removing and installing, refer to ⇒ “5.3 Shock Absorber”, page 143 .
❑ Note installed position. Refer to ⇒ page 129 .
❑ Pay attention to the different types of suspension; see vehicle data plate. Refer to ⇒ page 81 .
⇒ “2.2 Rear Gas-Filled Strut, Venting”, page 3
❑ Check removed shock absorber, refer to ⇒ “4.3 Shock Absorbers, Removed, Checking”, page 7 .
10 - Bolt
❑ 36 Nm
11 - Bolt
❑ 150 Nm + 90° turn
❑ Always replace.
❑ Tighten bolts only in curb weight position.

Speed Sensor Wire Routing on Trapezoidal Control Arm

1 - Bolt with cylindrical shoulder, 10 Nm
2 - Collar bolt, 10 Nm
3 - Cable guide
- To remove, remove collar bolt -2- and carefully slide cable guide
off of bolts -1- -arrow A-.
- To remove complete wiring, also unclip at subframe -arrow B-.
Shock Absorber Location

Longer collar on shock absorber -arrow A- muss sit in centering
seat on stub axle carrier/wheel bearing housing -arrow B-.
2.6 Wheel Bearing Housing Overview, Steel, AWD


ling, refer to
⇒ “6.3 Wheel Bearing
Housing, Steel, AWD”,
page 188 .
2 - Wheel Bearing
❑ Removing and installing
with wheel bearing
housing removed, refer
to
page 188 .
in vehicle, refer to
⇒ “5.5 Wheel Bearing,
Steel Wheel Bearing
Housing Installed,
AWD”, page 147 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Wheel Hub with respect to the correctness of information in this document. Copyright by AUDI AG.
with wheel bearing
housing removed, refer
to
page 188 .
in vehicle, refer to
⇒ “5.5 Wheel Bearing,
Steel Wheel Bearing
Housing Installed,

AWD”, page 147 .

4 - Bolt
❑ 200 Nm + 180° turn
❑ Always replace.
❑ Tighten to 200 Nm, if vehicle is raised, only tighten with additional turn when vehicle is on floor.
❑ If vehicle is resting on floor, do not loosen more than 90°.
5 - Drive Axle
❑ Removing and installing, refer to ⇒ “5.23 Drive Axle”, page 182 .
❑ Servicing (with inner joint diameter 100 mm), refer to
⇒ “6.4 Drive Axle with Inner CV Joint, 100 mm”, page 190 .
❑ Servicing (with inner joint diameter 108 mm), refer to
7 - Bolt
❑ 10 Nm
8 - Washer
9 - Nut
❑ Self-locking
❑ Always replace.
10 - Shock Absorbers
❑ Note different vehicle versions, see vehicle data plate. Refer to ⇒ page 81
⇒ “2.2 Rear Gas-Filled Strut, Venting”, page 3 .
❑ Check removed shock absorber. Refer to ⇒ “4.3 Shock Absorbers, Removed, Checking”, page 7 .
11 - Bolt
❑ 36 Nm
12 - Bolt
❑ 150 Nm + 90° turn
❑ Always replace.

2.7 Stabilizer Bar Overview
1 - Stabilizer Bar
❑ Be aware of the various
suspension versions.
Refer to ⇒ page 81 .
ling, refer to
⇒ “5.19 Stabilizer Bar”,
page 177 .
❑ Replace bearing, refer
to
⇒ “5.20 Stabilizer Bar
❑ Replace mounts always
on both sides of vehicle.
2 - Clamp
3 - Bolt
❑ 25 Nm
4 - Rubber Mount
❑ Replace, refer to
⇒ “5.20 Stabilizer Bar
❑ Replace mounts always
on both sides of vehicle.
5 - Coupling Rod
❑ Connects stabilizer with
trapezoidal control
with respect arm.
6 - Bolt
❑ 25 Nm
7 - Bolt
❑ 45 Nm

2.8 Wheel Bearing Housing Overview, Aluminum, AWD

ling, refer to
Housing, Aluminum,
AWD”, page 154 .
page 188 .
2 - Wheel Bearing
ling, refer to
⇒ “5.6 Bolted Wheel
Bearing Unit”,
page 149 .
3 - Wheel Hub
ling, refer to
Bearing Unit”,
page 149 .
4 - Bolt
❑ 200 Nm + 180° turn
❑ Always replace.
❑ Tighten to 200 Nm, if ve‐
hicle is raised, only tight‐
en with additional turn
when vehicle is on floor.
❑ If vehicle is resting on
floor, do not loosen
more than 90°.
5 - Drive Axle

ling, refer to
⇒ “5.23 Drive Axle”, page 182 .
❑ Servicing (with inner joint -diameter 100 mm), refer to
❑ Servicing (with inner joint -diameter 108 mm), refer to
6 - Washer
7 - Nut
❑ Self-locking
❑ Always replace.
8 - Shock Absorbers
9 - Bolt
❑ 36 Nm
10 - Bolt
❑ 10 Nm
12 - Bolts
❑ 80 Nm + 90° turn
❑ Always replace.
❑ Quantity: 4
13 - Bolt
❑ 150 Nm + 90° turn
❑ Always replace.
2.9 Level Control System Sensor with Auto‐

matic Headlamp Vertical Aim Control
Overview
Note
♦ Refer to
⇒ “1.3 Vehicle Level Sensor for Vehicles with Automatic Head‐
lamp Vertical Aim Control”, page 13 .
♦ Vehicle level sensor is available as replacement part only
complete with coupling rod and upper and lower retaining
plates. To remove it completely, subframe must be removed.
♦ Replacing with subframe installed. Refer to
⇒ “5.1 Vehicle Level Sensor”, page 141 .

1 - Bolt
❑ 85 Nm + 90° turn
❑ Always replace.
2 - Left Rear Level Control Sys‐
tem Sensor - G76- or -G77-
❑ Complete with compo‐
nents.
❑ Lever -arrow- must face
toward center of vehicle.
❑ Replace in vehicle. Re‐
fer to Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “5.1 Vehicle Level
Sensor”, page 141 with
. respect to the correctness of information in this document. Copyright by AUDI AG.
❑ After replacing, perform
headlamp basic setting.
Refer to ⇒ Electrical
System; Rep. Gr. 94 ;
Diagnosis and Testing .
3 - Bolt
❑ 10 Nm
4 - Trapezoidal Control Arm

2.10 Subframe Mount Overview
1 - Bolt
❑ 55 Nm
2 - Rear Differential Mount
3 - Nut
4 - Subframe
5 - Nut
❑ 40 Nm
6 - Bolt
❑ 40 Nm
7 - Final Drive Support
8 - Washer
9 - Rear Cross Member
10 - Bolt
❑ 40 Nm
11 - Bolt
12 - Rear Differential Mount
Web Alignment
13 - Washer Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

3 Specifications

Coupling Rod to Stabilizer Bar Bolt - 45
Coupling Arm to Trapezoidal Control Arm Bolt - 25
Drive Axle to Rear Final Drive Bolt M8 40
M10 65
Drive Axle Cover to Rear Final Drive Bolt, AWD - 25
Front Transmission Support to Rear Final Drive Bolt, AWD - 40
Front Transmission Support to Subframe Nut, AWD - 40
Rear Crossmember to Subframe Bolt, AWD - 55
Rear Final Drive to Rear Crossmember Bolt, AWD - 40
Rear Level Control System Sensor to Trapezoidal Control Arm Bolt - 10
Shock Absorber to Body Bolt - 36
Shock Absorber to Shock Absorber Mount Nut 1 - 25
Shock Absorber to Stub Axle Carrier Bolt 1, 2 - 150 + 90° turn
Stabilizer Bar to Subframe Bolt - 25
Stone Deflector to Trapezoidal Arm Bolt - 25
Subframe to Body Bolt 1 - 110 + 90°
Tie Rod to Wheel Bearing Housing Bolt 1 - 85 + 90°
Transverse Link to Subframe Bolt 1 - 85 + 90°
Transverse Link to Wheel Bearing Housing Nut 1, 2 - 95
Trapezoidal Control Arm and Tie Rod End to Subframe Nut 1, 2 - 85 + 90°
Wheel Bearing to Wheel Bearing Housing Bolt, Aluminum AWD 1 - 80 + 90°
Wheel Bearing Unit to Stub Axle Carrier Bolt, FWD 1, 3 - 200 + 180°
Wheel Hub to Wheel Bearing Housing Bolt, AWD 1, 3 - 200 + 180°
Wheel Speed Sensor Mounting Bolt - 10

• 2 Tighten nuts only in curb weight position.
• 3 Tighten to 200 Nm, if vehicle is raised, only tighten with ad‐
ditional turn when vehicle is on floor. If vehicle is resting on
floor, do not loosen more than 90°.

⇒ “4.1 Outer Constant Velocity Joint, Checking”, page 138
⇒ “4.2 Inner CV Joint, Checking”, page 139
4.1 Outer Constant Velocity Joint, Checking

Disassembling
– Before disassembling mark ball hub position in relation to the
ball cage and housing with an electric scriber or oil stone (see
-arrow-).
– Turn cage until two cage windows -arrow- rest on joint body.
– Swing a hub segment in a cage window.

Checking
hub, cage
Protected and balls
by copyright. forforsmall
Copying private depressions (pitting
or commercial purposes, in partbuild-up)
or in whole, isand
not
chafing. Excessive circumferential backlash in joint makes
itself
joint.
Assembling
– Press quantity of grease into joint body. Refer to
⇒ page 190 (diameter 100 mm) or ⇒ page 195 (diameter 108
mm).
Note

established again.

4.2 Inner CV Joint, Checking

Disassembling
Note
– Swing ball hub and ball cage and pull out of joint in
-direction of arrow-.
-arrows-.
Checking
Note
Excessive circumferential backlash in joint makes itself noticed

and running marks of balls are no reason to replace joint.
Assembling
– Press quantity of grease into joint body. Refer to
⇒ page 190 (∅ 100 mm) or ⇒ page 195 (∅ 108 mm).

Note
When inserting, make sure that in each case the wide gap -a- at
joint piece contacts narrow gap -b- at hub after swinging in.
paths.

-arrow-.


⇒ “5.1 Vehicle Level Sensor”, page 141
⇒ “5.2 Coil Spring”, page 142
⇒ “5.3 Shock Absorber”, page 143
⇒ “5.4 Stub Axle Carrier/Wheel Bearing Housing, Steel”,
page 144
⇒ “5.5 Wheel Bearing, Steel Wheel Bearing Housing Installed,
AWD”, page 147
⇒ “5.6 Bolted Wheel Bearing Unit”, page 149
⇒ “5.7 Wheel Bearing Housing, Aluminum, AWD”, page 154
⇒ “5.8 Light Weight Wheel Hub Slide Washer”, page 155
⇒ “5.9 Transverse Link”, page 156
⇒ “5.10 Transverse Link Bracket”, page 157
⇒ “5.11 Nut Securing Transverse Link to Subframe”, page 158
⇒ “5.12 Trapezoidal Control Arm”, page 159
⇒ “5.13 Subframe”, page 162
⇒ “5.14 Subframe Mount, Replacing”, page 168
⇒ “5.15 Rear Differential Mount”, page 172
⇒ “5.16 Tie Rod”, page 173
⇒ “5.17 Tie Rod Stone Deflector, Old Three-Part Version”,
page 174
⇒ “5.18 Tie Rod Stone Deflector, New One-Part Version”,
page 175
⇒ “5.19 Stabilizer Bar”, page 177
⇒ “5.20 Stabilizer Bar Mount”, page 178
⇒ “5.21 Stabilizer Bar Coupling Rod”, page 178
⇒ “5.22 Front or Rear Diagonal Braces”, page 179
⇒ “5.23 Drive Axle”, page 182
5.1 Vehicle Level Sensor

– Dismount tire.


– Remove bolts -2- with angled wrench. Do not bend upper re‐
taining plate when doing so.
Transverse link is not shown to improve clarity.
– Adapt replacement part accordingly and install.
Note
Hold Level Control System

Protected by copyright. Sensor
Copying forsecurely when tightening
private or commercial bolts
-2-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Tightening specifications:
- Item 1: 10 Nm
- Item 2: 5 Nm
– After replacing, perform basic setting for headlamps. Refer to
⇒ Electrical Equipment; Rep. Gr. 94 ; Diagnosis and Testing .
5.2 Coil Spring

♦ Spring Compressor - VAG1752/1-
♦ Spring Compressor Kit - Adapter Blocks - VAG1752/9-
♦ Spring Retainer - VAG1752/16-
Removing
– Remove wheel.
– Insert Spring Compressor Kit - Spring Tensioner -
VAG1752/1- with Spring Compressor Kit - Adapter Blocks -
VAG1752/9- and Spring Compressor Kit - Spring Retainer -
VAG1752/16- in coil spring. If necessary, guide spring holder
individually into windings and then fasten to spring compres‐
sor. Do not damage trapezoidal control arm when doing so.
It must be compressed 4 turns.
If this is not possible, compress only 3 turns and turn coil spring
until 4 turns prescribed can be compressed.
WARNING
Make sure that correct seating of coil spring in Spring Com‐

pressor Kit - Spring Retainer - VAG1752/16- (accident risk).
– Compress spring compressor to stop and remove spring.

Installing
Note
♦ When installing new spring, ensure conical end points down‐

ward.
♦ -Arrow B-: Colored markings must be at bottom.

– Lower spring seat -1- has a pin.

– Insert this pin in trapezoidal control arm hole -2-.
– Turn ends of coil spring so that it rests on spring seat stop
-arrow A-.
– Then insert upper spring seat (not in illustration) in upper
spring end.
– Tension spring. Align upper spring seat in body hole.
5.3 Shock Absorber

Removing
On vehicles with Dynamic Ride Control (DRC II), empty the sys‐
tem. Refer to
– Dismount tire.
– Remove coil spring. Refer to ⇒ “5.2 Coil Spring”, page 142 .
– Remove nut -1- and remove bolts (Illustration without cover
plate).
– Remove bolts
permitted -2-.
Note
Wheel housing liner remains installed.
– Remove shock absorber.

Installing
Note
Replace the bolts and self-locking nuts. Notes, refer to

page 129 .

– Tighten the bolts -2- (36 Nm).

Pay attention to the location of the lower mounting. Refer to
⇒ page 129 .
– Bonded rubber bushings have a limited range of motion. Only
page 119 .
– Tighten connection -1- (150 Nm + 90° turn).
– Install coil spring. Refer to ⇒ “5.2 Coil Spring”, page 142 .
On vehicles with Dynamic Ride Control (DRC II), fill the system.
refer to
5.4 Stub Axle Carrier/Wheel Bearing Hous‐

ing, Steel
♦ Grease Cap Puller - VW 637/2-
♦ Fitting Sleeve - 3241/4-
♦ Socket - T40027-
Removing
With FWD
Note
If wheel bearing unit is not replaced, do not remove collar bolt and
dust cap.
– Remove wheel.
– Loosen dust cap from seat by lightly tapping on claws.

– Press of dust cap.

– Mount wheel and place vehicle on wheels.

– Loosen collar bolt -arrow- only 90°, otherwise wheel bearing
will be damaged.
WARNING
When loosening and tightening collar bolt, vehicle must stand

on wheels.
– Dismount tire.
– Remove brake caliper -arrows-. To do so, use -T40027- .
Note
♦ Secure brake caliper to body with wire.

♦ Do not allow brake
permitted caliper
unless tobyhang
authorised from
AUDI AG. brake
AUDI line.
AG does not guarantee or accept any liability


– Remove cover plate -3-.

With FWD
– Remove wheel bearing unit -2-.
Note
If wheel bearing unit can be removed from stub axle carrier by

hand, wheel bearing unit is OK and can be reinstalled.

– Remove speed sensor -2-.
– Mark eccentric bolt position -1- at top of stub axle carrier/wheel
bearing housing, for example with a felt-tip pen.
– Separate connections listed in sequence: -5, 3, 4, 1-.
– Remove stub axle carrier or wheel bearing housing.
Note
Carefully press drive axle off on all wheel drive vehicles.
Installing
Note
Replace bolts and self-locking nuts. Notes, refer to

⇒ “2.2 Subframe Overview, FWD”, page 120 .
Bonded rubber bushings have a limited torsional range. Only

page 119 .
With FWD
– Install new wheel bearing unit if necessary. Notes,
Protected refer to Copying for private or commercial purposes, in part or in whole, is not
by copyright.
⇒ page 146 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Tighten connections -1, 3, 4, and 5-.
– Secure speed sensor -2- (10 Nm).
– Install cover plate and brake caliper at stub axle carrier or
wheel bearing housing. Refer to ⇒ Brake System; Rep. Gr.
All Wheel Drive
– Tighten 5 wheel bolts and tighten parking brake.


– First tighten collar bolt -1- only to pre-tightening specification
without additional turning (turn additionally when vehicle is
resting on wheels
). Refer to
⇒ “2.5 Stub Axle Carrier Overview, FWD”, page 127 or
page 129 .
Tightening Specifications:
♦ Item 1 - (Bring eccentric bolt into previously marked position)

(95 Nm).
♦ Items -3 and 4- (85 Nm + 90° turn).
♦ Item -5- (150 Nm + 90° turn).
– Tighten collar bolt -1-. Refer to ⇒ page 147 .
With FWD
– Dismount tire.
– Drive on a new dust cap.
Note
♦ Damaged (dented) protective caps

Protected must be
by copyright. replaced.
Copying for private or commercial purposes, in part or in whole, is not
♦ Damaged (dented) protectivewithcaps allow
respect moistureof to
to the correctness enter.in this document. Copyright by AUDI AG.
information
Therefore, always use the tool shown.

Alignment must take place on a VW/Audi recommended align‐
ment stand.
5.5 Wheel Bearing, Steel Wheel Bearing

Housing Installed, AWD
♦ Engine and Gearbox Jack - VAS6931- with Universal Trans‐
mission Support - VAG1359/2-
♦ Foot Pump W/High Pressure Hose - VAG1389 A/1-
♦ Wheel Bearing Tool - VAG1459B-
♦ Hollow Piston Cylinder HKZ-15 with Hydraulic Thrust Piece -
E-0-204-T-

♦ Tie Bolt - E-0-217+218-

♦ Special Nut - E-8-214-
♦ Press Piece - E-5-
♦ Supplementary Set - VAG1459 B/2-
♦ Bell - E-40-
♦ Thrust Sleeve - E-44-1-
♦ Hand Pump - VAG1389/1-
♦ Conversion Kit - VAG1389/4-
If available in shop, -VAG1389/1- can also be modified for use as
a foot pump.
To do so, use -VAG1389/4- .
– Remove brake caliper, brake disc and brake disc cover. Refer
to ⇒ Brake System; Rep. Gr. 46 ; Removal andProtected
Installation .
– Remove drive axle. Refer to ⇒ “5.23 Drive Axle”, page 182 .
Place Engine and Gearbox Jack - VAS6931- underneath (danger

of accident from falling parts when removing the wheel hub and
the wheel bearing).
Wheel Hub, Pulling Out
– Attach bell -1-, hollow piston cylinder -2- with tension bolt and
special nut -3-.
– Remove wheel hub by operating pump while holding tool se‐
curely.
1 - Bell E-40
2 - Hollow piston cylinder HKZ-15
3 - Special nut E-8-214 and tie bolt
Wheel Bearing, Pulling Out

– Attach pressure piece -1- with collar to bearing, pressure
sleeve -2- with four tiered interior diameters to wheel bearing
housing, hollow piston cylinder -3- with tie bolt and special nut
-4-.
– Operate pump and remove the wheel bearing.
1 - Thrust piece E-5
2 - Thrust sleeve E-44-1

Wheel Bearing, Pressing In

Installation position: Larger internal diameter of wheel bearing
faces outward.
– Put wheel bearing -1-, pressure piece -2- (put collar into bear‐
ing), and hollow piston cylinder -3- with tie bolt on wheel
bearing housing.
– Attach pressure piece -4- with angles toward wheel bearing
housing and special nut -5- from inside.
– Press wheel bearing in by operating the pump.
1 - Wheel bearing
2 - Thrust piece E-14-1
Wheel Hub, Pressing In

– Put wheel hub -1- and hollow piston cylinder -2- with tie bolt
onto wheel bearing.
– Attach pressure piece -3- with collar to special nut -4- from
inside.
– Press in hub by operating the pump.
1 - Wheel hub
Further installation is in the reverse sequence to removal.
– Install the drive axle. Refer to
– Install brake caliper, brake disc and brake disc cover. Refer to
⇒ Brake System; Rep. Gr. 46 ; Removal and Installation .
5.6 Bolted Wheel Bearing Unit


❑ Wheel bearing housing,
removing and installing,
refer to
Housing, Aluminum,
AWD”, page 154 .
2 - Wheel Bearing
3 - Wheel Hub
ling, refer to
Bearing Unit”, page 149 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 200 Nm + 180° turn
❑ Always replace.
❑ Tighten to 200 Nm, if ve‐
hicle is raised, only tight‐
en with additional turn
when vehicle is on floor.
❑ If vehicle is resting on
floor, do not loosen
more than 90°.
5 - Drive Axle
ling, refer to
⇒ “5.23 Drive Axle”,
page 182 .
❑ Servicing (with inner
joint diameter 100 mm),
refer to
⇒ “6.4 Drive Axle with In‐
ner CV Joint, 100 mm”,

page 190 .
❑ Servicing (with inner
joint diameter 108 mm), refer to ⇒ “6.5 Drive Axle with Inner CV Joint, 108 mm”, page 195 .
6 - Washer
7 - Nut
❑ Self-locking
❑ Always replace.
8 - Shock Absorbers
9 - Bolt
❑ 36 Nm
10 - Bolt
❑ 10 Nm
12 - Bolts
❑ 80 Nm + 90° turn
❑ Always replace.
❑ Quantity: 4
13 - Bolt
❑ 150 Nm + 90° turn
❑ Always replace.

♦ Thrust Plate - VW 402- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Tube 37 mm Dia. - VW 416 B- with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Punch - VW 407-
17-2-

Removing
– Drive axle, removing and installing, refer to
– Remove securing bolts -1- from brake caliper.
– Remove brake caliper and hang on body.
– Remove cap bolts -1 and 2-.
– Pull wheel bearing unit outward.
Pressing Wheel Hub out of 82 mm Diameter Wheel Bearing

Housing

Press the Bearing Inner Race from the Hub.

– Insert separating tool into ring groove of bearing inner race
-arrow-, and pretension with spindle.
Note
Use a commercially available separating device for example Pull‐

er - Kukko Separating Tool - Diameter 22-115mm - 15-2- or Puller
- Kukko Quick Action Separating Tool - 22-115mm - 17-2-
– Press bearing inner race off from wheel hub.

With light weight wheel hubs, slide washer must be replaced. Re‐
fer to ⇒ “5.8 Light Weight Wheel Hub Slide Washer”, page 155 .
Pressing Wheel Hub into 82 mm Diameter Wheel Bearing

– When pressing in, -VW 511- may only lie against bearing inner
race.
Installing
page 119 .
Tightening Specifications:
Drive axle to wheel hub M14, use new bolt! 115 Nm + 180°
Drive axle to wheel hub M16, use new bolt! 200 Nm + 180°
Drive axle to flange shaft M8 40 Nm
M10, drive axle to joint flange 70 Nm
Brake caliper to stub axle carrier 70 Nm + 90°
Wheel bearing unit to stub axle carrier 80 Nm + 90°

5.7 Wheel Bearing Housing, Aluminum,

AWD
Removing
– Remove the drive axle bolt. Refer to
– Remove wheels.
– Remove securing bolts -1- from brake caliper.
– Remove brake caliper and hang on body.
– Remove socket head bolt -1-.

– Remove ABS wheel speed sensor -2- from wheel bearing
housing.
– Remove bolt -1- for coupling rod.
– Remove the bolt -A- for tie rod.

– Mark installation position of eccentric washer for bolt -B-.
– Remove bolt -B-.

– Remove bolt -2- for transverse link -1-.

– Pull wheel bearing housing off drive axle.
Installing
page 119 .
Otherwise the rubber mounting will be stressed, resulting in a re‐
duced service life.
ment stand.
5.8 Light Weight Wheel Hub Slide Washer

♦ Thrust Piece - T40089/1-
Slide Washer, Replacing
– Carefully pry off slide washer -1-, for example with a screw‐
driver.
– Position slide washer on wheel hub.


1- -VW 473-
2- -T40089/1-
3- Slide washer
4- Wheel hub
5- -VW 401-
– Press slide washer off using -T40089/1- as shown in illustra‐
tion up to wheel bearing hub radius.
Note
Slide washer must be pressed on up to wheel bearing hub radius.
5.9 Transverse Link

♦ Torque Wrench 1331Protected
5-50Nm - VAG1331-
♦ Torque Wrench 1332permitted
40-200Nm - VAG1332-
Note
♦ Because of poor accessibility to inner bolt -1- when the vehicle

is resting on wheels, transverse link can only be removed
when subframe is removed.
Removing
– Remove subframe. Refer to ⇒ “5.13 Subframe”, page 162 .
– Mark eccentric bolt -2- to stub axle carrier/wheel bearing hous‐
ing, for example with a felt-tip pen.
– Separate connections -1 and 2-.
Installing
Note
♦ Replace bolts and self-locking nuts. Notes, refer to

♦ Do not interchange right and left parts. R or L is marked on
back of transverse link.

Installation position of control arm at subframe

– Loosely screw the transverse link -2- to the subframe.
– Lay a ruler or straight edge -1- flat against stabilizer bar mount‐
ing bracket -arrow-.
– Position transverse link so that -dimension a- = 14 2± 1 mm.
– Fasten transverse link to subframe in this position, refer to
⇒ Item 10 (page 125) .
– Attach stub axle carrier or wheel bearing housing to transverse

control arm and tighten new nuts to 20 Nm. Note location of
eccentric bolt -2-.
– Install subframe. Refer to ⇒ “5.13 Subframe”, page 162 .
page 119 .
– Loosen connection -2- and retighten (95 Nm).
The axle alignment must be performed on a VW/Audi
permittedapproved
alignment stand. with respect to the correctness of information in this document. Copyright by AUDI AG.
5.10 Transverse Link Bracket

♦ Punch - VW 412-
♦ Press Tube - 2040-
♦ Mounting Universal Joint - 41 - 501-
Pulling In Bonded Rubber Bushing

– Press bracket on until ends project evenly on both sides.

5.11 Nut Securing Transverse Link to Sub‐

frame
Note
♦ Replace nut for securing transverse link to subframe if dam‐

aged. Only use replacement nut listed in the parts catalog for
repairs.
♦ Because of poor accessibility to inner bolt -1- when vehicle is
resting on wheels, transverse link can only be removed when
subframe is removed.
Removing
– Remove subframe. refer to ⇒ “5.13 Subframe”, page 162 .
– Separate connection -1-.
– Swing transverse link upward out of subframe bracket.
Note
When installing cylinder bolt, ensure transverse link is not dam‐

aged.
– Install, for example, a cylinder bolt with hex socket head M12
x 1.5 x 20 (ET No. N902 268 01) -1- in nut -2- up to stop.
As an emergency solution, you can also use bolt M12.1.5 x 20.
– Turn cylinder bolt more until damaged nut unscrews from sub‐
frame bracket.
Installing
Note

– Insert transverse link in subframe bracket.

– Insert replacement nut -2- in subframe bracket using new bolt
-1-.
– Tighten the combi-bolt -1- -item 10- ⇒ Item 10 (page 125) .

ment stand.

5.12 Trapezoidal Control Arm

Removing
– Remove underbody trim in front of trapezoidal control arm.
Convertible Only
– Remove diagonal braces -1 and 2-. Refer to
Vehicles with Heavy Duty Suspension
– Remove stone impact protection from trapezoidal control arm.
Continuation for All
Protected Vehicles
– Disengagewithparking brake
respect to the cable
correctness of from bracket
information under trapezoidal
in this document. Copyright by AUDI AG.
control arm. Loosen bolts to do this.
– Remove bolt -1- on vehicles with headlamp range control.

– Remove speed sensor cable guide -2-. Refer to ⇒ page 129 .

– Remove bolt -1-. Counter hold joint with wrench.
– Mark eccentric bolt -5- to subframe.
– Loosen trapezoidal control arm (items -3 to 6-).
Note
On vehicle with all wheel drive and with right trapezoidal control
arm on vehicles with front wheel drive, subframe should be low‐
ered slightly before removing bolts.
All Wheel Drive

– Remove the driveshaft from rear final drive. Refer to ⇒ Rear
Final Drive 01R; Rep. Gr. 39 ; Removal and Installation .
– Secure driveshaft to body with wire.
– Remove shock absorber from wheel bearing housing.
– Disengage parking brake cable at fuel tank.
– Remove brake caliper. Refer to ⇒ Brake System; Rep. Gr.
– Remove right drive axle cover (remove right trapezoidal con‐
trol arm).
– Lower subframe slightly. Refer to
⇒ “5.13 Subframe”, page 162 .
Vehicles with Front Wheel Drive, Removing Left Trapezoidal
Control Arm
– Remove heat shield from body eccentric screw and press to
side.
Vehicles with Front Wheel Drive, Removing Right Trapezoidal
Control Arm
– Remove shock absorber from wheel bearing housing.
– Remove brake caliper. Refer to ⇒ Brake System; Rep. Gr.
– Lower subframe slightly. Refer to
⇒ “5.13 Subframe”, page 162 .


– Remove trapezoidal control arm (items -3 to 6-).
Note
When doing so, ensure subframe is held securely.
Installing
Replace bolts and self-locking nuts. Notes,
permitted refer toby AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
⇒ “2.2 Subframe Overview, FWD”,withpage 120 .


– Install shock absorber. Refer to
⇒ “5.3 Shock Absorber”, page 143 .
– Install brake caliper. Refer to ⇒ Brake System; Rep. Gr. 46 ;
Removal and Installation
– Install driveshaft to rear final drive. Refer to ⇒ Rear Final Drive
01R; Rep. Gr. 39 ; Removal and Installation
– Install the driveshaft shield (25 Nm).
page 119 .
– Tighten the threaded connections -3, 4 and 6-. Refer to

⇒ “2.4 Trapezoidal Control Arm, Transverse Link and Tie Rod
Overview”, page 124 .
– Tighten nut -5- (bring eccentric bolt into previous position), re‐
fer to -item 4- ⇒ Item 4 (page 125) .
– Install speed sensor cable guide -2-. Refer to ⇒ page 129 .
– Tighten bolt -1-, refer to -item 7- ⇒ Item 7 (page 132) .
– Engage parking brake cable in bracket.
– Tighten bolt -1- on vehicles with headlamp range control, refer

to -item 3- ⇒ Item 3 (page 135) .
ment stand.
– Install stone impact protection and tighten bolts (25 Nm).

Convertible Only
– Install diagonal braces -1 and 2-. Refer to
– Install underbody trim.
5.13 Subframe
♦ Socket - T40027-
Note
♦ The procedure steps show you how you can remove the sub‐
frame as a complete unit (that is, with rear axle transmission,
stub axle carrier/wheel bearing housing, trapezoidal control
arm).
– Loosen bolt -arrow- only 90° on vehicle resting on wheels if

you want to remove components that require removal of collar
bolt.
WARNING
WhenProtected
loosening and Copying
by copyright. tightening collar
for private bolt, vehicle
or commercial purposes, must
in part orstand
in whole, is not
on wheels.
Removing
WARNING
Before LOOSENING subframe bolts, secure vehicle against

tipping over (for example load luggage compartment with ap‐
proximately 50 kg).

Convertible Only
– Remove diagonal braces -1 and 2-. Refer to

– Remove rear and side underbody trim in front of subframe.
– Dismount tires.
– Secure brake discs with a wheel bolt.
– Remove the rear portion of the exhaust system. Refer to ⇒
Engine Mechanical; Rep. Gr. 26 ; Removal and Installation .
– Remove shock absorber from wheel bearing housing -1-.

– Disengage parking brake cable from bracket under trapezoidal
control arm. Loosen bolts to do this.

– Remove brake caliper -arrows-. To do so, use -T40027-

.
Note
♦ Secure brake caliper to body with wire.

♦ Do not allow brake caliper to hang from brake line.
– Remove speed sensor and cable guide. Refer to

⇒ page 129 .
– On vehicles with headlamp range control remove connector
from level control system sensor.
All Wheel Drive
– Disengage parking brake cable at fuel tank.
– Remove bolts -2- and remove shock absorber.

– Remove brake disc and brake disc cover.


– Position Engine and Gearbox Jack - VAS6931- with -
VAG1359/2- and a corresponding wooden block at subframe
or final drive (Fig. for vehicles with front wheel drive).
– Tighten band around subframe or final drive.
WARNING
Before LOOSENING subframe bolts, secure vehicle against

tipping over (for example load luggage compartment with ap‐
proximately 50 kg).
– Remove subframe bolts -arrows-.

With FWD
– Lay parking brake cable with brake caliper over transverse
link.
– Carefully lower subframe. Guide subframe so it does not shift.
AWD
– Carefully lower subframe approximately 15 cm. Guide sub‐
frame so it does not shift.
– Slide subframe left so that right parking brake cable with brake
caliper
Protected can beCopying
by copyright. laid over transverse
for private or commerciallink.
Note
Make sure that brake hose is not stretched.
– Slide subframe right so that left parking brake cable with brake
caliper can be laid over transverse link.
– Lower subframe.
Installing
Note
Replace bolts and self-locking nut. Notes, refer to

Insertion of subframe occurs in reverse order of removal.

– Center subframe over four bearing holes to body.
– Install the new subframe screws and washers and tighten, re‐
fer to ⇒ “2.2 Subframe Overview, FWD”, page 120 , -item 3-
⇒ Item 3 (page 121) and -item 4- ⇒ Item 4 (page 121) (front
wheel drive) or -item 6- ⇒ Item 6 (page 122) and -item 7-
⇒ Item 7 (page 122) (all wheel drive).
All Wheel Drive
– Install brake disc cover.
Refer to ⇒ Brake System; Rep. Gr. 46 ; Removal and Instal‐
lation .
– Install brake disc and secure with wheel bolt.
01R; Rep. Gr. 39 ; Removal and Installation .

– Install shock absorber on body -item 11-

⇒ Item 11 (page 131) .
– Engage parking brake cable at fuel tank.
– Install and align exhaust system. Refer to ⇒ Engine Mechan‐
ical; Rep. Gr. 26 ; Removal and Installation .
– Place headlamp range control connector on level control sys‐
tem sensor.
– Install speed sensor and cable guide. Refer to ⇒ page 129 .
– Secure brake caliper to stub axle carrier or wheel bearing
housing. Refer to ⇒ Brake System; Rep. Gr. 46 ; Removal
and Installation .
– Install parking brake cable with bracket below trapezoidal con‐
trol arm and tighten bolts (25 Nm).

– First tighten shock absorber nut -1- to 20 Nm.

Only when you have loosed collar bolt:
Always use a new collar bolt!
– On vehicles with all wheel drive, install 5 wheel bolts hand tight
and apply parking brake.
– Tighten collar bolt to specified torque without additional turn‐
ing. Refer to
page 129 .
– Bonded rubber bushings have a limited torsional range. Only
page 119 .
– Tighten connection -1- (150 Nm + 90° turn).
Only when you have loosed collar bolt:
– Tighten collar bolt with specified additional turning. Refer to
page 129 .
WARNING

on wheels.
– Install rear and side underbody trim.

Alignment must
Protected by takeCopying
copyright. place for on a VW/Audi
private or commercialrecommended
purposes, in part or in align‐
whole, is not
mentpermitted
stand.unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Convertible Only
– Install diagonal braces -1 and 2-. Refer to


5.14 Subframe Mount, Replacing

♦ Engine and Gearbox Jack - VAS6931- with Universal Trans‐
mission Support - VAG1359/2-
♦ Foot pump with high pressure hose - VAG1389 A/1-
♦ Wheel bearing tool - VAG1459 B-
♦ Hollow piston cylinder HKZ-15 - E-0-204-T-
♦ Tie bolt - E-0-217+218-
♦ Special nut - E-8-214-
♦ Press piece - E-5-
♦ Press piece - T40033/1-
♦ Support ring - T40033/2-
♦ Tube - T40033/3-
♦ Mount - T40033/4-
♦ Press piece - T40033/5-
♦ Mount - T40033/6-
♦ Spindle - T40034-
♦ Nut - T40034/1-
♦ Nut - T40034/2-
If available in shop, -VAG1389/1- can also be modified for use as
a foot pump.
To do so, use -VAG1389/4- .
Note
♦ The same special tools and workshop equipment can be used

to replace subframe mounting on vehicles with front and all
wheel drive.
♦ The subframe does not have the usual bonded rubber mount‐
ings, but rather has hydraulic mountings. Allocation, refer to
the Replacement Parts Catalog.
♦ The mountings can only be removed and installed with the
subframe lowered.
♦ Identify mounting location to subframe before removing.

Remove Front or Rear Hydraulic Mountings

– Remove wheels.
– Remove left and right coil spring. Refer to
⇒ “5.2 Coil Spring”, page 142 .
– Only remove left/right rear underbody trim if front hydraulic
mounting will be replaced.
1 - Left underbody trim
– If present, remove diagonal braces -1 and 2-. Refer to

Only with Rear Hydraulic Mounting
– Remove the stabilizer bar. Refer to
⇒ “5.19 Stabilizer Bar”, page 177 .
Procedure for Front and Rear Hydraulic Mountings

– Position Engine and Gearbox Jack - VAS6931- with -
VAG1359/2- and a corresponding wooden block at subframe
or final drive (Fig. for vehicles with front wheel drive).
– Tighten band around subframe or final drive.
♦ If a front hydraulic mounting is to be replaced, only loosen front
subframe bolts.
♦ If a rear hydraulic mounting is to be replaced, only loosen rear
subframe bolts.
♦ If another bolt for subframe at front or rear is loosened, vehicle
alignment must be performed after installation.
– Loosen front or rear bolts for subframe.

– Carefully lower subframe approximately 5 cm.
– Only remove bolt for subframe where hydro mount must be
replaced.

– Mark location of hydraulic mounting -1- to subframe -2-, for

example with a felt-tip pen (Fig. shows subframe on front
wheel drive vehicle).
-Arrow A-: Driving direction
-Arrows B and C-: Marking

1 - -T40034/1- or -T40034/2-
2 - -T40033/1-
3 - -T40033/2-
4 - -T40033/3-
5 - -T40033/4- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - -HKZ-15- with respect to the correctness of information in this document. Copyright by AUDI AG.
7 - -E-5-
8 - -E-8-214-
9 - -T40034-
10 - Subframe
– Pretension special tools.
– Remove hydraulic mounting by operating pump.
Note
When removing hydraulic mounting with -VAG1459 B- , you must

cut back.
Pull in Front or Rear Hydraulic Mounting

Front and hydraulic mountings are different. Make sure that cor‐
rect allocation when installing. Allocation, refer to the Parts Cat‐
alog.
Hydraulic mounting must be installed in the correct direction, note
marking on subframe.

– Insert special tool with hydraulic mounting in subframe as

shown.
Make sure that correct location when inserting -T40033/6- .
1 - -T40034/1- or - T40034/2-
2 - -T40033/6-
3 - Hydraulic support
4 - -T40033/5-
5 - -HKZ-15-
6 - -E-5-
7 - -E-8-214-
8 - -T40034-
9 - Subframe
– Pretension special tool with hydraulic mounting.
– Completely coat hydraulic mounting with installation lubricant
G 294 421 A1 thinned with water at a ratio of 1:100.
– Make sure that ends of rubber beads on hydraulic mounting

-1- align with markings -arrows B and C- on subframe -2-.
-Arrow A- direction of travel
– Pull in hydraulic pump to stop by operating pump.
Note
♦ When pulling in hydraulic mounting with -VAG1459 B- you

must cut back.
♦ Make sure that hydraulic mounting does not tilt while it is being
pulled in, otherwise outer ring could be damaged!
– Raise subframe using Engine and Gearbox Jack - VAS6931- .

– Install new subframe bolts and washers and tighten. Refer to
-item 3- ⇒ Item 3 (page 121) and -item 4-
⇒ Item 4 (page 121) (front wheel drive) or -item 6-
⇒ Item 6 (page 122) and -item 7- ⇒ Item 7 (page 122) (all wheel
drive).
Only Rear Hydraulic Mounting
– Install stabilizer bar. Refer to
Procedure for Front and Rear Hydraulic Mountings

– If present, install diagonal braces -1 and 2-. Refer to

– Install right and left underbody trim.
– Install left and right coil spring. Refer to
⇒ “5.2 Coil Spring”, page 142 .
ment stand.
5.15 Rear Differential Mount

♦ Removal and Assembly Tool - T40032-
♦ Universal Transmission Support - VAG1359/2-
Removing
– Place Engine and Gearbox Jack - VAS6931- with -
VAG1359/2- under rear final drive and secure rear final drive.
– Remove bolts from -VAG1359/2- and rear final drive -arrows-.
– Remove the bolts on differential mount (55 Nm).
– Remove rear cross member/rear final drive bolts (40 Nm).
Note
Lower rear final drive enough so that upper bolt can be removed.
– Remove rear cross member downward.
– Use -T40032- as shown in illustration and remove differential

mount.
Note
To provide a better illustration, subframe is shown removed.
Installing
– Align differential mount.

– Use -T40032- as shown in illustration and remove differential

mount -arrow-.
Note
♦ Installation device from front.

♦ Bearing outer race flush with sleeve on subframe.
– Place rear cross member on rear final drive and tighten bolts
(40 Nm).
– Fasten rear cross member with subframe (55 Nm).
– Fasten front transmission support to rear final drive (40 Nm).
01R; Rep. Gr. 39 ; Removal and Installation
– Remove Engine and Gearbox Jack - VAS6931- .
5.16 Tie Rod

Note
An axle alignment may be required. Refer to

Removing
– Dismount tire.
– Remove threaded connections -1 and 2- and remove tie rod.
Installing
Note

– First tighten threaded connections nuts -1 and 2- only to 20

Nm.

– Tighten threaded connections -1 and 2- (85 Nm + 90° turn).

page 119 .
ment stand.
5.17 Tie Rod Stone Deflector, Old Three-Part

Version
♦ Torque Wrench - VAG1410- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
♦ Tie rod stone impact suspension is only installed on vehicles

with heavy duty suspension.
♦ Stone impact protection 8E0 501 561 (old version) can only
be installed on vehicles with a three-part tie rod (old version).
Stone Impact Protection, Replacing with Tie Rod Removed

– Loosen bolts -2-.
– Slide clamping parts -1- inward.
– Unclip stone impact protection from tie rod.
Tightening specification item 2: 5 Nm
Stone Impact Protection, Replacing with Tie Rod Installed
Removing
– Cut stone impact protection with a knife in threaded connec‐
tion area at trapezoidal control arm. Do not damage tie rod.
– Loosen bolts -2-.

Installing
– Cut in new stone impact protection at top -A-.
– Clip stone impact protection onto tie rod.
– Slide clamping parts -1- outward and tighten bolts -2- to 5 Nm.
5.18 Tie Rod Stone Deflector, New One-Part

Version
Note
Tie rod stone impact suspension is only installed on vehicles with

heavy duty suspension.
Stone impact protection, replacing with tie rod removed

– Press clips -1- forward in direction of travel out of stone impact
protection -2-.
– Unclip stone impact protection -2- from tie rod -3-.
When installing stone impact protection, ensure it engages cor‐
rectly with tie rod.
Stone Impact Protection, Replacing with Tie Rod Installed
Note
Replacement of stone impact protection on right side of vehicle

is described and shown in illustration.
Removing
– Cut stone impact protection with a knife in threaded connec‐
tion area at trapezoidal control arm/tie rod. DoProtected
not damage tieCopying for private or commercial purposes, in part or in whole, is not
by copyright.
rod or other suspension components. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Press clip -3- forward in direction of travel out of stone impact

protection -2-.
– Press clip -1- forward in direction of travel out of stone impact
protection -2- until head of clip rests on trapezoidal control
arm.
4 - Tie Rod

– Cut clip head -1- at ⇒ area marked in illustration. Do not dam‐

age any other suspension components when doing so.
2 - Tie Rod
3 - Stone protection plate
– Pull rest of clips -1- back in direction of travel out of stone im‐
pact protection.
Installing
– Cut new stone impact protection for right side at markings
-A- and for left side at markings -B-.
– First insert stone impact protection on interior side (side facing
center of vehicle), then on exterior side.
– File clip off about 2 mm on interior side at both marks

-arrows-.
– Press filed clip from behind in direction of -arrow- on vehicle

interior side through tie rod and stone impact protection.
– Clip stone impact protection onto tie rod. Make sure that stone
impact protection engages correctly.

– Press clip -1 and 3- back in direction of travel in stone impact

protection -2-.
5.19 Stabilizer Bar

Removing
– Remove rear underbody trim.
Convertible Only
– Remove rear diagonal brace. Refer to
Vehicles with Exhaust System with 2 Rear Mufflers
– Remove the rear portion of the exhaust system. Refer to ⇒
Engine Mechanical; Rep. Gr. 26 ; Removal and Installation
– Remove bolts -2-. Counter hold joint with the wrench.
– Remove stabilizer with mount.
Installing
– Rubber bushing
permitted unless must rest
authorised on stabilizer
by AUDI AG. AUDI AG bar collar
does not -arrow-.
guarantee or accept any liability

– Install bolts -3- and only hand tighten for the time being.
– Install and tighten bolt -2- (45 Nm).
– Install and tighten bolt -1- (25 Nm).
– Place vehicle on wheels and bounce several times.
– Tighten bolts -3- to specified torque (25 Nm).
Vehicles with Exhaust System with 2 Rear Mufflers
– Install and align exhaust system. Refer to ⇒ Engine Mechan‐
ical; Rep. Gr. 26 ; Removal and Installation .
Convertible Only
– Install rear diagonal brace. Refer to
– Install rear underbody trim.
5.20 Stabilizer Bar Mount

Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove bolts -1-. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove clamp -2- and rubber bushing -3-.
Installing
– Rubber bushing must rest on stabilizer bar collar -arrow-.
– Only hand-tighten bolts -1- for the time being.
– Tighten bolts -1- (25 Nm).
5.21 Stabilizer Bar Coupling Rod

Removing
– Remove wheel.


– Remove bolts -2-. Counter hold joint with the wrench.
– Remove connecting link.
Installing
Install in reverse order of removal.
⇒ “2.7 Stabilizer Bar Overview”, page 132
5.22 Front or Rear Diagonal Braces

Front and rear diagonal braces are only installed in the converti‐
ble.
Short diagonal braces are installed in the subframe at the start of
production.
In each case, the diagonal brace is connected once to the rear
outer subframe and to the underbody -arrows-.
With running changes, the front subframe is repositioned at the

start of production with the diagonal brace lengthwise.
In each case, the diagonal brace is connected once to the front
and center subframe and to the underbody -arrows-.
There are no subframes for the first version that are available as
replacement parts. Therefore, the diagonal braces must be repo‐
sitioned lengthwise when exchanging subframes for the following
version, refer to ⇒ page 181 . The allocation for the respective
replacement parts may be found in the Parts Catalog.
Note
If necessary, for a future repair for which the subframe must be

removed, the welded connection must be cut with workshop
equipment.

Removing
– Remove the front underbody trim before removing the front
diagonal braces. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Re‐
moval and Installation
– Remove rear underbody trim before removing rear diagonal
braces -1-. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Removal
and Installation
– If the same diagonal braces -1, 5 or 6- are to be reinstalled,

identify location of braces to body, for example with a felt-tip
pen.
• If the diagonal brace -1- on the threaded connection for the
underbody -2- is welded, the welded connection must be cut
with shop equipment.
– Put the vehicle on its wheels.
– Loosen bolts -2 and 4-.
– Raise the vehicle.
– Remove bolts -2 Protected
or 4-. by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove diagonal brace -1, 5 or 6-.
3 - Subframe
Installing
– Align diagonal brace -1, 5 or 6- according to threaded holes or
markings on body.
– Insert new bolts -2 or 4- but do not tighten yet.
– Tighten bolts -2 or 4-.
Tightening Specifications: 65 Nm
– Install the front or rear underbody trim. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 66 ; Removal and Installation .

Procedure for connecting the “long” diagonal brace to the under‐

body after replacing the subframe
– Attach the diagonal brace -1- to the subframe and the under‐
body.
– Tighten the bolts -2 and 3- by hand.
– Mark the area around the diagonal brace and in the oblong
hole -arrow-.
– Remove the bolts -2 and 3- then remove the diagonal brace

-1-.
– Sand the marked area -arrow- on the underbody until the metal
is bare to prepare it for welding.
– Attach the diagonal brace -1- to the subframe.

– Tighten the bolts -2 and 3- and press the diagonal brace -1-
into the welding position area on the underbody.
– Weld the diagonal bracepermitted
as shown
unless in the illustration
authorised in aAG
by AUDI AG. AUDI gas-does not guarantee or accept any liability
shielded arc continuous weld seam with the -VAS6045A- .


Seam Welding
• When executing the seam welding make sure that there is
enough of an inlet or outlet -A or B-.
♦ Outlet seam -A- = 15 mm
♦ Welding seam -B- = 10 mm
♦ Welding seam -C- = 10 mm
♦ Inlet seam -D- = 10 mm
♦ Inlet seam -E- = 10 mm
♦ Welding seam -F- = 65 mm
♦ Calculated seam thickness -Y- = 3 mm
♦ Seam thickness -Z- ≈ 4.5 mm
– Apply the corrosion protection.
• The corrosion protection applied at the start of production is
reapplied after being serviced with manufacturer materials.
– Loosen bolts -2 and 3-.

– Tighten the new bolts -2 and 3-.
Tightening Specifications: 65 Nm
5.23 Drive Axle

Removing

– Loosen collar bolt -arrow- only 90°, otherwise wheel bearing

will be damaged
WARNING

on wheels.
– Remove wheel.
– Install all 5 wheel bolts and tighten by hand.
– Engage parking brake.
– Remove collar bolt -arrow-.
– Remove coil spring. Refer to ⇒ “5.2 Coil
Protected Spring”,
by copyright. page
Copying 142or .commercial purposes, in part or in whole, is not
for private
– Remove bolts -2- and cover. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Raise trapezoidal control arm with hand until drive axle can be
taken forward out of flange shaft/transmission.
– Press exhaust pipe downward slightly -arrow A- and slide drive

axle inward -arrow B- until it can be removed from wheel hub.
– Press exhaust pipe down again slightly and guide drive axle
outward over cover plate.

– Remove drive axle downward -arrow A-.
Note
Make sure that cover plate -arrow B- and body are not damaged.
Installing
Note


– Insert drive axle from below and slide into wheel hub up to
stop.
– Align drive axle holes and flange shaft/transmission holes with

each other, install bolts -1- and tighten.
– Insert the cover, install the combi-bolts -2- and tighten, refer
to -item 12- ⇒ Item 12 (page 123) .
– Install new collar screw and tighten to specified torque without
turning any farther, refer to -item 4- ⇒ Item 4 (page 131) .
– Lower vehicle onto its wheels.
– Tighten the collar screw to the specified additional turn angle,
refer to -item 4- ⇒ Item 4 (page 131) .

6 Disassembly and Assembly

⇒ “6.1 Shock Absorber”, page 185
⇒ “6.2 Stub Axle Carrier, FWD”, page 186
⇒ “6.3 Wheel Bearing Housing, Steel, AWD”, page 188
⇒ “6.4 Drive Axle with Inner CV Joint, 100 mm”, page 190
⇒ “6.5 Drive Axle with Inner CV Joint, 108 mm”, page 195
6.1 Shock Absorber
1 - Nut
❑ 25 Nm
❑ Self-locking Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Always replace. with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Loosening and tighten‐
ing, refer to
⇒ page 186 .
2 - Shock Absorber Mounting
3 - Buffer Stop
4 - Protective Sleeve
5 - Shock Absorbers
ling, refer to
⇒ “5.3 Shock Absorber”,
page 143 .
❑ Note different vehicle
versions, see vehicle
data plate. Refer to
⇒ page 81 .
❑ Faulty shock absorbers
must be vented and
emptied before dispos‐
al. Refer to
⇒ “2.2 Rear Gas-Filled
Strut, Venting”, page 3 .
❑ Check removed shock
absorber, refer to
⇒ “4.3 Shock Absorb‐
ers, Removed, Check‐
ing”, page 7 .

♦ Shock Absorber Set - T10001-

Loosening and Tightening Bolted Connection for Shock Absorber

Mount
1 - Ratchet (commercially available)
2 - Socket - T10001/10-
3 - Ratchet - T10001/11-
4 - Socket - T10001/2-
6.2 Stub Axle Carrier, FWD
1 - Stub Axle Carrier

ling, refer to
❑ Front seal -arrow- must
not grind against wheel
bearing unit.
❑ Do not remove front
seal.
2 - Cover Plate
3 - Wheel Bearing Unit
❑ Does not need to be re‐
placed.
❑ If wheel bearing unit can
be removed from stub
axle carrier by hand,
wheel bearing unit is OK
and can be reinstalled.
❑ If it cannot be removed
by hand, wheel bearing
unit must be replaced.
plete unit.
4 - Collar Bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
tion, refer to
⇒ “2.5 Stub Axle Carrier
Overview, FWD”,
page 127 .
❑ Always replace.
5 - Bolt

tion, refer to ⇒ Brake

System; Rep. Gr. 46 ; Description and Operation .
6 - Rubber Bushing

♦ Punch - VW 411-
♦ Punch - VW 412-
♦ Sleeve - VW 415 A-
♦ Arbor - VW 434-
♦ Installation Arbor - VW 792-
Rubber Bushing, Removing
– Continuously press out rubber bushing.
Note
Securely hold stub axle carrier/wheel bearing housing when

pressing out.
Rubber Bushing, Installing

– Clean bearing seat in stub axle carrier/wheel bearing housing.
– Completely coat rubber bushing and stub axle carrier/wheel
bearing housing bearing set using installation lubricant G 294
421 A1 thinned with water at a ratio of 1:100.
– Position rubber bushing -A- so that wide collar faces down‐
ward -arrow-.
– Continuously press rubber bushing into stub axle carrier or

wheel bearing housing until rubber bushing collar rests on -
VW 792- and is pressed (noticeable increase of pressure).
Note
♦ If pressing process is interrupted, rubber expands and bushing

cannot be pressed in farther without damaging it.
♦ Securely hold stub axle carrier/wheel bearing housing when
pressing on.

– Press rubber bushing back again until -dimension a- = 10 ±

0.8 mm is reached.
6.3 Wheel Bearing Housing, Steel, AWD

ling, refer to
2 - Wheel Bearing
❑ Interior diameter in
tiered version.
❑ Installation position:
Larger internal diameter
of wheel bearing faces
wheel hub.
⇒ page 189 .
❑ Pressing in, refer to
⇒ page 189 .
3 - Cover Plate Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 - Wheel Hub with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Tiered version
⇒ page 189 .
❑ Pressing in, refer to
⇒ page 190 .
❑ Light construction wheel
hub, refer to
⇒ “1.2 Light Weight
Wheel Hub Characteris‐
tics”, page 118 .
5 - Bolt
tion, refer to ⇒ Brake
System; Rep. Gr. 46 ;
Description and Opera‐
tion .
6 - Rubber Bushing


♦ Punch - VW 412-
♦ Tube 60 mm Dia. - VW 415 A-
♦ Thrust Pad - 3005-
♦ Press Tool - 3345-
♦ Press Tube - 30-100-
Wheel Hub, Removing
Note
Wheel bearing housing must rest on machined screw hole sur‐

face.
Pressing Wheel Bearing Out of Wheel Bearing Housing
Note
Wheel bearing housing must rest on machined screw hole sur‐

face.
Pressing Wheel Bearing in Wheel Bearing Housing

– Wheel bearing in tiered version
Note
Large internal diameter of wheel bearing faces wheel hub
– Press wheel bearing -A- onto stop.

Pressing Wheel Hub into Wheel Bearing

– Install wheel hub -B- and press on over wheel bearing inner
race to stop.
Note
-VW 415 A- must press onto center of bearing inner race.
Grease filling of CV joints, allocation, refer to the Electronic Parts
Catalog.
tity
[mm] [g] [g] [g]
88 90 40 50
paths
100 80
Grease joint when replacing CV boot.

1 - Cover
❑ Carefully drive off using
a drift. Refer to
⇒ page 194 .
❑ Always replace.
❑ Coat sealing surface
with D 454 300 A2 be‐
fore installing on CV
joint. Refer to
⇒ page 195 .
❑ Align cover to bolt holes.
2 - Locking Ring
❑ Remove and install us‐
ing commercially availa‐
ble locking ring pliers.
❑ Always replace.
3 - Inner Constant Velocity
Joint
mm
plete unit.
❑ Pressing off, refer to
⇒ page 194 .
❑ Pressing on, refer
Protected by copyright. to for private or commercial purposes, in part or in whole, is not
Copying
⇒permitted
page unless
194 .authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 190 .
splines on the axle shaft
must be lightly coated
with grease used in
joint.
4 - Backing Plate
5 - Bolt
M8 bolt: 40 Nm

M10 bolt: 65 Nm
6 - Protective Boot for Inner CV Joint with Cap
❑ With ventilation bore.
❑ Carefully drive off cap with drift.
❑ Always replace.
❑ In case of damage, check inner CV joint. Refer to ⇒ “4.2 Inner CV Joint, Checking”, page 139 .
❑ Coat sealing surface with D 454 300 A2 before installing on CV joint. Refer to ⇒ page 195 .
❑ Protective boot/drive axle sealing surfaces must be free of grease at installation.
7 - Drive Axle
⇒ “4.1 Outer Constant Velocity Joint, Checking”, page 138 .
❑ Protective
with respect boot/drive
to the correctness axle/joint
of information in this sealing surfaces
document. Copyright must
by AUDI AG.be free of grease at installation.
9 - Clamp
❑ Always replace
10 - Securing Ring
❑ Always replace.
❑ Exterior diameter: 88 mm
❑ Driving off, refer to ⇒ page 193 .
❑ When installing the joint on the axle shaft, the splines on the axle shaft must be lightly coated with grease
used in joint.
12 - Collar Bolt
❑ Always replace.
❑ Torque specification, refer to ⇒ “2.6 Wheel Bearing Housing Overview, Steel, AWD”, page 129 .

♦ Press Block - 40-204 A-
♦ Punch - VW 411-

Pressing Off Outer CV Joint

– Secure the drive axle with protective covers in the vise.
– Loosen clamp and turn back protective boot.
– Drive CV joint from drive axle using a drift -A-.
Drift must be placed precisely on star of CV joint.
Driving Joint On
– Before installing joint piece, splines -A- must be lightly coated
with grease used in joint.
– Insert sealing ring in groove on shaft.
– Slide on CV joint up to sealing ring.

– Align sealing ring at center with opening upward
-see arrows-.
– Drive onto shaft with plastic hammer until securing ring en‐
gages.
Tighten Clamp

Drive Off Cover for Inner Joint
Pressing Off Inner Constant Velocity Joint

– Rebound circlip
– Drive off protective boot with drift.
Note
Support ball hub with -VW 402- .
Pressing On Inner CVwith

Joint


Use -VW 522-
– Install lock ring.
Note

axle.

Coat Cover or Cap Sealing Surface with D 454 300 A2

– Apply sealant (hatched surface) to clean cover or cap surface.
Sealant bead: apply 2 to 3 mm diameter in area of inner holes
-arrow-.
– Align cover and cap to bolt holes and drive or press onto joint.

Grease filling of CV joints, allocation, refer to the Electronic Parts
Catalog.
Grease quan‐ of total:
tity
[mm] [g] [g] [g]
88 90 40 50
paths
108 120
Grease joint when replacing CV boot. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

1 - Cover
❑ Carefully drive off using
a drift. Refer to
⇒ page 194 .
❑ Always replace.
❑ Coat sealing surface
with D 454 300 A2 be‐
fore installing on CV
joint. Refer to
⇒ page 195 .
2 - Locking Ring
❑ Remove and install with
commercially available
locking ring pliers.
❑ Always replace.
3 - Inner CV Joint with Protec‐
tive Boot Cap
mm
plete unit.
❑ Pressing off, refer to
⇒ page 198 .
❑ Pressing on, refer to
⇒ page 198 .
❑ Greasing, refer
Protected to
⇒ pagepermitted
195 . unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
splines on the axle shaft
must be lightly coated
with grease used in
joint.
4 - Backing Plate
5 - Bolt
M8 bolt: 40 Nm

M10 bolt: 65 Nm
6 - Clamp
❑ Always replace.
7 - Protective Boot for Inner Constant Velocity Joint
❑ With ventilation bore.
❑ In case of damage, check inner CV joint. Refer to ⇒ “4.2 Inner CV Joint, Checking”, page 139 .
❑ Protective boot/drive axle/cap sealing surfaces must be free of grease at installation.
8 - Drive Axle
❑ Exterior diameter: 88 mm
⇒ “4.1 Outer Constant Velocity Joint, Checking”, page 138 .
❑ Protective boot/drive axle/joint sealing surfaces must be free of grease at installation.
10 - Clamp
❑ Always replace
11 - Securing Ring
❑ Always replace.
❑ Driving off, refer to ⇒ page 193 .
❑ When installing the joint on the axle shaft, the splines on the axle shaft must be lightly coated with grease
used in joint.
13 - Collar Bolt
❑ Always replace
❑ Torque specification, refer to ⇒ “2.6 Wheel Bearing Housing Overview, Steel, AWD”, page 129 .

♦ Punch - VW 409-
♦ Thrust Disc - VW 412-unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted

Pressing Off Inner Constant Velocity Joint

– Rebound circlip
– Drive off protective boot with drift.
Note
Cap -A- must not be supported on -VW 401- . Use -T10065/4- as

spacers.
Pressing on Inner CV Joint


– Install lock ring.
Note

axle.

7 Special Tools

equipment required
♦ Tube 37 mm Dia. -
VW 416 B-
♦ Punch - VW 407-

♦ Grease Cap Puller -

VW 637/2-
♦ Fitting Sleeve - 3241/4-
40-200Nm - VAG1332-
♦ Torque Wrench -
VAG1410-
♦ Socket - T40027-

♦ Engine and Gearbox Jack -

VAS6931-
♦ Engine/Gearbox Jack
Adapter - Wheel Hub Sup‐
port - T10149-


♦ Foot Pump W/High Pressure Hose - VAG1389 A/1-
♦ Wheel Bearing Tool - VAG1459B-
♦ Supplementary Set - VAG1459 B/2-
♦ Puller - 15-17-

♦ Removal and Assembly Tool - T40032-
♦ Shock Absorber Set - T10001-

♦ Not illustrated: with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Press Tube - 30-100-

♦ Mounting Universal Joint - 41 - 501-
♦ Press Tube - 2040-
♦ Thrust Pad - 3005-
♦ Press Tool - 3345-
♦ Hollow Piston Cylinder HKZ-15 with Hydraulic Thrust Piece -
E-0-204-T-
♦ Tie Bolt - E-0-217+218-
♦ Special Nut - E-8-214-
♦ Bell - E-40-
♦ Thrust Sleeve - E-44-1-
♦ Assembly tool - T10065/4-
♦ Assembly tool - T40089/1-
♦ Gas-Shielded Welder 250A - VAS6045A-
♦ Punch - VW 409-
♦ Punch - VW 411-
♦ Tube 60 mm Dia. - VW 415 A-

♦ Installation Arbor - VW 792-

43 – Self-Leveling Suspension
⇒ “1.1 Dynamic Ride Control”, page 206
1.1 Dynamic Ride Control

Only approved oil for filling and draining must be used. Refer to
the Parts Catalog.
Filling must only be performed at ambient temperature of approx‐
imately 20 °C (68 °F).
As a replacement part, shock absorbers and lines are delivered
empty.
Lines/dampers and central valves may only be suctioned, evac‐
uated and filled when they are installed and connected.
When the DRC system is disconnected from the individual com‐
ponents (for example, the connection between the line/damper/
central valve), the vehicle must not be standing on its wheels.
While filling the DRC system, the gas reservoir to the pressure
clamps is checked for leaks on the piston on the inside of the
central valve.
If, while filling of the DRC system, a pressure of 22 bar cannot be
reached or continually drops, then check all connections for dam‐
age andunless
permitted leakage. If bynoAUDI
authorised issues areAGfound
AG. AUDI does noton the outside,
guarantee the
or accept any gas
liability
reservoir totothe
with respect pressure
the correctness clamps on
of information the
in this pistonCopyright
document. on thebyinside
AUDI AG.of the
central valve is leaking. Replace the central valve.
To attach or detach DRC syst. pressure tester, Audi RS4 - V.A.S
6209/2- , system line to be checked must be locked at central
valve to limit the quantity of oil leaked to a minimum and to prevent
pressurized central valve from emptying.
Small oil leak with locked central valve which results from con‐
necting or disconnected -V.A.S 6209/2- at connection is not crit‐
ical. Avoid repeating measurements because a small quantity of
oil is removed from the system every time the -V.A.S 6209/2- is
connected. Every connection results in a pressure decrease of
approximately 0.3 bar from the previous reading. Multiple repea‐
ted measurements decrease system pressure below minimum
pressure or failure, which then requires a replacement of central
valve of respective DRC line.
If the DRC system is being extracted, evacuated or filled, then this
must be performed on the front and rear extraction/filling valves
for each damper line. Observe the following when doing so:
WARNING
Always wear safety goggles!
Before removing or disconnecting any DRC components, extract

the affected line completely.
Shock absorbers must only be filled when installed.
Vehicle must never be placed on wheels with closed, filled system
and locked central valves. This inevitably leads to leaks and sys‐
tem malfunction.
Lines must not be bent.
206 Rep. Gr.43 - Self-Leveling Suspension


⇒ “2.1 Dynamic Ride Control Component Locations”, page 207
⇒ “2.2 Central Valve and Bolted Connections to Suspension
Struts”, page 208
⇒ “2.3 Dynamic Ride Control, Emptying and Filling”, page 209
2.1 Dynamic Ride Control Component Locations

Dynamic Ride Control (DRC II).
Illustration applies to sedan and avant.
1 - Right Front Suspension

Strut
❑ Refer to ⇒ page 209 .
2 - Right Front Extraction/Fill‐
ing Valve
3 - DRC Line to Front Right
Suspension Strut
4 - Right Rear Extraction/Fill‐
ing Valve
5 - Right Rear Shock Absorber
6 - DRC Line to Right Rear
Shock Absorber
7 - Left Front and Right Rear
Central Valve
❑ Central valve is installed
in direction of travel at
right. Refer to
⇒ “2.2 Central Valve and
Bolted Connections to
Suspension Struts”,
page 208 .
8 - Right Front and Left Rear
Central Valve
left. Refer to
⇒ “2.2
Protected by copyright. Central
Copying Valve
for private and purposes, in part or in whole, is not
or commercial
Bolted byConnections
permitted unless authorised AUDI AG. AUDI AG todoes not guarantee or accept any liability
Suspension Struts”,
page 208 .
9 - DRC Line to Left Rear
Shock Absorber
10 - Left Rear Extraction/Filling Valve
11 - Left Rear Shock Absorber
12 - DRC Line to Left Front Suspension Strut
13 - Left Front Extraction/Filling Valve
14 - Left Front Suspension Strut

2.2 Central Valve and Bolted Connections to Suspension Struts
1 - Front Right and Rear Left

Central Valve
left.
2 - Nut
❑ 23 Nm
3 - Left Rear Wiring Harness Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Shut-off Valve
4 - Right Front Wiring Harness

Shut-off Valve
5 - Nut
❑ 23 Nm
6 - Left Front Wiring Harness
Shut-off Valve
7 - Right Rear Wiring Harness
Shut-off Valve
8 - Left Front and Right Rear
Central Valve
right.
9 - DRC Line to Right Rear
Shock Absorber
❑ 19 Nm
10 - DRC Line to Left Front
Suspension Strut
❑ 19 Nm
11 - DRC Line to Right Front
Suspension Strut
❑ 19 Nm
12 - DRC Line to Left Rear Shock Absorber
❑ 19 Nm
13 - Shut-off Screw
❑ To shut off, turn clockwise to stop.
❑ To open, turn counter-clockwise to stop.
14 - Nut
❑ 12 Nm

Front Suspension Strut
Note
When fastening item -2-, make sure lug is seated properly in

bracket.
-1- Tightening specification: 19 Nm

Rear Shock Absorber
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ When fastening item -2-, make sure lug is seated properly in
bracket.
♦ When tighten, item -2- must be counter held at connection
block -3-.

2.3 Dynamic Ride Control, Emptying and

Filling
Note
Extracting, evacuating and filling the whole DRC line (lines/damp‐

er and central valve) is performed with the -VAS6544- . Depend‐
ing on the DRC system equipment in the dealership, the
equipment may need to modified or updated to match -
VAS6544- . The following choices are possible:

♦ DRC System Filling Device Supplemental Set - VAS6209/4-
♦ The -VAS6209/4- serves as an upgrade to the filling device for
DRC system - VAS6209- already found in dealerships.
♦ Retrofit kit, DRC system - VAS6209/5-
♦ The -VAS6209/5- is needed if the dealership has the pressure
pump - VAS6209/3- and wants to upgrade the -VAS6544- .
The supplement set, DRC system - VAS6209/6- is also nec‐
essary.
♦ Supplement set, DRC system - VAS6209/6-
♦ The -VAS6209/6- is needed up upgrade the already available
pressure pump - VAS6209/3- in the -VAS6544- . The require‐
ment is that the dealership already have the -VAS6209- . If the
dealership does have the filling device for DRC system -
VAS6209- , then the -VAS6209/5- must be obtained.
♦ Filling Device for DRC System - VAS6544-

Note
Updating the equipment for the DRC system must be done one
time only. It is not necessary to convert back again. The proce‐
dure for draining and filling the complete DRC system is described
using the -V.A.S 6544- .
Only approved oil for filling and draining must be used. Refer to
the Parts Catalog.
As a replacement part, shock absorbers and lines are delivered
empty.
Filling must only be performed at ambient temperature of approx‐
imately 20 °C (68 °F).
Lines/dampers and central valves may only be suctioned, evac‐
uated and filled when they are installed and connected.
Note
The shut-off valve for the wiring harness at the central valve must
remain open when extracting, evacuating and filling the DRC sys‐
tem (lines/damper and central valve).
While filling the DRC system, the gas reservoir to the pressure
clamps is automatically checked for leaks at the piston in the cen‐
tral valve.
WARNING

Valves of filling device are open when ratchet levers
with respect are
to the parallel
correctness of information in this document. Copyright by AUDI AG.
to direction of flow.
Lines must not be bent.
Required Equipment

1 - Front Shock Absorber

Adapter
❑ Not for this model.
2 - Rear Shock Absorber
Adapter
❑ Not for this model.
3 - Fill Lines with Quick-Re‐
lease Fastener
4 - Venturi Injector with Ex‐
haust Hose
❑ From the -VAS6209- .
5 - Connecting Hose
❑ From the -VAS6209- .
6 - Charging Device for DRC
System - VAS6544-
7 - Container for Used Oil
❑ Empty before starting
the work.
❑ Identification: Red dot.
Note
♦ Before filling the DRC system, make sure the oil reservoir for
the -VAS6544- and the line between the pressure pump and
oil reservoir are filled with oil.
♦ The old oil reservoir from the -VAS6544- must be empty.

Drain the Old Oil Reservoir.

– Remove the cap -arrow- from the old oil reservoir -1- and drain
the old oil.
– Install the cap -arrow- on the old oil reservoir -1-.
Fill and Bleed the -VAS6544- .

– Fill the oil reservoir -2- with new oil up to the marking and po‐
sition the O-ring to the height of the oil level. Refer to the Parts
Catalog.
– Close the shut-off valve -A and C- on the -VAS6544- .

– Close the needle valve -B-.

– Connect the hose -2- to the old oil reservoir -arrow- and to the
quick-release fastener -4- on the -VAS6544- .
– Connect the Venturi injector -3- and vent hose to the old oil
reservoir -arrow- as illustrated.
– Connect the compressed air to the Venturi injector -3-.
– Open the locking valve -C-.

– Open the locking valve -A- briefly, for approximately 1-2 sec‐
onds, until the connecting line -1- between the oil reservoir
-2- and pressure pump is filled and does not contain bubbles.
– Close the locking valve -C-. Remove the compressed air con‐
nector form the Venturi injector.
Extracting and Filling
WARNING
– Turn the front wheel on the side to be suctioned toward the

outside.
– Remove the dust cap from the front suction/fill valve.
– Connect the fill line and quick-release fastening -1- from the -
VAS6544- -item 3- ⇒ Item 3 (page 211) to the front suction/fill
valve on the line to be suctioned.
– Remove the rear wheel on the side of the line to be suctioned.
– Free up the wheel housing liner for the rear suction/fill valve.
– Remove the dust cap from the rear suction/fill valve.
– Connect the fill line and quick-release fastening -1- from the -
VAS6544- -item 3- ⇒ Item 3 (page 211) to the rear suction/fill
valve on the line to be suctioned.

– Connect the fill lines -item 3- ⇒ Item 3 (page 211) to the con‐
nections -A and B- on the -VAS6544- .
Shut-off valve -A and C- on the -VAS6544- closed.

Needle valve -B- closed.
Hose connected -2- to the old oil reservoir -arrow- and to the -
VAS6544- -4-.

Venturi injector -3- connected to the old oil reservoir vent hose
-arrow- on the -VAS6544- .
Compressed air to the Venturi injector -3- connected.
– Open the valve -C- until the last of the oil is extracted from the
DRC system. (Visible on the return hose -2- to the used oil
reservoir).
– When the pressure manometer shows approximately negative
0.9 bar, close the valve -C- and disconnect the compressed
air hose from the Venturi injectors.
• Check for leaks.
Note
Vacuum must be stable for at least 2 minutes at negative 0.9 bar.
– Check the oil level on the oil reservoir, fill with new oil up to the
marking if necessary and position the O-ring to the height of
the oil level. Refer to Parts Catalog.
– Open the needle valve -B- approximately 2 turns and let the
oil run out of the oil reservoir on the -VAS6544- into the evac‐
uated DRC system.
Oil flows from the reservoir into the connected DRC system. This
is shown by the decreasing oil level in the oil reservoir. Depending
on the amount of oil remaining after extraction, the procedure may
take several minutes. As the system fills up, the oil level goes
down slower. If the level of the oil no longer moves, the first step
of the filling process is complete.
– Close the needle valve -B-.

– Open the valve -A- and fill the DRC system to 22 bar by pump‐
ing the lever on the hand pump -1- several times.
Note
While filling, make sure the oil reservoir on the -VAS6544- does
not run dry; fill with reservoir with new oil if necessary.
• When a pressure of 22 bar is reached, close the valve -A- and

do not pump the hand pump lever any more.
Note
If the pressure does not reach 22 bar or if it continually drops,

check all connections for damage or leaks. If no issues are found
on the outside, the gas reservoir to the pressure clamps on the
piston on the inside of the central valve is leaking. Replace the
central valve.
– Open the needle valve -B- slightly and let the pressure drop to
16 bar.
• Close the valve -B- when the indicator on the pressure man‐
ometer reaches the 16 bar marking.
DRC system is filled.

– Disconnect the fill line and quick-release fastener on the -

VAS6544- -item 3- ⇒ Item 3 (page 211) from the rear and front
suction/fill valve.
– Install the dust cap on the rear and front suction/fill valve.
– Mount the rear wheel.

3 Specifications

Central Valve Nut - 12
Central Valve Mounting Nut - 23
DRC Line to Suspension Strut/Shock Absorber - 19


⇒ “4.1 Dynamic Ride Control, Fault Finding”, page 219
⇒ “4.2 Dynamic Ride Control, Checking System Pressure”, page
220
4.1 Dynamic Ride Control, Fault Finding

Start
Rattle coming Strong side
from area of inclination of
suspension or body while
rear of vehicle turning
while driving steering
on rough ter‐ wheel.
rain
→ Oil leakage detected? ←
↓ ↓
♦ Check ← Yes No → Check all
compo‐ connections
nents. to central
valves,
♦ Check shock ab‐
connec‐ sorbers and
tions to wiring har‐
central nesses.
valves,
shock ab‐
sorbers
and wiring
harnesses.
♦ Replace
leaking
shock ab‐
sorbers.
↓ ↓
↓ Complaint eliminated?
↓ ↓ ↓
↓ No ↓ Yes ↓
↓ Check ↓
system
pressure
in both
lines.
(Central
valve
must be
locked
when con‐
necting
and dis‐
connect‐
ing charg‐
permitted unless authorised by AUDI AG. AUDI ingAG de‐does not guarantee or accept any liability
vice.)
↓ ↓ ↓
↓ System pressure larg‐ ↓
er than 12.0 bar?
↓ No ↓ Yes ↓ ↓

Extract, evacuate and fill the com‐ ↓ ↓

plete DRC line with -VAS6544- ,
check for leaks. Refer to
⇒ “2.3 Dynamic Ride Control, Emp‐
tying and Filling”, page 209 .
↓ ↓ ↓
↓ ↓
↓
End
4.2 Dynamic Ride Control, Checking Sys‐

tem Pressure
♦ DRC Syst. Pressure Tester, Audi RS4 - V.A.S 6209/2-
♦ Hand Vacuum Pump - VAS6213-
Bleed -V.A.S 6209/2-
Use only approved oil for the bleeding procedure. Refer to the
Parts Catalog.
Note
♦ The Charging Device - V.A.S 6209/2- must always be bled the

first time it is used.
♦ If the Charging Device - V.A.S 6209/2- still shows a residual
pressure greater than 0.5 bar (for example, from a previous
reading), bleeding must not be done.
– To bleed pressure gauge -B- and line section -A-, install spe‐
cial tool as shown in illustration.
Note
Illustration shows bleeding process by extracting hydraulic oil with

-VAS6213-
– Bleed process must be performed until air bubbles are no lon‐

ger visible in hose -C-.
– Disconnect hose -C and D- and perform system pressure
check.
System pressure check is performed on front shock absorber of
corresponding DRC line.
To attach or detach -V.A.S 6209/2- , system line to be checked

must be locked at central valve to limit the quantity of oil leaked

to a minimum and to prevent pressurized central valve from emp‐
tying.
– Remove wheel.

– Remove the plastic cover -1-.
– Loosen lock nut -1- on line to be checked, screw in shut-off

screw -2- until it is hand tight and lock nut -1- again.
– Remove dust cap and connect -V.A.S 6209/2- .
– Loosen lock nut -1- on line to be checked, unscrew shut-off

screw -2- until it is hand tight and lock nut -1- again.

– Read system pressure at -V.A.S 6209/2- .
Note
Pressure increase at -V.A.S 6209/2- occurs slowly and takes ap‐

proximately 2 minutes. DRC system pressure can only be read
when -V.A.S 6209/2- needle has finally come to a stop.
– Disconnect -V.A.S 6209/2- and install dust cap.
Note
Small oil leak which results from connecting or disconnected -

V.A.S 6209/2- at connection is not critical. Avoid repeating meas‐
urements because a small quantity of oil is removed from the
system every time the -V.A.S 6209/2- is connected. Every con‐
nection results in a pressure decrease of approximately 0.3 bar
from the previous reading. Multiple repeated measurements de‐
crease system pressure below minimum pressure or failure,
which then requires a replacement of central valve of respective
DRC line.
– If the pressure is not OK, determine the cause and service the
system.
– Install the plastic cover -1-.

DRC System Pressure Values
Pressure values refer to reference temperature of 20 °C (68 °F).
♦ 16 bar = maximum pressure. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ 15 bar – 16 bar = central valve new or as good as new.
♦ 12 - 15 bar = normal range of operation, system OK.

♦ < 12 bar = system leaking or not filled completely, air entering
system, central valve has no pressure/is empty.


⇒ “5.1 Central Valve”, page 223
5.1 Central Valve

Removing
– Remove the plastic cover -1-.
WARNING
Note
The DRC lines must be extracted before disconnecting them from

the central valve. Refer to
Note
Perform this step on both wiring harnesses on the central valve.
– Remove the union nuts -9 and 10- or -11- and -12-, depending
on the central valve.
– Remove the nuts -2 or 5-, depending on the central valve.

Installing
– Installation is performed in the reverse order of removal. Ob‐
serve the following when doing so:
⇒ “2.2 Central Valve and Bolted Connections to Suspension
Struts”, page 208 .
– Insert the central valve.
– Install the nuts.
– Install the DRC line connections for the appropriate lines on
the central valve.
Note
The new central valve is filled and the shut-off valves are closed.
Only when a new central valve is installed: Open the shut-off

screws (-item 6- ⇒ Item 6 (page 208) and -item 7-
⇒ Item 7 (page 208) or -item 3- ⇒ Item 3 (page 208) and
-item 4- ⇒ Item 4 (page 208) ) on the new central valve and secure
them with a lock nut.

– Fill the DRC system. Refer to

⇒ “2.3 Dynamic Ride Control, Emptying and Filling”,
page 209 .

6 Special Tools
♦ DRC Syst. Pressure Tester, Audi RS4 - V.A.S 6209/2-
♦ Pressure Pump - VAS6209/3-
♦ DRC System Filling Device Supplemental Set - VAS6209/4-
♦ Retrofit Kit, DRC System - VAS6209/5-
♦ Supplement Set, DRC System - VAS6209/6-

♦ Not illustrated:
♦ Hand Vacuum Pump - VAS6213-
♦

44 – Wheels, Tires, Wheel Alignment

⇒ “1.1 Wheels and Tires”, page 228
⇒ “1.2 Tire Pressure Monitoring System”, page 228
⇒ “1.3 Tire Pressure Monitoring System Usage”, page 228
⇒ “1.4 Wheel
Protected Alignment”,
by copyright. Copying for page
private or230
commercial purposes, in part or in whole, is not
1.1 with respect toWheels and Tires
You can find this information in ⇒ Wheel and Tire Guide; Rep.
Gr. 44 ; General Information .
1.2 Tire Pressure Monitoring System

Observe notes about usage in your owner's manual.
Damaged wheel electronics or valves should be replaced for
safety reasons.
Do not clean wheel electronics with steam blasting or strong com‐
pressed air.
Replace wheel electronics after using tire sealant as the accu‐
mulation of sealant on the pressure sensor can cause false
readings.
The tire pressure monitoring system monitors the pressure of the
4 tires while driving.
If wheel positions on vehicle are changed or wheels or wheel
sensors replaced, this must be confirmed using the steering col‐
umn or the control unit in the center console. Finally, the system
has to relearn the wheel sensors.
Note
When changing wheels with wheel electronics (summer/winter

tires), pressure must be checked and control module must relearn
wheel electronics.
A fault may be saved in the Diagnostic Trouble Code (DTC) mem‐

ory if:
Less than three wheels with wheel electronics are installed.
Winter tires without wheel electronics are installed. (If this is the
case, the yellow warning lamp in instrument cluster is set and
cannot be deactivated by the system.)
1.3 Tire Pressure Monitoring System Usage

Function:
Tire pressure monitoring system is controlled via the steering col‐
umn or the control unit in the center console.
The system monitors the tire pressure you have set and entered
for monitoring.
– You must first check, correct and save the tire pressures.
– Then check and correct the tire pressure for the tires on the
vehicle (including spare tire) according to the specifications on
the sticker on the fuel filler flap.
228 Rep. Gr.44 - Wheels, Tires, Wheel Alignment

Save tire change or tire pressure via right steering column from
steering wheel.
The correct saving of the specified values in the basic require‐
ment for dependable tire pressure monitoring. After this, system
will automatically perform teach-in process.
Proceed as follows:
– Turn ignition on.
– Press rest button on steering column.
– Using rocker switch, select set function in instrument cluster
and acknowledge this with reset button.
– Using rocker switch, select tire pressure function in instrument
cluster and acknowledge this with reset button.
– Using rocker switch, select save pressures or tire change
function in instrument cluster and acknowledge with reset but‐
ton.
Saving of tire pressures must be started after every change de‐
sired to the specified values and after every tire change.
Save tire change or tire pressures via control unit in center con‐
sole.
The correct saving of the specified values in the basic require‐
ment for dependable tire pressure monitoring. After this, system
will automatically perform teach-in process.
– Turn ignition on.
– Press Menu button in center console.
– Using rotary switch, select Systems in CAR menu and ac‐
knowledge by pressing rotary switch.
– Using rotary switch, select Set in CAR menu and acknowledge
by pressing rotary switch.
– Using rotary switch, select Tire pressure in CAR menu and
acknowledge by pressing rotary switch.
– Using rotary switch, select Save pressures or Tire change in
CAR menu and acknowledge by pressing rotary switch.
Saving of tire pressures must be started after every change de‐
sired to the specified values and after every tire change.
Recode Tire Pressure Monitoring Control Module - J502- .
If tire pressure monitoring control module is replaced, new control
module must be coded. To do this, proceed as follows.
– Connect the vehicle diagnosis, testing, and information sys‐
tem - VAS5051A- and select the function test using Functions/
Component selection.
Then
– Chassis
– Tire Pressure Monitoring System
– 01- On Board Diagnostic (OBD) capable systems
– J502 - Tire Pressure Monitoring Control Module
– Tire Pressure Monitoring functions
– J502 - Code control module with respect to the correctness of information in this document. Copyright by AUDI AG.

1.4 Wheel Alignment

Wheel alignment must only performed using VW/Audi-approved
wheel alignment equipment!
Each time wheels are aligned, both front and rear wheels must
be aligned.
Otherwise, proper vehicle drivability cannot be ensured.
Note
♦ Wheels should not be aligned until the vehicle has been driven
1,000 to 2,000 km, since it takes this long for the coil springs
to settle.
♦ The individual specifications should be followed as exactly as
possible when making adjustments.


⇒ “2.1 Tire Pressure Monitoring System Component Overview”,
page 231
⇒ “2.2 Wheel Electronics Overview”, page 232
⇒ “2.3 Wheel Alignment Test Prerequisites”, page 232
⇒ “2.4 Measurement Preparations”, page 234
⇒ “2.5 Adapters, Allocating to Suspension for Alignment”,
page 234
⇒ “2.6 Initial Position for Alignment”, page 235
⇒ “2.7 Raising the Vehicle with Suspension 1BA, 1BB, 1BR, 1BE,
1BV, 1BD, 2MC, 2ME”, page 237
2.1 Tire Pressure Monitoring System Component Overview
1 - Left Front Tire Pressure

Monitoring Sensor - G222- ,
Right Front -G223- , Left Rear
-G224- and Right Rear -G225-
❑ Spare Tire Pressure
Monitoring Sensor -
G226-
ling, refer to
⇒ “5.2 Metal Valve
Body”, page 248 .
2 - Rear Tire Pressure Moni‐
toring Antenna - R96-
ling, refer to
⇒ “5.4 Rear Tire Pres‐
sure Monitoring Anten‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
na R96 ”, page 249 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
3 - Tire Pressure Monitoring
Control Module - J502-
❑ If tire pressure monitor‐
ing control module is re‐
placed, system must be
recoded.
4 - Display in Instrument Clus‐
ter
❑ Diagnose using vehicle
diagnostic, test and in‐
formation system -
VAS5051A- .

2.2 Wheel Electronics Overview
1 - Metal Valve Body

❑ Only install valve ac‐
cording to the Parts Cat‐
alog.
❑ Delivered complete.
❑ Replace valve insert
with every tire change.
ling, refer to
⇒ “5.2 Metal Valve
Body”, page 248 .
2 - Valve Core
3 - Seal
ling, refer to Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “5.2 Metal Valve permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Body”, page 248 . with respect to the correctness of information in this document. Copyright by AUDI AG.
4 - Rim
❑ Tires, mounting and dis‐
mounting, refer to
⇒ “5.1 Tires, Changing”,
page 247 .
5 - Wheel Electronics
❑ Must be completely re‐
placed.
❑ Battery life approxi‐
mately 7 years.
❑ Remaining battery life,
temperature and pres‐
sure can be read via di‐
agnosis with the vehicle
diagnostic, measuring
and information system
- VAS5051A- .
6 - Microencapsulated Bolt
❑ Torx® T20
❑ Tightening specification: 4 Nm
❑ Bolts must be replaced.
❑ Can only be obtained as a replacement part with wheel electronics.
7 - Union Nut
❑ Tightening specification: 4 Nm
❑ Removing and installing, refer to ⇒ “5.2 Metal Valve Body”, page 248 .
8 - Beveled Washer
2.3 Wheel Alignment Test Prerequisites

Clarification of Production Control Numbers (PR No.):
Suspension version installed in vehicle is indicated by the corre‐
sponding PR. No. on the vehicle data plate -arrow-.

Sample Vehicle Data Label

In this example the vehicle is equipped with the standard sus‐
pension -arrow-.
The vehicle data sticker is located at rear of spare wheel well and
in Maintenance booklet.
1BA = Standard suspension
1BB = heavy duty suspension, China
1BE = sport suspension (20 mm lower than 1BA)
1BD = Sport suspension S4
1BR = comfort heavy duty suspension (13 mm higher than 1BA)
1BV = sport suspension (quattro GmbH)
2MC = basic suspension (quattro GmbH RS 4)
2ME = sport suspension (quattro GmbH RS 4)
• The measurement sensor must be properly adjusted and at‐
tached to the vehicle; observe device manufacturer's operat‐
ing instructions.
• Tread depth difference may be no more than 2 mm on an axle.
• Tires inflated to prescribed pressure
• Make sure that the sliding plates and turn tables are not touch‐
ing the end stop when checking the wheel alignment.
• Vehicle curb weight. Refer to 1).
1) Vehicle curb weight position means: The weight of the vehicle ready for the
road (completely filled fuel tank and windshield washer fluid reservoir, spare tire,
vehicle tool kit, vehicle jack) and with no driver.
Spare wheel, vehicle tools and vehicle jack must be located in the
position specified by the vehicle manufacturer.
• Vehicle accurately aligned, suspension bounced and rocked
several times.
• Check suspension, steering and steering linkage for excessive
play and damage, repair if necessary.
• Perform wheel run-out compensation: Permissible axial run-
out of the wheel rims can exceed the specified toe setting
tolerance. If compensation for wheel run-out is not performed,
it will not be possible to obtain a correct toe-in adjustment.
Wheel alignment is necessary when:
♦ Vehicle shows handling problems.
♦ Involved in an accident.
♦ Axle components were removed.
♦ Tire wear patterns are uneven.
Front Suspension Wheel
with respect Alignment
to the correctness ofToe Constant
information S
in this document. Rear Suspension
Copyright by AUDI AG. Wheel Alignment
Components Check Required Adjusting Neces‐ Components Check Required
sary
Yes No Yes No Yes No
Upper rear control X X Shock Absorbers X
arm
Upper front control X X
arm
Lower guide control X X Coil spring X
arm

Front Suspension Wheel Alignment Toe Constant S Rear Suspension Wheel Alignment
Components Check Required Adjusting Neces‐ Components Check Required
sary
Yes No Yes No Yes No
Suspension Strut X X
Lower track control X X Transverse Link X
arm
Mounting bracket X X Tie Rod X
Wheel Bearing Hous‐ X X Stub axle carrier/ X
ing wheel bearing hous‐
ing
Tie Rod X X Trapezoidal Control X
Arm
Steering Gear X X Subframe X
Subframe X X
Stabilizer Bar X X Stabilizer Bar X
2.4 Measurement Preparations

♦ Brake Pedal Actuator - VAG1869/2-
Rim Run-Out Compensation
Note
♦ The lateral run-out of the wheel must be compensated for.

Otherwise, measurement will result in false readings.
♦ A correct toe-in adjustment will not be possible without per‐
forming lateral run-out compensation!
– Carry out wheel run-out compensation. For this, observe notes

by manufacturer of wheel alignment equipment.
– Insert -VAG1869/2- .
2.5 Adapters, Allocating to Suspension for

Alignment
♦ Spacer - VAG1925-
♦ Adapters (Two in Set) - VAG1925/3-
♦ Adapter - VAG1925/4-
♦ Adapter for VAG 1925 - VAG1925/6-
♦ Vehicle diagnosis, testing and information system -
VAS5051A-

Adapter Standard Sport Sus‐ Sport Suspension Comfort Heavy Duty

Suspen‐ pension Quattro GmbH (1BV), Suspension (1BA),
sion (1BE, Basic Suspension Heavy Duty Suspen‐
(1BA) 1BD), Quattro GmbH RS 4 sion, China (1BB)
Converti‐ (2MC), Sport Suspen‐
ble (1BA) sion Quattro GmbH RS
4 (2ME)
-VAG1925- X X X X
-VAG1925/4- X X X X
-VAG1925/6- X X X
-VAG1925/3- 2) X X X X
2) Only necessary on certain lifts. -VAG1925/3- replaces -VAG1925/4-
Work Procedure, Vehicle Alignment, Overview
Note

♦ Exception: Measurement of toe-in curve according to instruc‐
tions from measuring program.
♦ Check which suspension is installed in the vehicle. This infor‐
mation can be found on the vehicle data plate. Refer to
⇒ page 232 .
Observe the following work sequence!

1 - Check front axle camber and adjust if necessary. Refer to
⇒ “4.2 Front Axle Camber, Checking and Adjusting”, Protected
page 242by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Check rear axle camber and adjust if necessary. Refer to to the correctness of information in this document. Copyright by AUDI AG.
with respect
⇒ “4.3 Rear Axle Camber, Adjusting”, page 243 .
3 - Check rear axle toe and adjust if necessary. Refer to
⇒ “4.4 Rear Axle Toe, Adjusting”, page 244 .
4 - If necessary, check toe-in curve behavior at front axle.
- If and when toe-in curve/toe constant S must be adjusted. Refer
to ⇒ page 233 or ⇒ “4.5 Front Axle Toe, Adjusting”, page 244 .
5 - Check toe in initial position at front axle and adjust if necessary.
Refer to ⇒ “4.7 Front Axle Toe, Adjusting”, page 246 .
6 - If adjustments have been made to the suspension, perform a
zero adjustment on the Steering Angle Sensor - G85- using -
VAS5051A- .
2.6 Initial Position for Alignment


Suspension 1BA, 1BB, 1BR, 1BE, 1BV, 1BD, 2MC, 2ME
Note
Due to differing measuring lifts, it may be necessary to raise ve‐

hicle at front axle in order to be able to insert the -VAG1925- .
Bounce vehicle after lowering.
– Insert -VAG1925- with -VAG1925/3- or -VAG1925/4- .

– Screw both threaded spindles out until they rest against the
subframe front bolts -arrow-.
The vehicle must not be raised by doing this!
The vehicle is now in the initial position.
Continuation for Sport Suspension 1BE, 1BV, 1BD, 2MC, 2ME

and 1BA Convertible
– Position axle lift under front jacking points and raise vehicle.
– Place -VAG1925/6- onto - VAG1925/3- or -VAG1925/4- of
spacer.
– Lower the vehicle on the adapter -arrow-.
Continuation for Heavy Duty Suspension 1BR

– Insert -VAG1925- with -VAG1925/3- or -VAG1925/4- and -
VAG1925/6- .

– Screw out both threaded spindles far enough so that they

make contact on front bolts -arrow- of subframe.
Note
The vehicle must not be raised by doing this!

With All Suspension Versions
Check of whether the present toe-in value of each wheel matches
the specification is performed in this position by the alignment
program on the alignment computer. If necessary, correct toe-in
using tie rod length adjuster.
Setting toe on front axle to start position, refer to
⇒ “4.7 Front Axle Toe, Adjusting”, page 246 .
Specified values for wheel alignment, refer to
⇒ “3.2 Wheel Alignment Specified Values”, page 239 .
The alignment program will display a message only if a correction
is necessary.
2.7 Raising the Vehicle with Suspension

1BA, 1BB, 1BR, 1BE, 1BV, 1BD, 2MC,
2ME
♦ Space - VAG1925-
♦ Adapter
Protected by copyright.for VAG
Copying for 1925
private or- commercial
VAG1925/6-purposes, in part or in whole, is not
Note
♦ During the next step make sure that the wheels do not lose
contact with the turntables when the vehicle is raised!
♦ If this should happen, turntables should not be moved. This
would give false results.
– Position axle lift under front jacking points and raise vehicle.
Note
The vehicle is raised by 60 mm or 40 mm.
– Remove the -VAG1925/6- in vehicles with heavy duty sus‐

pension 1BR.

With All Suspension Versions

– Move cylinder in threaded spindles and secure with bolts.
Note
Make sure that screws -arrows- are correctly positioned.
– Lower vehicle on -VAG1925- .

3 Specifications
⇒ “3.2 Wheel Alignment Specified Values”, page 239

Metal Valve Body Union Nut - 4
Wheel Electronics Microencapsulated Bolt - 4
3.2 Wheel Alignment Specified Values

Sedan and Avant (Front and All Wheel Drive)
Specifications valid for all engine versions
Front Suspension Standard Sus‐ Sport Sus‐ Sport Suspen‐ Comfort Heavy Sport Suspen‐
pension (1BA), pension sion (1BD), Ba‐ Duty Suspension sion Quattro
Heavy Duty (1BE), Sport sic Suspension (1BR) GmbH RS 4
Suspension, Suspension Quattro
Protected GmbH
by copyright. Copying for private or commercial purposes,(2ME)
China (1BB) Quattro permitted
RS 4 (2MC)
GmbH (1BV) with respect to the correctness of information in this document. Copyright by AUDI AG.
Camber - 33′ ± 25′ - 47′ ± 25′ - 51′ ± 25′ - 21′ ± 25′ - 76′ ± 25′
Maximum permis‐ 30′ 30′ 30′ 30′ 30′
sible difference
between both
sides
Toe setting for + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′
each wheel (unla‐
den)
Toe check value + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′
for each wheel
(unladen)
Toe constant per + 9′ ± 2′3) + 9′ ± 2′3) + 14′ ± 2′ + 9′ ± 2′3) + 14′ ± 2′
wheel (setting val‐ + 14′ ± 2′4) + 14′ ± 2′4) + 14′ ± 2′4)
ue)
Toe constant for + 9′ ± 7′3) + 9′ ± 7′3) + 14′ ± 7′ + 9′ ± 7′3) + 14′ ± 7′
each wheel (check + 14′ ± 7′4) + 14′ ± 7′4) + 14′ ± 7′4)
value)
Toe constant dif‐ max. 10′ max. 10′ max. 10′ max. 10′ max. 10′
ference between
both sides
Toe angle differ‐ 1° 6′ ± 30′ 1° 6′ ± 30′ 1° 6′ ± 30′ 1° 6′ ± 30′ 1° 6′ ± 30′
ence at 20 de‐
grees 5)
3) Data applies to market introduction sedan through VIN 8E_2_025687.

4) Data applies to Sedan from VIN 8E_2_025688 as well as to Avant.
5) Wheel stop on outer wheel is reduced by this amount. It can also be indicated
negatively in alignment computer, depending on manufacturer.
Rear Suspen‐ Standard Sus‐ Sport Suspen‐ Sport Suspen‐ Comfort Heavy Sport Suspension
sion pension (1BA), sion (1BE), sion (1BD), Ba‐ Duty Suspen‐ Quattro GmbH RS
Heavy Duty Sus‐ Sport Suspen‐ sic Suspension sion (1BR) 4 (2ME)
pension, China sion Quattro Quattro GmbH
(1BB) GmbH (1BV) RS 4 (2MC)
Camber - 1° 20′ ± 30′ - 1° 20′ ± 30′ - 1° 20′ ± 30′ - 1° 20′ ± 30′ - 1° 20′ ± 30′
Rear Suspen‐ Standard Sus‐ Sport Suspen‐ Sport Suspen‐ Comfort Heavy Sport Suspension
sion pension (1BA), sion (1BE), sion (1BD), Ba‐ Duty Suspen‐ Quattro GmbH RS
Heavy Duty Sus‐ Sport Suspen‐ sic Suspension sion (1BR) 4 (2ME)
pension, China sion Quattro Quattro GmbH
(1BB) GmbH (1BV) RS 4 (2MC)
Maximum per‐ 30′ 30′ 30′ 30′ 30′
missible differ‐
ence between
both sides
Total toe + 20′ ±10' 5' + 20′ ±10' 5' + 20′ ±10' 5' + 20′ ±10' 5' + 20′ ±10' 5'
Individual toe + 10′ ±5' 2,5' + ±5' 2,5'unless +authorised
10′ permitted 10′ ±5'by2,5' + 10′
AUDI AG. AUDI 5' not guarantee +
AG±does 2,5' or 10′
accept 5' liability
±any2,5'
Maximum per‐ 7′ 7′ 7′ 7′ 7′
missible devia‐
tion in direction
of travel relative
to vehicle longi‐
tudinal axis
Additional Vehicle Data for Vehicles with Front and All Wheel
Drive
This additional vehicle data only serves for a faster diagnosis in
the case of accidents.
Table, refer to ⇒ “3.1 Chassis”, page 5 or
⇒ “3.2 Steering”, page 6 .
Convertible (Front and All Wheel Drive)
Specifications valid for all engine versions
Front Suspension Standard Suspension Sport Suspension (1BE/ Sport Suspension
(1BA) 1BV) (1BD), Basic Suspen‐
sion Quattro GmbH
RS 4 (2MC)
Camber - 47′ ± 25′ - 47′ ± 25′ - 51′ ± 25′
Maximum permissible difference 30′ 30′ 30′
between both sides
Toe setting for each wheel (unla‐ + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′
den)
Toe check value for each wheel + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′
(unladen)
Toe constant per wheel (setting + 14′ ± 2′ + 14′ ± 2′ + 14′ ± 2′
value)
Toe constant for each wheel + 14′ ± 7′ + 14′ ± 7′ + 14′ ± 7′
(check value)
Toe constant difference between max. 10′ max. 10′ max. 10′
both sides
Toe angle difference at 20 de‐ 1° 6′ ± 30′ 1° 6′ ± 30′ 1° 6′ ± 30′
grees 1
1 Wheel stop on outer wheel is reduced by this amount. It can also

be indicated negatively in alignment computer, depending on
manufacturer.

Rear Suspension Standard Suspension Sport Suspension (1BE/ Sport Suspension

(1BA) 1BV) (1BD), Basic Suspen‐
sion Quattro GmbH
RS 4 (2MC)
Camber - 1° 20′ ± 30′ - 1° 20′ ± 30′ - 1° 20′ ± 30′
Maximum permissible difference 30′ 30′ 30′
between both sides
Total toe + 20′ ±10' 5' + 20′ ±10' 5' + 20′ ±10' 5'
Individual toe + 10′ ±5' 2,5' + 10′ ±5' 2,5' + 10′ ±5' 2,5'
Maximum permissible deviation in 10′ 10′ 7′
direction of travel relative to vehi‐
cle longitudinal axis
Additional Vehicle Data for Vehicles with Front and All Wheel
Drive
This additional vehicle data only serves for a faster diagnosis in
the case of accidents.
Table, refer to ⇒ “3.1 Chassis”, page 5 or
⇒ “3.2 Steering”, page 6 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

⇒ “4.1 Mechanical Center Position of Rack, Checking”,
page 242
⇒ “4.2 Front Axle Camber, Checking and Adjusting”, page 242
⇒ “4.3 Rear Axle Camber, Adjusting”, page 243
⇒ “4.4 Rear Axle Toe, Adjusting”, page 244
⇒ “4.5 Front Axle Toe, Adjusting”, page 244
⇒ “4.6 Adjusting Toe Constant S”, page 245
⇒ “4.7 Front Axle Toe, Adjusting”, page 246
4.1 Mechanical Center Position of Rack,

Checking
Mechanical center position (steering centering) of the steering
rack can be checked with Steering Centering Bolt - VAS6224- .
Refer to ⇒ page 259 .
4.2 Front Axle Camber, Checking and Ad‐

justing
Camber cannot be adjusted.
By moving subframe, it is possible to center camber evenly within
the specified/tolerance range.
– Remove noise insulation.
Convertible Only
– Remove front diagonal brace. Refer to
– Loosen hex bolts -1, 2, 3, 4, 5, 6, 7, and 8-.

– Using a plastic-coated tire iron, slide subframe in correspond‐

ing location.
Press in center of subframe between subframe and body longi‐
tudinal member.
If you do not have a plastic-coated tire iron, wrap a standard tire
iron in adhesive tape.
WARNING
Do not damage any parts!
Specified values for wheel alignment. Refer to

⇒ “3.2 Wheel Alignment Specified Values”, page 239 .
– Install new bolts -7 and 8- and tighten. Specification: 110 Nm

+ 90° turn.
– Install new bolts -5 and 6- and tighten. Specification: 110 Nm
+ 90° turn.
– Install new bolts -1, 2, 3 and 4- and tighten. Specification: 75
Nm.
Convertible Only
– Install front diagonal brace. Refer to
Caution
Every timeProtected
camber is corrected,
by copyright. Copying foraxle alignment
private or commercialvalues
purposes, should
be checked.
4.3 Rear Axle Camber, Adjusting

– Remove wheel bearing housing/transverse link connection nut
-A-.
– Adjust camber by turning eccentric bolt -B-.
Note
♦ The maximum adjustment range is 90° to left or right of center

position.
♦ For a better illustration, camber adjustment is shown with
wheel removed.
– Install new nut -A- and tighten. Specification: 95 Nm.

– After tightening nut -A-, check camber value once more. Refer
to ⇒ “3.2 Wheel Alignment Specified Values”, page 239 .

4.4 Rear Axle Toe, Adjusting

– Install underbody trim -1- in front of trapezoidal control arm.
Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Removal and Instal‐
lation .
Convertible Only
– Remove diagonal brace -1 or 2- on side with toe to be adjusted.
Refer to ⇒ “5.22 Front or Rear Diagonal Braces”, page 179 .
Continuation forauthorised
permitted unless All Vehicles
by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove front interior trapezoidal control arm/subframe con‐
nection nut -C-.
– Adjust toe accordingly by turning eccentric bolt -D-.
– Install new nut -C- and tighten. Specification: 95 Nm.
Note
♦ The maximum adjustment range is 90° to left or right of center

position.
♦ The geometric drive axle is automatically changed when indi‐
vidual toe settings are changed.
– After tightening nut -C-, check toe value again.

Convertible Only
– Install diagonal brace. Refer to
– Install underbody trim. Refer to ⇒ Body Exterior; Rep. Gr. 66 ;
Removal and Installation .
4.5 Front Axle Toe, Adjusting

Explanation:
When the wheel compresses or rebounds, the wheel's toe
changes as a function of the compression and rebound travel.
The resulting toe measurements are described as the toe curve.

The change in the toe constants S is adjusted when the vehicle

is raised by vertically shifting the tie rod end. Refer to
⇒ “4.6 Adjusting Toe Constant S”, page 245
The wheel alignment computer determines the toe constant S
using values measured in the initial and raised positions. The
computer compares the measured values with the specifications
and displays them on the screen.
Depending on the suspension, various adapters are necessary
for raising the vehicle. Refer to
⇒ “2.5 Adapters, Allocating to Suspension for Alignment”,
page 234 .
Note
An incorrectly adjusting toe constant causes vehicle to turn when

braking/accelerating or when driving over bumps.
4.6 Adjusting Toe Constant Sunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
– Loosen hex head nut -A-.
– Remove bolt -B- and screw in a new bolt in approximately
4 mm.
– Push toe rod joint downwards onto stop.
Note

sealing washer -2- when removing tie rod, otherwise sealing
washer could be damaged.

– Install the bolt -B- until specified value is reached exactly.

– Tighten hex head nut -A- to 45 Nm and check value.
– Tighten bolt -B- to 5 Nm.
– Lower vehicle to initial position again.
– Screw threaded spindle down.
– Bounce suspension of vehicles with standard suspension sev‐
eral times.
Checking Toe Constant After Adjusting
Wheel alignment equipment will check toe constant again.
If the measured values for the second check are within the check
value tolerances then the adjustment is OK.
If measured values are not within control values, they must be set
again in raised position.
4.7 Front Axle Toe, Adjusting

– Loosen lock nut -B-.
– Adjust toe on left and right–hand wheels at hex -A-.
Note
Be sure that boot is not twisted after turning tie rods.
Twisted boots wear out quickly.

– Tighten lock nut -B- to 40 Nm and check toe-in again.
After tightening lock nut -B- it is possible that the value deviates
slightly.
If the measured toe nevertheless lies within the tolerance, the
adjustment is correct.


⇒ “5.1 Tires, Changing”, page 247
⇒ “5.2 Metal Valve Body”, page 248
⇒ “5.3 Tire Pressure Monitoring Control Module J502 ”,
page 249
⇒ “5.4 Rear Tire Pressure Monitoring Antenna R96 ”,
page 249
5.1 Tires, Changing
Note
♦ Nickel-plated valve insert must be replaced with every tire

change.
♦ Metal valve and wheel electronics can be reused.
– Let air out of tire by removing nickel-plated valve insert.

– Dismount tire. Refer to ⇒ page 247 .
– Perform a visual inspection for loose or damaged parts. If there
are loose threaded connections, replace entire valve unit.
Note
Damaged wheel electronics must be replaced.
– Mount tire. Refer to ⇒ page 248 .

– Install new nickel-plated valve insert.
– Fill tires, reinstall plastic cap.
– Balance tires.
Dismounting Tire
Roll or press tires off.
When using pressure paddles, first separate tires from side op‐
posite of valve.
Caution
Do not use pressure paddles in hatched area -a-.
– Position mounting head near valve so that so that tire iron can
be put on approximately 30° -b- next to tire valve.
– Then remove tire in valve area first.

Mounting Tire
Caution
Do not use pressure paddles in valve area.
– Position wheel electronics approximately 180° opposite of

mounting head.
– Press tire in bed approximately 90° in front of mounting head
-arrow-.
– Mount tire.
5.2 Metal Valve Body

– Place metal valve with rubber seal through rim from inside.
– Position beveled washer and union nut from outside and tight‐
en. Specification: 4 Nm.
– Secure against turning with counter hold -1- (for example 2
mm diameter drill bit).
– Press wheel electronics -1- into bed and fasten at rear of valve
with microencapsulated screw. Specification: 4 Nm.

5.3 Tire Pressure Monitoring Control Mod‐

ule - J502-
Removing
Tire Pressure Monitoring Control Module - J502- is located behind
side trim to the left of the luggage compartment.
– Remove the side trim panel in the left luggage compartment.
– Unclip control module -1-.
– Disconnect connector -2- and remove control module.
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation is performed in the reversewithorder
respect of removal.
5.4 Rear Tire Pressure Monitoring Antenna

- R96-
Removing
Reception antenna is found at bottom of rear bumper.
– Unclip Rear Tire Pressure Monitoring Antenna -1- in direction
of vehicle center.
– Disconnect connector from antenna.
– Remove antenna -1-.
Installing

6 Special Tools
♦ Wheel Alignment Computer - VAG1813-

♦ Brake Pedal Actuator - VAG1869/2-
♦ Steering Centering Bolt - VAS6224-
♦ Vehicle Diagnosis, Testing and Information System -
VAS5051A-

48 – Steering
⇒ “1.1 Steering Column Transport Protection”, page 251
⇒ “1.2 Power Steering, Checking Fluid Level”, page 251
⇒ “1.3 Power Steering Pump”, page 252
⇒ “1.4 Steering System, Bleeding after Reconstructing”,
page 252
1.1 Steering Column Transport Protection

New replacement steering columns are secured with transporta‐
tion protection.
This transport protection must be removed after installing the
steering column in vehicle.
If a used steering column is to be removed and reinstalled, an
assembly aid is useful in preventing upper and lower sections of
the steering column from separating when removing from steering
gear. Use for example a cable tie or wire as an assembly aid.
Caution
If the upper and lower sections of the steering column are

pulled too far apart or pushed too close together the splines
separate.
There may be rattling later if the splines are not in their original
installation position.
1.2 Power Steering, Checking Fluid Level

– Do not run engine and turn front wheels to straight ahead po‐
sition.
Fluid, when Cold (Outside Temperature Approximately +20 °C
(+68 °F)):
– Remove the cap.
– Wipe dipstick off with a clean cloth.
– Screw cap on hand-tight and unscrew again.
The cap must be fully screwed in order to obtain an accurate fluid
level reading.

– Check fluid level: Oil level must be within MAX marking.

Fluid at Operating Temperature (Engine Oil Temperature +80 °C
(+176 °F))
– Check fluid level: Oil level must be 10 mm above MAX mark‐
ing.
Note
♦ Fluid must be drawn off if the level is above the specified

range.
♦ If oil level is below aforementioned area, then the hydraulic
system must be checked for leaks. It is not sufficient to merely
top off the fluid.
♦ Do not use drained hydraulic oil.
1.3 Power Steering Pump

Power steering pump is not designed to be serviced. If a customer
has reported a problem, determine cause via pressure test and
leak test. If there is a malfunction, replace the power steering
pump.
♦ If the power steering fluid is low in reservoir, check steering
system for leaks.
♦ If there are leaks in the area of the line connections, the lines/
connections must first be inspected for leaks, tightened as
necessary and wiped dry.
♦ Replacement pumps from the distribution center do not con‐
tain any fluid. They must be filled with hydraulic fluid before
installation and turned by hand, otherwise pump noise or dam‐
age can result in operation.
1.4 Steering System, Bleeding after Recon‐

structing
After steering system reconstruction, system must be bled differ‐
ently depending on extent of reconstruction.
After Exchanging Entire Steering System or Exchanging Steering
Gear Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Check hydraulic fluid level and top off if necessary.
– Raise vehicle until front wheels are off the ground.

– Briefly start engine (maximum 2 sec.)
Pump must not draw in any air and steering wheel must not be
turned under any circumstances.
Approximately 30 seconds wait between individual engine starts.
– Repeat this process until oil level remains constant.
– Turn steering wheel from lock to lock 10 times, with engine
switched off.
– Start engine.
– Turn steering wheel 10 times from stop to stop.
252 Rep. Gr.48 - Steering

Any remaining air in steering system will dissipate by itself when

driving over the next 10 to 20 km.
When Reconstruction a Component of the Steering System Be‐
sides the Steering Gear (Pump, Hoses, Etc.)
– Briefly start engine (maximum 2 sec.)
Pump must not draw in any air and steering wheel must not be
turned under any circumstances.
Approximately 30 seconds wait between individual engine starts.
– Repeat this process until oil level remains constant.
– Start engine and allow to run 2 - 3 minutes, do not turn steering
wheel.
Any remaining air in steering system will dissipate by itself when
driving over the next 10 to 20 km.


⇒ “2.1 Steering Wheel with Airbag Overview”, page 254
⇒ “2.2 Steering Column Overview”, page 255
⇒ “2.3 Power Steering Gear Overview”, page 256
⇒ “2.4 Power Steering Gear Overview”, page 259
⇒ “2.5 Heat Shield Overview”, page 261
⇒ “2.6 Power Steering Gear, Adjusting”, page 261
⇒ “2.7 Servotronic Steering Gear Overview”, page 262
4-Cylinder Engines
⇒ “2.8 Power Steering Pump, Reservoir and Hydraulic Lines
6-Cylinder Engines
8-Cylinder Engines
⇒ “2.11 Suction Hose, Location on Power Steering Pump”,
page 270
⇒ “2.12 Suction Hose, Location on Power Steering Fluid Reser‐
voir”, page 270
2.1 Steering Wheel with Airbag Overview

1 - Steering Column Switch

Trim
ling, refer to ⇒ Body In‐
terior; Rep. Gr. 70 ;
Removal and Installa‐
tion .
2 - Steering Wheel
ling, refer to
⇒ “5.1 Steering Wheel
with Airbag”, page 281 .
Parts Catalog.
3 - Spiral Spring Connector
4 - Airbag Unit Connector
5 - Signal Horn Connector
6 - Airbag Unit
❑ Observe safety precau‐
tions. Refer to ⇒ Body
Interior; Rep. Gr. 69 ;
General Information
ling, refer to ⇒ Body In‐
terior; Rep. Gr. 69 ;
Removal and Installa‐
tion .
7 - Bolt
❑ 50 Nm
❑ Always replace
8 - Bolt
tion, refer to ⇒ Body Interior; Rep. Gr. 69 ; Description and Operation .
9 - Steering Column Adjustment Lever
2.2 Steering Column Overview

The steering column is delivered only as a complete replacement
part. Service is not possible.
Steering lock with ignition switch without lock cylinder can be
transferred.

1 - Retainer Plate
2 - Shear Head Bolt
❑ 15 Nm
3 - Steering Column
4 - Steering Lock with Ignition
Switch without Lock Cylinder
5 - Bolt
❑ 22 Nm
6 - Steering Gear
Note
Sliding splines between upper and

lower parts of steering column
should never be separated.
Caution
Sliding over a range of ±
5 cm can cause damage
to the steering column.
To avoid damage, refer
to
⇒ “1.1 Steering Column
Transport Protection”,
page 251 .
2.3 Power Steering Gear Overview

Power steering gear is completely removed and installed with tie
rods.

1 - Steering Gear with Tie Rods

ling, refer to
⇒ “5.4 Power Steering
Gear”, page 285 .
Gear Overview”,
page 259
❑ Different versions, refer
to the Parts Catalog.
2 - Bolt
❑ 40 Nm + 90° turn
❑ Protected
Always replace.
3 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 30 Nm
4 - Steering Column
5 - Bulkhead Boot
scuffing.
❑ Note installation loca‐
tion. Refer to

Gear”, page 285 .

6 - Bolt
❑ 40 Nm + 90° turn
❑ Always replace
7 - Bolt
❑ 5 Nm
8 - Bolt
9 - Nut
❑ 45 Nm
❑ Always replace
❑ Self-locking
10 - Stub Axle Carrier (Steering Arm)
11 - Banjo Fitting
❑ 47 Nm
12 - Seal
❑ Always replace.
13 - Return Hose
14 - Return Line Connection
❑ 40 Nm
❑ Colored marks must align.
15 - Seal
❑ Always replace.
16 - Cylinder Screw
❑ 22 Nm
❑ Screw plug. Refer to ⇒ page 259 .
17 - Seal
❑ Always replace.
18 - Extension Hose
❑ Different versions, -item 22- ⇒ Item 21 (page 258) or -item 22- ⇒ Item 22 (page 258) .
19 - Seal
❑ Always replace
20 - Banjo Bolt with Check Valve
21 - Extension Hose
❑ For 4-cylinder engines.
22 - Extension Hose
❑ For 6-cylinder engines.
23 - Tie Rod
❑ Removing and installing, refer to ⇒ “5.6 Tie Rods”, page 295 .
24 - Tie Rod End
❑ Removing and installing, refer to ⇒ “5.5 Tie Rod End”, page 293 .

Steering Centering

Steering gear in sectional view:
1 - Screw plug: 22 Nm
2 - Install Steering Centering Bolt - VAS6224- as far as possible
by hand.
3 - Steering rack
4 - Steering gear housing
– Move steering wheel slightly out of the center position.
– A second technician turns Steering Centering Bolt - VAS6224-
in steering gear until it noticeably engages in center hole.
2.4 Power Steering Gear Overview

This overview is provisionally for all vehicles.
Note
♦ Always replace self-locking nuts and bolts.

♦ Welding or straighten work on any steering components is not
permissible.
♦ To grease the steering rack, only use steering gear grease
with the part number AOF 063 000 04.

1 - Tie Rod End

ling, refer to
⇒ “5.5 Tie Rod End”,
page 293 .
❑ Check dust caps for
damage and correct
seating.
2 - Lock Nut
3 - Spring Clamp
❑ Always replace.
❑ Version, refer to the
Parts Catalog.
4 - Boot
❑ Check for damage.
❑ Must not be twisted after
toe is adjusted.
❑ Can be replaced with
steering gear installed.
❑ Remove to replace tie
rods. Refer to
⇒ “5.6 Tie Rods”,
page 295 .
5 - O-ring
❑ Always replace.
6 - Power Steering Gear
❑ Grease rack with steer‐
ing gear grease A0F
063 000 04
❑ Different versions, refer
to the Parts Catalog.
7 - Clamp
❑ Always replace.
❑ Tension using -VAG1275- .
8 - Tie Rod
❑ 100 Nm
❑ Removing and installing, refer to ⇒ “5.6 Tie Rods”, page 295 .
❑ Grease joint with steering gear grease A0F 063 000 04.

2.5 Heat Shield Overview
1 - Plenum Chamber
2 - Power Steering Gear
3 - Spreader Nut
Parts Catalog.
4 - Heat Shield
❑ With V6 TDI engines, re‐
move front catalytic con‐
verter. Refer to ⇒ En‐
gine Mechanical; Rep.
Gr. 26 ; Removal and
Installation .
❑ With 6 and 8-cylinder
gasoline engines, re‐
move front exhaust
pipe. Refer to ⇒ Engine
Mechanical; Rep. Gr.
26 ; Removal and Instal‐
lation .
Parts Catalog.
5 - Screw
❑ 2 Nm
6 - Heat Shield
❑ For all vehicles.
7 - Spreader Nut
Parts Catalog. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2.6 Power Steering Gear, Adjusting

Two technicians are required for adjustments. Adjust with engine
off.
– Raise vehicle on platform.
– Wheels in straight-ahead position.
– Turning the steering wheel back and forth (approximately 30°
off center axis) will produce a rattling noise if steering play is
too large.

– The second technician must carefully turn the adjustment

screw -arrow- until the knocking noise can no longer be heard
inside the vehicle.
– Carry out a road test.
– Make sure that when maneuvering or negotiating corners the
steering self-centers without sticking, re-adjust if necessary.
2.7 Servotronic Steering Gear Overview
1 - Steering Gear with Tie Rods

❑ Assembly overview, re‐
fer to
Gear Overview”,
page 256 .
2 - Servotronic Solenoid Valve
Connector
❑ Component location: in
front left wheel housing.
3 - Relay Carrier, 9-Pin
❑ Located under trim in
driver's footwell. Refer
to ⇒ Wiring diagrams,
Troubleshooting &
Component locations.
❑ Check voltage supply.
Refer to
⇒ “4.3 Voltage Supply
for Servotronic, Check‐
ing”, page 273 .
❑ Checking speed signal,
refer to
⇒ “4.4 Speed Signal,
Checking”, page 273 .
4 - Servotronic Solenoid Valve
- N119- with Fused Connector
Cable
❑ Remove steering gear
to replace servotronic
solenoid valve.
⇒ “4.5 Servotronic Con‐
trol Module J236 ,
Checking”, page 274 .
Note
Do not open Torx screws!
5 - Adapter Cable
6 - Bolt
❑ 3 Nm
❑ SW 2.5 mm

Note
Do not open Torx® bolts!
7 - Servotronic Solenoid Valve - N119- with Connector

❑ Remove steering gear to replace servotronic solenoid valve.
❑ Checking, refer to ⇒ “4.5 Servotronic Control Module J236 , Checking”, page 274 .
Note
Do not open Torx bolts!
8 - Seal
❑ Always replace.
9 - Seal
❑ Always replace.
10 - Strainer
❑ Always replace.
2.8 Power Steering Pump, Reservoir and

Hydraulic Lines Overview
Power steering pump is not designed to be serviced. If a customer
has reported a problem, determine cause via pressure test and
leak test. If there is a malfunction, replace the power steering
pump.
Note
♦ If power steering fluid is low in reservoir, check steering sys‐

tem for leaks.
♦ If there are leaks in the area of the line connections, the lines/
connections must first be inspected for leaks, tightened as
necessary and wiped dry.
♦ Replacement pumps from the distribution center do not con‐
tain any fluid. They must be filled with hydraulic fluid before
installation and turned by hand, otherwise pump noise or dam‐
age can result in operation.
♦ Oil type, refer to the Parts Catalog.

1 - Steering Gear
Parts Catalog.
2 - Return Hose
3 - Extension Hose
4 - Cap with Dip Stick
❑ Check fluid level. Refer
to
⇒ “1.2 Power Steering,
Checking Fluid Level”,
page 251 .
5 - Bolt
❑ 9 Nm
6 - Reservoir
❑ Refilling with hydraulic
oil, refer to the Replace‐
ment Parts Catalog.
7 - Rubber Bushing
8 - Clamp
❑ Tension using -
VAG1275- .
❑ Always replace.
9 - Return Hose
❑ Between reservoir and
cooling line.
10 - Clamp
❑ Tension using -

VAG1275- .
❑ Always replace.
11 - Bolt
❑ 10 Nm
12 - Cooling Line
13 - Cable Tie
14 - Clamp
❑ Always replace.
15 - Intake Hose
❑ Installed position, refer to ⇒ “2.11 Suction Hose, Location on Power Steering Pump”, page 270 .
16 - Clamp
❑ Always replace.
17 - Power Steering Pump
❑ For 6-cylinder FSI
❑ Fill with oil before installing.
18 - Seal
❑ Always replace.
19 - Seal
❑ Always replace.
20 - Banjo Fitting
❑ 50 Nm
❑ For 4-cylinder engine.
22 - Seal
❑ Always replace.
23 - Seal
❑ Always replace.
24 - Banjo Fitting
❑ 50 Nm
25 - Intake Hose
26 - Clamp
❑ Always replace.

2.9 Power Steering Pump, Reservoir and Hydraulic Lines Overview
1 - Steering Gear
Parts Catalog.
2 - Extension Hose
3 - Return Hose
to
page 251 .
5 - Bolt
❑ 9 Nm
6 - Reservoir
oil, refer to the Replace‐
ment Parts Catalog.
7 - Rubber Bushing
8 - Clamp
❑ Tension using -
VAG1275- .
❑ Always replace.
9 - Return Hose
❑ Between reservoir and with respect to the correctness of information in this document. Copyright by AUDI AG.
cooling line.
10 - Clamp
❑ Tension using -

VAG1275- .
❑ Always replace.
11 - Bolt
❑ 10 Nm
12 - Cooling Line
13 - Cable Tie
14 - Clamp
❑ Always replace.
15 - Intake Hose
16 - Clamp
❑ Always replace. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
17 - Intake Hose
18 - Clamp
❑ Tension using -VAG1275-
❑ Always replace.
❑ For 6-cylinder gasoline engines
20 - Seal
❑ Always replace.
21 - Extension Hose
22 - Seal
❑ Always replace.
23 - Banjo Fitting
❑ 50 Nm
24 - Bolt
❑ 8 Nm
25 - Extension Hose Connection
❑ 40 Nm

2.10 Power Steering Pump, Reservoir and Hydraulic Lines Overview
1 - Steering Gear
❑ Application, refer to
Parts Catalog.
2 - Pressurized Line
❑ Note the installation po‐
sition.
3 - Union Nut
❑ 40 Nm
4 - Return Line
❑ Tension using hosewith respect to the correctness of information in this document. Copyright by AUDI AG.
clamp pliers -
VAG1275- .
❑ Always replace.
6 - Bolt
❑ 9 Nm
to
page 251 .
8 - Reservoir
oil, refer to the Parts
Catalog.
9 - Rubber Bushing
10 - Spring Clamp
❑ Clamp using the spring

clamp pliers
11 - Intake Hose
❑ Note location on reservoir. Refer to
⇒ “2.12 Suction Hose, Location on Power Steering Fluid Reservoir”, page 270 .
12 - Return Hose
❑ The check valve is located in the return hose -arrow-. It must not be damaged by the hose clamps.
13 - Rubber Bushing
14 - Nut
❑ 8 Nm
15 - Hydraulic Fluid Cooler
❑ Depending on the engine, a cooling line may be installed instead of the hydraulic fluid cooler
16 - Bolt
❑ 10 Nm
17 - Intake Hose
18 - Union Nut
❑ 40 Nm
❑ Application, refer to Parts Catalog.
❑ Fill with fluid before installation.
❑ Checking delivery pressure, refer to
⇒ “4.9 Power Steering Pump, Checking Delivery Pressure”, page 278 .
❑ Removing and installing, refer to ⇒ “5.10 Power Steering Pump”, page 304 .
20 - Heat Shield
❑ Installed depending on the engine version.
21 - Seal
❑ Always replace.
22 - Banjo Bolt
❑ 50 Nm
❑ Always replace.
❑ Note the installation position. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Markings must align. with respect to the correctness of information in this document. Copyright by AUDI AG.

2.11 Suction Hose, Location on Power Steer‐

ing Pump
Illustration shows power steering pump and pressure line -2- as
well as suction hose -1- on a 6-cylinder TDI engine.
– Marking -P- on suction hose -1- must align with formed seam
on pump.
2.12 Suction Hose, Location on Power Steer‐

ing Fluid Reservoir
– Marking on suction hose -1- must align with formed seam on
power steering oil reservoir -arrows-.

3 Specifications

Cooling Line to Body Bolt - 10
Extension Hose to Steering Gear Banjo Bolt - 35
Extension Hose Retaining Bolt, 6-Cylinder MPI - 8
Oil Cooler to Body Nut, 8-Cylinder - 8
Pressure Hose/Line to Power Steering Pump Banjo Bolt - 50
Pressure Line Retaining Bolt - 8
Reservoir to Body Bolt - 9
Return Hose to Steering Gear Banjo Fitting - 47
Return Line to Steering Gear Union Nut - 40
Servotronic Solenoid Valve to Steering Gear Bolt - 3
Steering Column to Retainer Plate Bolt - 22
Steering Column to Steering Gear Bolt - 30
Steering Column to Steering Lock Shear Bolt - 15
Steering Gear Screw Plug - 22
Steering Gear Shield Screw - 2
Steering Gear to Subframe Bolt 1 - 40 + 90°
Steering Wheel to Steering Column Bolt 1 - 50
Suction Line Retaining Bolt, 8-Cylinder - 10
Tie Rod to Steering Gear - 100
Tie Rod to Tie Rod End Lock Nut - 40
Tie Rod End to Wheel Bearing Housing Bolt - 5
Tie Rod End to Wheel Bearing Housing Lock Nut 1 - 45

⇒ “4.1 Steering Column, Checking for Damage”, page 272
⇒ “4.2 Servotronic Steering Gear Fault Table”, page 272
⇒ “4.3 Voltage Supply for Servotronic, Checking”, page 273
⇒ “4.4 Speed Signal, Checking”, page 273
⇒ “4.5 Servotronic Control Module J236 , Checking”, page 274
⇒ “4.6 Steering System, Checking for Leaks”, page 274
4-Cylinder Engines
⇒ “4.7 Power Steering Pump, Checking Delivery Pressure”, page
275
6-Cylinder Engines
⇒ “4.8 Power Steering Pump, Checking Delivery Pressure”, page
277
8-Cylinder Engines
⇒ “4.9 Power Steering Pump,
Protected Checking
by copyright. Delivery
Copying for private Pressure”, page in part or in whole, is not
or commercial purposes,
278 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4.1 Steering Column, Checking for Damage

Visual Check
– Check whether parts of the steering column indicate damage.
Functional Check
– Check whether steering column can be turned without catch‐
ing or difficulty of movement.
– Check that steering column can be adjusted for height and
reach.
– Check gap -dimension A- between slits and mounting bracket.
- Dimension A: Maximum 0.5 mm or smaller
– If dimension -A- is greater than 0.5 mm, steering column is
damaged and must be replaced.
4.2 Servotronic Steering Gear Fault Table

♦ For vehicles with Servotronic, power steering support is elec‐
tronically regulated depending on vehicle speed.
♦ If electronics malfunction, steering works like the normal pow‐
er steering.
♦ The Servotronic Control Module - J236- is not capable of On
Board Diagnostics (OBD).

Fault Table
Possible Fault Possible Cause of Fault Corrective Action
♦ When maneuvering the vehi‐ ♦ Voltage supply interrupted. ♦ Check voltage supply. Refer to
cle, stronger steering force is ⇒ “4.3 Voltage Supply for Servo‐
needed than usual. ♦ Speed signal interrupted. tronic, Checking”, page 273 .
♦ Steering is unusually easy at ♦ Servotronic Solenoid Valve ♦ Check speed signal. Refer to
higher speeds. malfunctioning. ⇒ “4.4 Speed Signal, Checking”,
page 273 .
♦ Checking valve, refer to
⇒ “4.5 Servotronic Control Module
J236 , Checking”, page 274 .
♦ Difficulty of power steering ♦ Hydraulic defect in power ♦ Replace power steering gear. Refer
movement on one side, for ex‐ steering gear. to
ample: Steering loose to the ⇒ “5.4 Power Steering Gear”,
right and tight to the left page 285 .
4.3 Voltage Supply for Servotronic, Check‐

ingwith respect toauthorised
permitted unless by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Digital Multimeter - VAG1526-
– Remove storage compartment on driver side. Refer to ⇒ Body
Interior; Rep. Gr. 68 ; Removal and Installation .
– Remove Servotronic Control Module - J236- , item 2.
– Turn on ignition
– Set -VAG1526- to voltage measuring range up to 20 V.
– Measure control module connector between contacts 6 and 8.
Specified value: Approximately 12 Volt.
– If specified value is not obtained, check electrical wiring. Refer
to ⇒ Wiring diagrams, Troubleshooting & Component loca‐
tions.
4.4 Speed Signal, Checking

Speed signal comes from Instrument Cluster Control Module -
J285- .
– Remove Servotronic Control Module - J236- .
– If voltage supply, servotronic solenoid valve and speed display
on tachometer are OK, check electrical line between servo‐
tronic solenoid valve contact 4 and instrument cluster control
module. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐
ponent locations.
– If electrical line between contact 4 and instrument cluster con‐
trol module is OK, replace servotronic solenoid valve.

4.5 Servotronic Control Module - J236- ,

Checking
– Remove Servotronic Control Module - J236- .
– Set -VAG1526- to ohm measuring range up to 200 ohm.
– Measure control module connector between contacts 2 and 5.
Specified value: 5 to 20 Ohm.
If specified value is not reached:
– Disconnect Servotronic Control Module - J236- connector (in
left wheel housing).
– Check line between control module connector and servotronic
solenoid valve connector for short circuit and interruption. Re‐
fer to the ⇒ Wiring diagrams, Troubleshooting & Component
locations.
– If electric line to wiring harness in left wheel housing is OK,
remove steering gear.
– Vehicles with fused connector cable at servotronic solenoid
valve, replace solenoid valve.
– Vehicles with unfused connector cable at servotronic solenoid
valve, disconnect connector and check connector cable for
short circuit and interruption.
– If connector cable is OK, replace servotronic solenoid valve.
4.6 Steering System, Checking for Leaks
Note
Following installation operations and with no hydraulic fluid in the

expansion tank, the steering system must be checked for leaks.
– Start engine.
– Turn steering wheel in both directions to full lock and hold
briefly. This builds up the maximum possible pressure.
To avoid damage to pump, steering wheel must not be held at
stop longer than 10 seconds during this test.
In this position, the following components must be checked for
leaks.
♦ Seal ring for steering pinion at the steering gear valve housing.
♦ All line connections.
♦ Rack sealing rings.
This test can only be performed with boots slid back.
– Open spring-type hose clamp and boot hose clamp.
– Slide boot back.
If fluid is visible in steering gear housing and/or in boots, steering
gear must be replaced.

4.7 Power Steering Pump, Checking Deliv‐

ery Pressure
♦ Hose Clamps Up to 25 mm Dia. - 3094-
♦ Power Steering Test Unit - VAG1402-

– Clamp off suction and return line using -3094- .

– Remove pressure hose from power steering pump.
– Screw -VAG1402/3- into power steering pump in place of ban‐
jo bolt.
Note
If Power Steering Test Unit - Adapter 3 - VAG1402/3- threads are

too long, use more seals.
– Install the Power Steering Test Unit - VAG1402- hose on the

Power Steering Test Unit - Adapter 3 - VAG1402/3- .
– Close the pressure gauge shut-off valve (lever on the left).
– Remove the Hose Clamps - Up To 25 mm - 3094- .
Note
♦ To avoid damage to pump, observe the following:

♦ Pressure gauge shut-off valve must not remained closed lon‐
ger than 10 seconds during this test.
♦ Start engine without giving gas and run at idle.
♦ Read the pump pressure immediately after starting at idle
speed (have it read by second technician, if necessary).

♦ Because pressure falls over the course of the test, the highest
pressure shown is the decisive measurement.
– Start engine and top up fluid level in reservoir if necessary.

– Read the gauge pressure with the engine at idling speed (do
not measure longer than 10 seconds).
Pump Pressure Specified Value (Positive Pressure)
Engine Pump Pump Pressure
(bar)
4-cylinder gasoline 8E0 145 153 B 110 ... 118
engines 8E0 145 153 110 ... 118
8E0 145 155 L 110 ... 118
8E0 145 153 F 110 ... 118
8E0 145 153 G 110 ... 118
8E0 145 153 D 110 ... 118
6-cylinder gasoline 8E0 145 155 127 ... 131
engines (FSI) 8E0 145 155 M 123 ... 130
8E0 145 155 T 127 ... 131
8E0 145 155 Q 123 ... 130
8H0 145 155 123 ... 130
8E0 145 155 P 120 ... 127
8E0 145 155 F 120 ... 127
If specification is not obtained, replace power steering pump.
– Turn off engine.
– Remove pressure gauge.
– Connect pressure line to power steering pump with banjo bolt.
– Check power steering fluid level. Refer to
⇒ “1.2 Power Steering, Checking Fluid Level”, page 251 .

– Check steering system for leaks. Refer to

⇒ “4.6 Steering System, Checking for Leaks”, page 274 .
– Bleed steering system. Refer to
⇒ “1.4 Steering System, Bleeding after Reconstructing”, page
252 .

ery Pressure
– Remove engine cover.
– Disconnect extension hose -arrow- while counter holding ex‐
tension hose hex head.
Note
♦ Place a cloth under separation point to absorb escaping hy‐

draulic oil.
♦ Remove hydraulic line bracket if necessary to make work eas‐
ier.

– Screw -VAG1402- hose onto extension hose.

– Close the pressure gauge shut-off valve (lever on the left).
Note

pressure shown is the decisive measurement.
– Start engine and top off fluid level in reservoir if necessary.

– At idle speed, read the pressure on pressure gauge (meas‐
urement no longer than 10 seconds).
Pump Pressure Specified Value (Positive Pressure)
Engine Pump Pump Pressure
(bar)
6-cylinder gasoline 8E0 145 155 E 120 ... 127
engines (MPI) 8E0 145 155 F 120 ... 127
8E0 145 155 P 120 ... 127
If specification is not obtained, replace power steering pump.
– Remove
Protected bypressure gauge.
copyright. Copying for private or commercial purposes, in part or in whole, is not
– Connect extension
with respect hoseofwhile
to the correctness counter
information holdingCopyright
in this document. hose hex head.
by AUDI AG.

252

ery Pressure
♦ Hose Clamps Up To 25 mm Dia. - 3094-
♦ Adapter Hose - VAG1402/6-
♦ Drip Tray for VAS6100 - VAS6208-
Test Prerequisites
• Ribbed belt/ribbed belt tension OK.
• Sealing of system.

• Hoses/lines are not kinked or constricted.

Checking
– Clamp off suction and return line with -3094- .
Pressure hose is not removed at power steering pump to check
delivery pressure. Connection of -VAG1402- takes place at line

connection -arrow- at lower left of engine compartment.
– Place -VAS6208- under separating points to catch escaping
hydraulic fluid.
– Disconnect line connection -arrow-.
– Install -VAG1402- as shown.

1 - Pressure hose
2 - Power Steering Test Unit - VAG1402-
3 - Power Steering Test Unit - Adapter Hose - VAG1402/6-
4 - Power Steering Test Unit - Adapter Hose - VAG1402/6-
5 - Pressure hose
6 - Power Steering Test Unit - Adapter 4 - VAG1402/4-
– Remove Power Steering Test Unit - VAG1402- from pressure
hose.
– Remove the Hose Clamps - Up To 25 mm - 3094- .

– Make sure that lever on Pressure Gauge stands in position

-2-.
– Start engine without giving gas.
– Turn the steering wheel from lock to lock about 10 times.
– Turn off engine and, if needed, top off hydraulic fluid in reser‐
voir.
Note

pressure shown is the decisive measurement
– Now check delivery pressure.
– Start the engine and close shut-off valve to position -1- while
engine is idling and read the pressure (the lever must point
away from pressure hose). Do not perform measurement lon‐
ger than 10 seconds.
Specification for Delivery Pressure: 123 to 130 bar
If specification is not obtained, replace power steering pump. Re‐
fer to ⇒ “5.10 Power Steering Pump”, page 304 .
– Remove -VAG1402- .
– Tighten connection for pressure hoses to 40 Nm.
252 .
– Install noise insulation. Refer to ⇒ Body Exterior;
permitted Rep. Gr.
50 ; Description and Operation . with respect to the correctness of information in this document. Copyright by AUDI AG.


⇒ “5.1 Steering Wheel with Airbag”, page 281
⇒ “5.2 Steering Column”, page 281
⇒ “5.3 Steering Lock with Ignition Switch, without Lock Cylinder”,
page 284
⇒ “5.4 Power Steering Gear”, page 285
⇒ “5.5 Tie Rod End”, page 293
⇒ “5.6 Tie Rods”, page 295
4-Cylinder Engine ⇒ “5.7 Power Steering Pump”, page 296
6-Cylinder Engine (3.0)
6-Cylinder Engine (3.2)
8-Cylinder Engine ⇒ “5.10 Power Steering Pump”, page 304
5.1 Steering Wheel with Airbag

Removing
– Bring wheels to straight position.
– Remove airbag unit. Refer to ⇒ Body Interior; Rep. Gr. 69 ;
– Remove bolt.
Installing
When installing, observe the following:
Before positioning steering wheel, make sure wheels are in
straight position.
– Position steering wheel and tighten to 50 Nm.
Note
Always replace bolts.
5.2 Steering Column

Removing
– Remove driver side airbag unit. Refer to ⇒ Body Interior; Rep.
Gr. 69 ; Removal and Installation .

– Remove steering column adjustment lever.

– Remove airbag in the steering wheel. Refer to
⇒ “5.1 Steering Wheel with Airbag”, page 281 .
– Remove steering column switch trim. Refer to ⇒ Body Interior;
– Remove steering column switch. Refer to ⇒ Electrical System;
Note
An assembly aid is required so that the upper and lower sections

of the steering column do not pull apart when pulling off steering
gear.
Caution
If the upper and lower sections of the steering column are

pulled too far apart or pushed too close together the splines
separate.
There may be rattling later if the splines are not in their original
installation position.
Securing Steering Column before Removal

– Pull wire or cable tie through hole in lower section of steering
column -arrow- and spring.
– Wire or cable tie can also be pulled through spring and uni‐
versal joint.
– Remove connectors from ignition switch and coil.
Locking cable must be disengaged on vehicles with automatic
transmission:
– Move the selector lever into the parking position.
– Ignition key in position B, ignition on.

– Lift interlock lever -1- slightly and pull locking cable -2- from
ignition lock housing.

– Loosen bolt -arrow-.

– Remove lower section of steering column from power steering
gear.
– Remove bolts -1-

– Remove steering column.
Installing
Observe the following when installing:
New replacement steering columns are secured with transporta‐
tion protection.
This transport protection must be removed after installing steering
column in the vehicle.
– Insert steering column and install bolts -1- but do not tighten.
– Position steering column joint on power steering gear and in‐

stall bolt -arrow-.
– Align steering column free of tension on steering gear pinion
– Tighten steering column/retaining plate bolts. Specification: 22
Nm.
– Tighten joint bolts at power steering gear. Specification: 30
Nm.
– Remove transport protection or assembly aid.
Engage locking cable on vehicles with automatic transmission:

– To engage locking cable, ignition key in position B, ignition on.

– Move the selector lever into the parking position.
– Insert locking cable -2- into ignition lock housing. Make sure
locking bracket -1- engages.
Checking Locking Cable Function

Ignition key in position “B”, ignition on.
– The selector lever must be able to be moved out of the park
position without getting stuck.
– Ignition key should only be removable with the selector lever
in the park position.
Move the selector lever into the parking position.
– Ignition lock must be operable without catching.
– With the ignition key in the position “A”, ignition off, the selector
lever should not be able to be shifted out of the park position.
Ignition key can be removed.
– Basic adjustment and locking cable routing, refer to ⇒ Auto‐
matic Transmission; Rep. Gr. 37 ; Description and Operation .
– Place connector on coil and ignition switch.
– Install steering column switch. Refer to ⇒ Electrical System;
– Install steering column switch trim. Refer to ⇒ Body Interior;
– Install airbag steering wheel. Refer to
⇒ “5.1 Steering Wheel with Airbag”, page 281 .
– Install steering column adjustment lever.
– Install driver side airbag unit. Refer to ⇒ Body Interior; Rep.
Gr. 69 ; Removal and Installation .
5.3 Steering Lock with Ignition Switch, with‐

out Lock Cylinder
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove steering column. Refer to to the correctness of information in this document. Copyright by AUDI AG.
with respect
⇒ “5.2 Steering Column”, page 281 .

– Drill out shear head bolt.
Note
♦ To drill out shear head bolt, steering column must be clamped

in a vise.
♦ With steering column installed, mounting bracket will be dam‐
aged.
– Remove the lock cylinder. Refer to ⇒ Electrical Equipment;

– Remove steering lock with ignition switch without lock cylinder.
Installing
– Place steering lock with ignition switch without lock cylinder on
steering column and install shear head bolt.
– Install the lock cylinder. Refer to ⇒ Electrical Equipment;
permitted Rep.by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
Gr. 94 ; Removal and Installation . with respect to the correctness of information in this document. Copyright by AUDI AG.
– Tighten shear head bolts to 20 Nm.
Note
Bolt head must be sheared off in this torque range.
Further installation occurs in reverse of removal.

– Install steering column. Refer to
⇒ “5.2 Steering Column”, page 281 .
5.4 Power Steering Gear

♦ Open Socket Insert SW 19 and SW 22 (commercially availa‐
ble)
Removing
– Remove plenum chamber cover. Refer to ⇒ Body Exterior;
– Disconnect battery and remove if necessary. Refer to ⇒ Elec‐
trical Equipment; Rep. Gr. 27 ; Removal and Installation .
WARNING
Bring steering wheel into center position and do not turn during
repairs because this may damaged airbag unit spiral spring.
– Remove ignition key with steering wheel in center position.

– Move steering wheel slightly so that the steering lock engages.
– Remove driver storage compartment

. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Removal and Instal‐

lation .
– Remove the bolt -arrow-.
– Secure steering column against slipping apart. Refer to
⇒ page 282 . Secure steering column before removal.
Note
♦ If bulkhead boot is damaged, a new one must be installed.

♦ Make sure that bulkhead boot is seated correctly.

– Remove front wheels.
– Loosen suspension strut/control arm threaded connection (on‐

ly on left side of vehicle)
– Position suspension strut -1- in front of control arm -2- as seen
in direction of travel.
– Loosen nut -1-, remove bolt and remove both control arms
-2- upward (only on left side of vehicle).
WARNING

– Remove bolt -3- and remove threaded connection -4-.

– Remove tie rod downward out of steering arm or press out.

Note

– Secure wheel bearing housing -1- at left with help of tensioning

band -2- at suspension strut -3-.
– Remove metal nut -arrow-.

– Pry out clips.
– Disengage the electrical wire.
– Remove the plastic cover.
Relates to 6-Cylinder Engine with Factory-Installed Auxiliary
Heater
– Removing the transmission. Refer to ⇒ Manual Transmission;
Rep. Gr. 34 ; Removal and Installation or ⇒ Automatic Trans‐
mission; Rep. Gr. 37 ; Removal and Installation .
Relates to All Engines with a Factory-Installed Auxiliary Heater
– Where installed, remove the shield on the driver side. Refer to
-item 4- ⇒ Item 4 (page 261) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “2.5 Heat Shield Overview”, page 261 . unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted

– Remove threaded connections -1 and 2- of coolant pipes

-3 and 4- for the auxiliary heater from the body and shift the
coolant pipes for the auxiliary heater slightly forward.
Depending on the version, a bolt may be installed instead of nut
-1-.
Note
Be careful not to damage any components.
Continuation for All Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– On 6 and 8-cylinder engines, the heat shieldofon the driver side Copyright by AUDI AG.
with respect to the correctness information in this document.
must be removed. Refer to
⇒ “2.5 Heat Shield Overview”, page 261 .
♦ In order to remove the heat shield on the driver side with the
6-cylinder engines, the front catalytic converter must be re‐
moved.
♦ In order to remove the heat shield on the driver side with the
8-cylinder engines, the front exhaust pipe must be removed.
– Loosen bolt -1- approximately one turn

– Remove bolts -2 and 3-
– Swing steering gear on driver side forward in direction of trav‐
el.
– Place a pan underneath to catch hydraulic oil.
– Remove return line banjo bolt (22 mm AF) from steering gear.
With certain engine-transmission versions, banjo bolt can only be
loosened from wheel housing.
To do this, use an open socket insert SW 22 (commercially avail‐
able).

– Remove pressure line banjo bolt (SW 19 mm) -arrow- from

steering gear.
With certain engine-transmission versions, banjo bolt can only be
loosened from the wheel housing.
To do this, use an open socket insert SW 19 (commercially avail‐
able).

– Take out steering gear through left-hand wheel housing (sec‐
ond technician required).
Note
Make sure that bulkhead boot is not damaged by steering gear

pinion.
permittedInstalling
Center removed steering gear using Steering Centering Bolt -
VAS6224- .
– To do this, remove hex socket-head bolt -1- from steering
gear.
– Move steering rack until centering position on rack -arrow-
aligns with thread -2-.
– Hand-tighten Steering Centering Bolt - VAS6224- .
– Steering gear in area of bulkhead boot seat is lubricated with
lubricant G 052 745 A3.
– Position steering gear at plenum chamber (2nd technician
needed).
Make sure threads and contact surfaces of bolts are free of oil
and grease.
– Position bolt -1- but do not tighten yet.

– Swing steering gear on driver side forward in direction of travel

– Install return hose and tighten banjo bolt -2- (SW 22). Speci‐
fication: 47 Nm.
– Install pressure hose and tighten banjo bolt with check valve
-1- (SW 19). Specification: 35 Nm.
Note
♦ Always use new seals for banjo bolt.

♦ Pressure and return hose must not touch or come in contact
with other parts!
With certain engine-transmission versions, banjo bolts can only

be tightened from the wheel housing.
To do this, use an open socket insert SW 19 or SW 22 (commer‐
cially available). with respect to the correctness of information in this document. Copyright by AUDI AG.
– Reinsert bulkhead boot while noting installation location.

Tab on bulkhead boot must align with marking on body.
Note
♦ Replace damaged bulkhead boot if necessary.

♦ Make sure that bulkhead boot is seated correctly!
– Position bolt -2- but do not tighten yet.

– Install and fasten bolt -3-. Specification: 40 Nm + 90° turn.
– Now tighten bolts -1 and 2-. Specification: 40 Nm + 90° turn.
– Release steering lock.
– Bring steering wheel to center position then place universal
joint on steering pinion.
– Tighten bolt -arrow-. Specification: 30 Nm.

– Remove mounting device from steering column.
– Install driver's side stowage compartment. Refer to ⇒ Body

Applies to 6 Cylinder and 8 Cylinder Engines

– Remove the Steering Centering Bolt - VAS6224- from the
steering gear.
– Install the heat shield on the driver side and seal the steering
gear with the hex socket head bolt -1-.
Continuation for All

– Install plastic cover in wheel liner.
– Engage electrical line.
– Insert new bolt -2- and self-locking nut and tighten -item 8-
⇒ Item 8 (page 17) .
– Insert fork-head suspension strut in control arm and hand
tighten threaded connection -1-.
Bonded rubber bushings have a limited torsional range. Only
page 119 .

– Insert tie rod in steering arm to stop.
Note
Install tie rod in steering arm -1- only by hand and do not stress
tie rod end seal -2- when doing so.
– Install threaded connection -4- and tighten nut. Specification:

45 Nm.
– Install the bolt -3- and tighten it. Specification: 5 Nm.

– Remove the Steering Centering Bolt - VAS6224- from steering

gear.
1 - Hex socket head bolt.
2 - Threaded bore in steering gear.
– Seal the steering gear using the multi-point socket head bolt
-1-. Refer to ⇒ page 259 .
– After completing installation of steering gear, remove -3094- .
– Connect or install battery and install plenum chamber cover.
Refer to ⇒ Electrical system; Repair group 27; Battery; Re‐
moving and installing battery
– Mount wheels and tighten. Refer to ⇒ Wheel and Tire Guide;
– Tighten suspension strut/control arm threaded connection to
specified torque (90 Nm).
252 .
– Check the steering system for leaks. Refer to
– An axle alignment may beProtected
required. ReferCopying
by copyright. to for private or commercial purposes, in part or in whole, is not
⇒ “2.3 Wheel Alignment Test Prerequisites”,
permitted unless authorised page
by AUDI232 . AG does not guarantee or accept any liability
AG. AUDI
ment stand.
5.5 Tie Rod End

♦ Tool Insert, AF 22 - VAG1332/12-
Removing
– Remove wheel.
– Remove hex head nut -5- and remove bolt -2-.

Note
♦ The slits in the wheel bearing housing must not be widened

using a chisel or similar tool.
– Press tie rod downward
– Loosen hex head nut -3- and remove tie rod ball joint. Hex
head -4- on tie rod aids in counter holding.
– Make sure that tie rod ball joint and clamp hole on wheel bear‐
ing housing are free of grease.
Installing
Installation is performed in the reverse order of removal. Observe
the following when doing so:
– Screw tie rod ball joint onto tie rod to stop.
– Tighten combi-nut -3- -item 2- ⇒ Item 2 (page 260) , to do this,

use -VAG1332/12- . When tightening, counter hold at tie rod
hex head -4-.
– Align tie rod so that tie rod ball joint pints are in installation
location.
Note
tie rod end seal -2-bywhen
Protected doing
copyright. so.
Copying for private or commercial purposes, in part or in whole, is not

– Insert bolt -2- and screw on nut -5- and tighten. Specification:
45 Nm.
– Install the bolt -1- and tighten. Specification: 5 Nm.
ment stand.
5.6 Tie Rods

♦ Open-Jaw Torque Wrench Insert - VAG1923-
The left and right tie rods are identical.
They can be removed and installed with the steering gear in the
vehicle.
Removing
– Remove front wheel.
– Remove bolt -3- and remove threaded connection -4-.
Note
– Remove tie rod downward out of steering arm or press out.
Note

– Take out cover for tie rod. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Open spring hose clamp and the hose clamp -arrows- at boot.
– Pull the boot toward outside as far as possible.
– Remove tie rod using -VAG1923- .

Installing
– Install tie rod and tighten. Specification: 100 Nm.
– When installing boot, ensure that:
- Smaller boot diameter snaps into groove on tie rod.
- Boot does not get twisted.
– Replace the spring hose clamp and the hose clamp.
– Install tie rod cover.
– Align tie rod so that tie rod ball joint pints are in installation
location.
Note
tie rod end seal -2- when doing so.
– Install threaded connection -4- and tighten nut. Specification:

45 Nm.
– Install and fasten bolt -3-. Specification: 5 Nm.
ment stand.


♦ Drift - 3204-
♦ Spanner Wrench - 3212- or Water Pump Wrench - VAG1590-
if necessary
♦ Support Tool - 3369-
Removing
For All Vehicles
For All Vehicles except TFSI
– Remove front bumper. Refer to ⇒ Body Exterior; Rep. Gr. 63 ;
– Bring lock carrier into service position. Refer to ⇒ Body Exte‐
rior; Rep. Gr. 50 ; Description and Operation .
For All Vehicles
– Tension ribbed belt. Refer to ⇒ Engine Mechanical; Rep. Gr.
– Remove ribbed belt from power steering pump belt pulley.
– Position drip tray underneath.
– Remove the intake hose.
– Remove pressure hose, SW 22 mm.
For All Vehicles Except TFSI

– Remove the pulley of vane pump depending on version, coun‐
ter hold using -3212- do to do.

For All Vehicles with TFSI

– Remove power steering pump connections -1- through holes
in ribbed belt pulley.
For All Vehicles

– Remove connections -arrow- on back side of power steering
pump.
– Remove power steering pump
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation is the reverse of removal,
withwith special
respect attention
to the correctness to the in this document. Copyright by AUDI AG.
of information
following:
♦ Replace seals and gaskets.
♦ Before installing new pump on intake side, fill hydraulic oil and
turn by hand until oil escapes on pressure side.
♦ Secure all hose connections using new hose clamps. Refer to
the Parts Catalog.
– Turn the hub by hand until oil runs out of the pressure side.
– Fasten power steering pump to bracket.

– Install and fasten bolts -1-. Refer to ⇒ Engine Mechanical;
– Tighten bolt -arrow- on back side of power steering pump. Re‐

fer to ⇒ Engine Mechanical; Rep. Gr. 13 ; Removal and
Installation .
– Install new sealing rings onto banjo bolt.
– Tighten pressure hose banjo bold -item 24-
⇒ Item 24 (page 265)
– Install intake line. Installation location, refer to
page 270 .

– Tighten power steering pump belt pulley. Refer to ⇒ Engine

Mechanical; Rep. Gr. 13 ; Removal and Installation .
– Install ribbed belt. Refer to ⇒ Engine Mechanical; Rep. Gr.
When installing ribbed belt, make sure it is seated correctly on
pulleys.
– Install lock carrier. Refer to ⇒ Body Exterior; Rep. Gr. 50 ;
Description and Operation .
– Install bumper. Refer to ⇒ Body Exterior; Rep. Gr. 63 ; Re‐
moval and Installation .
– Fill hydraulic oil. Refer to the Parts Catalog.
– Start engine and check belt running.
252
– Check steering system for leaks.
permitted Refer
unless to by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
⇒ “4.6 Steering System, Checking fortheLeaks”,
with respect to correctnesspage 274 .in this document. Copyright by AUDI AG.
of information

♦ Spanner Wrench - 3212-
Removing
– Remove ribbed belt. Refer to ⇒ Engine Mechanical; Rep. Gr.
– Unbolt power steering pump pulley -arrows-, counter holding
with -3212- .
– Remove ignition coil.
Not for A4 with 3.0L Engine

– Remove rear power steering pump bolt with socket and ex‐
tension.
Note
On vehicles where a threaded pin and nut are installed, it may be

necessary to remove the intake manifold. Refer to ⇒ Fuel Injec‐
tion and Ignition; Rep. Gr. 24 ; Removal and Installation .

– Remove banjo bolt -1-.

– Remove suction hose -2-.
– Remove bolts -arrows- and remove power steering pump with
bracket.
Note
Place a cloth under hydraulic pressure lines to absorb escaping

hydraulic oil.
Installing
following:
Note

♦ Secure all hose connections using new hose clamps. Refer to
the Parts Catalog.
– Turn the hub by hand until oil runs out of the pressure side.
– Install power steering pump. Refer to ⇒ Engine Mechanical;
– Install new sealing rings onto banjo bolt.
– Tighten pressure hose banjo bolt. Specification: 50 Nm.
– Install intake line. Installation location, refer to
page 270 .
– Install ribbed belt. Refer to ⇒ Engine Mechanical; Rep. Gr.
252 .

♦ Torque Wrenchwith
1331 5-50Nm
respect - VAG1331-

Removing

– Remove bumper. Refer to ⇒ Body Exterior; Rep. Gr. 63 ;

– Bring lock carrier into service position. Refer to ⇒ Body Exte‐
rior; Rep. Gr. 50 ; Description and Operation .
– If necessary, remove cover over power steering oil reservoir.
– Remove ribbed belt. Refer to ⇒ Engine Mechanical; Rep. Gr.
Note
Identify direction of travel before removing ribbed belt. Reversed

direction of travel with a used belt can lead to malfunctions. When
installing ribbed belt, make sure it is seated correctly on pulleys.
Remove the Air Conditioning (A/C) Compressor
Note
♦ Lines remain connection and must notbybecopyright.

Protected bent. Copying for private or commercial purposes, in part or in whole, is not
♦ After removal, secure compressorwith
to respect
longitudinal member,
to the correctness for in this document. Copyright by AUDI AG.
of information
example with wire and do not allow to hang by coolant lines.
♦ When installing compressor make sure both centering bush‐
ings -B- are properly seated.
– Remove bolts -A-.
– Unbolt power steering pump pulley, counter holding with

-3212- .
Note
For better depiction, shown on removed engine.


– Place a pan underneath to catch hydraulic oil.
– Remove the hose clamp from the intake hose -1-.

– Remove the intake hose and move it to the side.
– Remove expansion hose -2-.
– Connect connection holes with plugs.

– Remove the bolts -1- (quantity: 3) and remove the power
steering pump -3-.
Installing
Installation is performed in the reverse order of removal. Observe
the following when doing so:
Tightening specifications, refer to ⇒ Engine Mechanical; Rep. Gr.
13 ; Description and Operation
Note

♦ Before installing new power steering pump on intake side, fill
hydraulic oil and turn by hand until oil escapes on pressure
side.
♦ Secure all hose connections with new hose clamps. Refer to
the Parts Catalog.

Marking -P- on suction hose -1- must align with formed seam on
power steering pump -2- -arrows-.
– Clean oiled places in engine compartment.
– Install A/C compressor. Refer to ⇒ Heating, Ventilation and
Air Conditioning; Rep. Gr. 87 ; Removal and Installation .
Install power steering pump ribbed belt. Refer to ⇒ Engine Me‐
chanical; Rep. Gr. 13 ; Removal and Installation .
– Install lock carrier. Refer to ⇒ Body Exterior; Rep. Gr. 50 ;
Description and Operation .
– Install bumper. Refer to ⇒ Body Exterior; Rep. Gr. 63 ; De‐
scription and Operation . authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless
252 .
– Checking steering system for proper seal. Refer to

Assembly Overview
Note
♦ Always replace seals.

♦ Do not reuse fluid you have drained.
♦ Only use hydraulic oil.

1 - Union Nut
❑ 40 Nm
❑ Note the installation po‐
sition.
3 - Banjo Bolt
❑ 50 Nm
❑ Always replace.
4 - Seal
❑ Always replace.
❑ Different versions. Allo‐
cation, refer to the Parts
Catalog.
❑ Fill with hydraulic oil be‐
fore installing.
❑ Checking delivery pres‐
sure. Refer to
Pump, Checking Deliv‐
ery Pressure”,
page 278 .
6 - Bolt
❑ 65 Nm
7 - O-ring
8 - Sleeve
❑ Lubricate the splines all
around with grease.
Parts Catalog.
9 - Input Shaft
❑ Lubricate the splines all around with grease.
10 - Spring
❑ Coat lightly with grease
permitted before by
unless authorised inserting in the
AUDI AG. AUDI AG input
does notshaft.
guarantee or accept any liability
11 - Buffer Stop
12 - Bolt
❑ 25 Nm
13 - Heat Shield
❑ Installed depending on the engine version.
14 - Bolt
❑ 9 Nm
15 - Clamp
❑ Tension using hose clamp pliers - VAG1275- .
❑ Always replace.
16 - Intake Hose
❑ Note the installation position.
❑ Markings must align.

❑ The lines -magnified area of the illustration- are shown without spring clips.

♦ Engine Support Bridge - 10-222 A-
♦ Oil Extractor - VAG1358 A- or
♦ Old Oil Collecting and Extracting Device - VAG1782-
Removing
– Remove power steering hydraulic oil from reservoir using -
VAG1358 A- or -VAG1782- .
– Remove engine cover. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Position -10-222 A- on bolted fender edges. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Engage support bridge hooks on engine lifting eyes.

– Slightly pretension engine using engine support bridge spin‐
dle, do not lift.
– Remove from left wheel.
– Loosen quick-release connectors -1-, remove bolts -2- and

remove noise insulation.
– Remove heat shield for left drive axle -arrows-.

– Remove left and right stabilizer bar bracket nuts -1- to -4-.
– Remove nuts -2-.

– Remove bolts -1 and 3- and remove left engine bracket.
– Remove left coolant line bracket -arrows-.
– Disconnect the connector -1- on the left engine mount.

– Remove nut -2- and remove engine mount. (If nut -2- cannot
be loosened due to poor accessibility, skip this step).
Note
Shown in illustration with engine removed.


– Remove return pipe from vane pump for power steering
-arrow-.
– Remove left engine support -arrows-.
– Remove the hydraulic pressure line at power steering pumpwith respect to the correctness of information in this document. Copyright by AUDI AG.
-arrow-.
– Move the hydraulic pressure line to the side.

– Remove bolts -1 and 2- and remove power steering pump.
Note
When removing power steering pump, note location of input shaft.
Installing
Especially observe the following during installation:
♦ Clean oiled places in engine compartment.
♦ Always replace the O-rings on the power steering pump drive
shaft.
♦ Always replace seals.

Depending on the Version of the Power Steering Pump

On vehicles that did not have spring -6- installed, repair kit with
spring cannot be installed.
– Complete power steering pump as shown in illustration and

install engine.
1 - Power steering pump
2 - O-ring
3 - Sleeve, grease the splines all the way around
4 - O-ring
5 - Drive shaft, grease the splines all the way around
6 - Spring, lubricate before installing into the drive shaft
7 - Buffer stop

Depending on the Version of the Power Steering Pump:

– Complete vane pump as shown in illustration and install on
engine.
1- Power steering pump
2- Seal
3- Drive shaft, when reinstalling, lubricate the drive shaft
splines and the power steering pump all the way around,
apply grease into the hole on the end of the shaft on the
engine side.
– Secure all hose connections with hose clamps appropriate to
the model. Allocation, refer to the Parts Catalog.
– Install engine bracket and tighten subframe. Refer to
⇒ “2.2 Front Suspension Overview”, page 16 .
– Install stabilizer bar. Refer to
– Bleed the steering. Refer to
252 .
– Check the steering for leaks. Refer to
⇒ “4.6 Steering System, Checking for Leaks”,
Protected pageCopying
by copyright. 274 .for private or commercial purposes, in part or in whole, is not
Tightening Specifications with respect to the correctness of information in this document. Copyright by AUDI AG.
Component Nm
Power steering pump to engine M8 22
M12 65
Engine supports to cylinder block 42
Coolant line bracket to
Oil pan upper section 10
Bracket 10
Hydraulic pressure line to the power steering 50
pump
Return line Engine support 10
to Coolant line 10
Engine mount Engine support 23
to Engine mount bracket 23
Drive axle heat shield to transmission 23

6 Special Tools

equipment required
♦ Hose Clamps Up to 25 mm
Dia. - 3094-
♦ Power Steering Test Unit -
VAG1402-
♦ Adapter Hose -
VAG1402/6-

♦ Engine Support Bridge - 10-222 A-

♦ Support Tool - 3369-
♦ Tool Insert, AF 22 - VAG1332/12-

♦ Oil Extractor - VAG1358 A- or Old Oil Collecting and Extracting

Device - VAG1782-
♦ Open-Jaw Torque Wrench Insert - VAG1923-
♦ Drip Tray for VAS6100 - VAS6208-
♦ Drift - 3204-
♦ Oil Extractor - VAG1358 A-

♦ Adapter Hose - VAG1402/6-
♦ Water Pump Wrench - VAG1590-
♦ Old Oil Collecting and Extracting Device - VAG1782-
Edition: A00559032921 LU 02/20/2015 - TMP

7 Revision History
Re Dat Job Type Feedback # Notes Editor
vi‐ e
sio
n
3
2 02/ Local Up‐ An axle Tom
20/ date alignment Perry
201 may be re‐
5 quired. Refer
to
1 7/8/ Factory Up‐ N/A Jim
201 date Harder
4
7. Revision History 315

Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in
this manual, we suggest you leave such repairs to an authorized Audi retailer or other qualified
shop. We especially urge you to consult an authorized Audi retailer before beginning repairs on
any vehicle that may still be covered wholly or in part by any of the extensive warranties issued by
Audi.
•= Disconnect the battery negative terminal (ground strap)whenever you work on the fuel system or
the electrical system. Do not smoke or work near heaters or other fire hazards. Keep an approved
fire extinguisher handy.
•= Audi is constantly improving its vehicles and sometimes these changes, both in parts and
specifications, are made applicable to earlier models. Therefore, part numbers listed in this
manual are for reference only. Always check with your authorized Audi retailer parts department
for the latest information.
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be
necessary to reestablish Transmission Control Module (TCM) basic settings using the VAG 1551
Scan Tool (ST).
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose.
Do not support a vehicle on cinder blocks,Protected
hollow by copyright. Copying for private or commercial purposes, in part or in whole, is not
tiles or other props that may crumble under
continuous load. Never work under a vehicle withthat is tosupported
respect solely
the correctness by a jack.
of information Never work
in this document. under
Copyright by AUDI AG.
the vehicle while the engine is running.
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before
disconnecting the battery or removing the radio. If the wrong code is entered when the power is
restored, the radio may lock up and become inoperable, even if the correct code is used in a later
attempt.
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block
the wheels to keep the vehicle from rolling. Disconnect the battery negative terminal (ground
strap) to prevent others from starting the vehicle while you are under it.
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to
yourself and others if you are tired, upset or have taken medicine or any other substances that
may impair you or keep you from being fully alert.
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work
with acid. Wear goggles, gloves and other protective clothing whenever the job requires working
with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when
you work near machine tools or running engines. If your hair, clothing, or jewelry were to get
caught in the machinery, severe injury could result.
=Page 1 of 3
© 2002 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual
property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be
modified or reposted to other sites, without the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are
designed to be used only once and are unreliable and may fail if used a second time. This
includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow the
recommendations in this manual - replace these fasteners with new parts where indicated, and
any other time it is deemed necessary by inspection.
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or
under the vehicle. Make sure the bulb is enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or oil. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create
dust by grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and
asbestos dust. Breathing asbestos can cause serious diseases such as asbestosis or cancer, and
may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running
machinery, or be crushed by heavy parts.
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read
all the instructions thoroughly, do not attempt shortcuts. Use tools that are appropriate to the work
and use only replacement parts meeting Audi specifications. Makeshift tools, parts and
procedures will not make good repairs.
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage
containers that might mislead someone into drinking from them. Store flammable fluids away from
fire hazards. Wipe up spills at once, but do not store the oily rags, which can ignite and burn
spontaneously.
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these
tools to tighten fasteners, especially on light alloy parts. Always use a torque wrench to tighten
fasteners to the tightening torque listed.
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping
hydrogen gas is ignited, it will ignite gas trapped in the cells and cause the battery to explode.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper
way to dispose of the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or
lake. Consult local ordinances that govern the disposal of wastes.
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C
system should be serviced only by trained automotive service technicians using approved
refrigerant recovery/recycling equipment, trained in related safety precautions, and familiar with
regulations governing the discharging and disposal of automotive chemical refrigerants.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect
the battery negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive
heat will increase system pressure and may cause the system to burst.
=Page 2 of 3
Version 1.0
Cautions & Warnings
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the
Transmission Control Module (TCM), the ABS control module, and the trip computer. In cases
where one or more of these components is not separately fused, disconnect the control module
connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system
(SRS), that automatically deploys an airbag in the event of a frontal impact. The airbag is operated
by an explosive device. Handled improperly or without adequate safeguards, it can be accidentally
activated and cause serious personal injury. To guard against personal injury or airbag system
failure, only trained Audi Service technicians should test, disassemble or service the airbag
system.
•= Do not quick-charge
with respect to the battery of(for
the correctness boostinstarting)
information forCopyright
this document. longerbythan
and do not exceedone minute,
AUDI AG.
16.5 volts at the battery with the boosting cables attached. Wait at least one minute before
boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be
tested by trained Audi Service technicians using the VAG 1551 Scan Tool (ST) or an approved
equivalent. The airbag unit must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that
may have been inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of
ignition away from the tire repair area. Inflate and deflate the tire at least four times before
breaking the bead from the rim. Completely remove the tire from the rim before attempting any
repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or
lap while the vehicle is in motion. Objects between you and the airbag can increase the risk of
injury in an accident.
I have read and I understand these Cautions and Warnings.
=Page 3 of 3
Version 1.0

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Service

Service Department. Technical Information

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Copyright © 2015 Audi AG, Ingolstadt D3E8001FE7A

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5.11 Tunnel Crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

42 - Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

5.4 Stub Axle Carrier/Wheel Bearing Housing, Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

5.15 Rear Differential Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

43 - Self-Leveling Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

44 - Wheels, Tires, Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

4.4 Rear Axle Toe, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

7 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

00 – General, Technical Data

1.1 Repairing Damaged Threads

1.2 Thread in Longitudinal Member, Servic‐

Wear protective goggles when drilling.

♦ Have the thread repair checked by the responsible foreman or

2 Description and Operation

2.1 Front Gas-Filled Strut, Venting and

Wear protective goggles while drilling.

– Drill a 3 mm hole -arrow A- through the outer shock absorber

Gas escapes when drilling.

– Continue drilling until the tube inside is drilled through (ap‐

Special tools and workshop equipment required

Wear protective goggles when drilling or sawing.

2 Rep. Gr.00 - General, Technical Data

– Drill a 3 mm diameter hole -arrow- through the outer shock

Gas escapes when drilling or sawing.

– Attach a pipe cutter as shown in illustration, and cut through

2.2 Rear Gas-Filled Strut, Venting

Wear protective goggles while drilling.

– Drill a hole 3 mm hole -arrow A- through outer shock absorber

Gas escapes when drilling.

– Continue drilling until the tube inside is drilled through (ap‐

Special tools and workshop equipment required

Wear protective goggles when drilling or sawing.

2. Description and Operation 3

– Drill a 3 mm diameter hole -arrow- through the outer shock

Gas escapes when drilling or sawing.

– Attach a pipe cutter as shown in illustration, and cut through

2.3 Power Steering Gear, Emptying

Room temperature must be at least 20 °C (68 °F) when emptying

4 Rep. Gr.00 - General, Technical Data

Vehicles up to VIN 400 000

♦ 1These target values correspond to a wheel offset of ET 39

♦ The specified values apply to all engine versions.

6 Rep. Gr.00 - General, Technical Data

4 Diagnosis and Testing

4.1 Shock Absorbers, Leaking

under the following circumstances:

♦ Oil leak (shown screened in illustration) is visible, but dull,

4.2 Shock Absorber, Noises

4.3 Shock Absorbers, Removed, Checking

4. Diagnosis and Testing 7

poor stretches of road. Moreover, they can be recognized by a

Shock absorbers are maintenance-free, shock absorber oil can‐

A removed shock absorber can be checked by hand as follows: