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Audi AMB Service Manual

A4 quattro 2005

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ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB

ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB

00 - GENERAL, TECHNICAL DATA

TECHNICAL DATA

Engine number

Fig. 1: Locating Engine Number

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The engine number ( "Engine code" and "Serial number" ) can be found on the rear left of the cylinder block.

Additionally there is a sticker on the toothed belt guard giving the "Engine code" and "Serial number".

The engine code is also given on the vehicle data sticker.

NOTE:

The engine code is also stamped on the front lifting eye (visible when



engine cover panel is removed).

Engine data

Engine code

Manufactured

Capacity

Power

Torque

Bore

Stroke

Compression ratio

RON

Injection/ignition system

Knock control

On Board Diagnostic

2005 Audi A4 Quattro

2005 Audi A4 Quattro

2:39:52 AM

2:39:49 AM

l

kW at RPM

Nm at RPM

diameter mm

mm

Page 1

Page 1

AMB

08.01 -->

1.781

125/5700

210/1750 to 4600

81.0

86.4

9.5

95 * See note

Bosch Motronic

yes

yes

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Summary of Contents for Audi AMB

Page 1 2005 Audi A4 Quattro 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 00 - GENERAL, TECHNICAL DATA TECHNICAL DATA Engine number Fig. 1: Locating Engine Number Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 2 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Oxygen sensor control Catalytic converter Charging *Standard unleaded RON 91 also permitted, however reduced power. Engine code Exhaust gas recirculation Intake manifold change-over function Camshaft timing control...
Page 3 2005 Audi A4 Quattro 2005 Audi A4 Quattro DTC INDEX DTC Index - 1.8L (AMB Engine) DTC INDEX DTC Index - 1.8L (AMB Engine) DTC INDEX DTC Index - 1.8L (AMB Engine) DIAGNOSTIC TROUBLE CODES (DTC) INDEX DTC Index - 1.8L (AMB Engine)
Page 4: O2 Sensor Circuit, Bank 1 Sensor 1
2005 Audi A4 Quattro DTC INDEX DTC Index - 1.8L (AMB Engine) REGULATION BEHIND P0038 16422 CATALYTIC CONVERTER, CHECKING . Mass or Volume Air Flow Circuit Check Mass Air Flow (MAF) Range/Performance Sensor -G70-. See MASS AIR P0101 16485 FLOW (MAF) SENSOR -G70-, CHECKING .
Page 5: Table Of Contents
2005 Audi A4 Quattro DTC INDEX DTC Index - 1.8L (AMB Engine) Sensor 1 Check oxygen sensor heater for oxygen sensors before Three Way Catalytic Converter (TWC). See P0135 16519 OXYGEN SENSOR (O2S) HEATER -Z19- BEFORE CATALYTIC CONVERTER, CHECKING .
Page 6: Sensor
2005 Audi A4 Quattro DTC INDEX DTC Index - 1.8L (AMB Engine) Check exhaust system for proper seal. See EXHAUST SYSTEM, CHECKING FOR LEAKS . Check Secondary Air Injection (AIR) system for proper seal. See SECONDARY AIR INJECTION (AIR) SYSTEM, CHECKING FOR PROPER SEAL .
Page 7 2005 Audi A4 Quattro DTC INDEX DTC Index - 1.8L (AMB Engine) Throttle/Pedal Position Sensor/Switch Module -J338-. See THROTTLE P0222 16606 "B" Circuit Low VALVE CONTROL MODULE - J338-, CHECKING . Throttle/Pedal Position Sensor/Switch P0223 16607 "B" Circuit High Fuel Pump Primary Circuit Check Fuel Pump (FP) Relay -J17- and activation.
Page 8 2005 Audi A4 Quattro DTC INDEX DTC Index - 1.8L (AMB Engine) P0328 16712 Single Sensor KNOCK SENSORS . P0332 16716 Knock Sensor 2 Circuit Low, Bank 2 P0333 16717 Knock Sensor 2 Circuit High, Bank 2 Camshaft Position Sensor "A" Circuit,...
Page 9 2005 Audi A4 Quattro DTC INDEX DTC Index - 1.8L (AMB Engine) SENSOR (HO2S) -G39- AND OXYGEN SENSOR REGULATION BEFORE CATALYTIC CONVERTER, CHECKING . Check Oxygen Sensor (O2S) and oxygen sensor control behind Three Way Catalytic Converter (TWC). P0420 16804...
Page 10 2005 Audi A4 Quattro DTC INDEX DTC Index - 1.8L (AMB Engine) Voltage supply too low Motronic Engine Control Module (ECM) P0562 16946 power supply checking Voltage supply too high P0563 16947 Overview of component locations Brake light switch F...
Page 11: Check Intake Air System For Leaks (False Air). See Intake
2005 Audi A4 Quattro DTC INDEX DTC Index - 1.8L (AMB Engine) ECM/PCM Power Relay Control Circuit Module (ECM) Power Supply P0687 17071 High Relay -J271- and activation. See CHECK MOTRONIC ENGINE Power supply relay J271 , load circuit CONTROL MODULE (ECM)
Page 12 2005 Audi A4 Quattro DTC INDEX DTC Index - 1.8L (AMB Engine) LEAKS (FALSE AIR) . P1292 17700 F265 - Map Controlled Engine Cooling P1293 17701 Thermostat Cooling system components, overview P1294 17702 Malfunction in cooling system Check Engine Coolant Temperature (ECT) Sensor -G62-.
Page 13 2005 Audi A4 Quattro 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB...
Page 14 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Injection/ignition system Bosch Motronic Knock control On Board Diagnostic Oxygen sensor control Catalytic converter Charging *Standard unleaded RON 91 also permitted, however reduced power. Engine code...
Page 15 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar, switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module --> 91 - COMMUNICATION Engine, removing and installing Fig.
Page 16 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Drip tray VAG1306  Socket attachment 15 mm A/F Matra V/175  Fig. 3: Identifying Hose Clip Pliers VAG 1921 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 17 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 4: Removing Rubber Seal From Plenum Chamber Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove rubber seal from plenum chamber cover in direction of - arrow -.
Page 18 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 6: Removing Securing Clips And Cowl Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen hex nuts - 4 - by a few turns.  Tilt wiper arm - 2 - slightly to remove it from wiper shaft.
Page 19 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 8: Air Cleaner Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove air cleaner cover - arrow -.  Fig. 9: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 20 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 10: Removing Bolts Securing Exhaust Pipe Of Auxiliary/Additional Heater To Sound Insulation Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - arrows - securing exhaust pipe of auxiliary/additional heater to sound insulation.
Page 21 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Unbolt sound insulation holder.  Fig. 13: Removing Air Duct In Front Of Charge Air Cooler Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove air duct in front of charge air cooler - arrows -.
Page 22 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 15: Disconnecting Coolant Hose From Oil Cooler Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect coolant hose from oil cooler - arrow - and drain remaining coolant.
Page 23 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Remove lower air hose - arrow - between turbocharger and lock carrier.  Fig. 18: Using 3093 To Clamp Off Inlet And Outlet Pipe Of Cooling Coil For Power Steering Hydraulic Fluid Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 24 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 20: Disconnecting Connector From A/C Pressure Switch F129 & Ambient Temperature Sensor Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector - 1 - from A/C pressure switch F129.
Page 25 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 55 HOOD, LIDS  55 - HOOD, LIDS for CABRIOLET  Fig. 22: Removing Top Coolant Hose From Radiator & Disconnecting Connectors For Left/Right Airbag Sensor Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 26 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB NOTE: Observe the rules for cleanliness when working on an automatic  transmission: -->  37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD.
Page 27 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 25: Disconnecting Fuel Supply Line And Set Aside Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect fuel supply line - 1 - and set aside.
Page 28 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB CAUTION: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection. Fig. 27: Disconnecting Fuel Supply Line Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 29 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Disconnect hose to secondary air injection pump motor - 8 -.  Move wires clear.  Unbolt air cleaner housing - 9 -.  Remove air cleaner.
Page 30 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 31: Removing Engine Control Module Courtesy of VOLKSWAGEN UNITED STATES, INC. Carefully pry off retainer bar with screwdriver - arrow -.  Fig. 32: Disengaging Electrical Connector Retainers And Disconnecting Electrical Connectors From Engine Control Module (ECM) J623 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 31 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connectors 1...4 from connector rail.  Unbolt wire connector - 5 -.  Fig. 34: Releasing Catches, Lifting Off Control Module Support & Pulling Auxiliary Relay Carrier In Electronics Box Upward To Remove Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 32 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 36: Disconnecting Connector From Secondary Air Injection (AIR) Pump Motor V101 & Hose From Pipe To Secondary Air Combination Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 33 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 38: Guiding Tube For Positive Wire To Starter Is Attached Using Bolt Securing Engine To Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC. Guide tube for positive wire to starter is attached using bolt securing engine to transmission.
Page 34 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 40: Separating Exhaust System At Clamp Courtesy of VOLKSWAGEN UNITED STATES, INC. Separate exhaust system at clamp.  Fig. 41: Removing Bolts Securing Catalytic Converter To Front Exhaust Pipe Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 35 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 42: Disconnecting Connectors From Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect both connectors - arrows - from transmission.  Fig. 43: Swiveling Tensioner In To Loosen Ribbed Belt Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 36 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Gauge Connector From Oil Pan Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect compressor clutch connector from air conditioning compressor.  Disconnect oil level gauge connector from oil pan.
Page 37 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB NOTE: Differing mounting holes are provided for different engine versions.  Fig. 47: Threaded Connections And Positioning Sleeves On Lower Engine Mounts Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 38 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Attach transmission support 3147 to support bar 10-222A.  Use support bar 10-222A to lift engine/transmission assembly until engine mount bolts are positioned  approx. 1 cm above engine supports.
Page 39 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 50: Separating Transmission From Engine And At Same Time Remove Torque Converter From Drive Plate Courtesy of VOLKSWAGEN UNITED STATES, INC. Separate transmission from engine and at same time remove torque converter from drive plate.
Page 40 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 52: Identifying Engine Transmission Bracket VW540 Courtesy of VOLKSWAGEN UNITED STATES, INC. When working on the engine, secure it to the engine stand using engine bracket VW540.
Page 41 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 53: Checking Torque Converter Is Correctly Positioned Courtesy of VOLKSWAGEN UNITED STATES, INC. If the torque converter has been correctly installed, the distance between bottom contact surfaces at threaded holes in torque converter and joint surface on torque converter bell housing with automatic transmission 01V, is approx.
Page 42 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 54: Disconnecting Fuel Supply Line And Set Aside Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten union nut of fuel supply line - 1 - to 22 Nm.
Page 43 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB After connecting battery, enter radio anti-theft code. Radio operating instructions.  Use electric window lifters to completely close door windows.  Then actuate all window lifter switches again for at least 1 second in "close" position to activate ...
Page 44 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 56: Identifying Engine/Transmission Mountings (Automatic/Manual Transmission) Courtesy of VOLKSWAGEN UNITED STATES, INC. Engine/transmission mountings (manual transmission) Item Bolt 1, 3, 4 M12 x 67...
Page 45 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB M12 x 90 M10 x 60 A: Dowel sleeves for centering Component Bolts/nuts except the following: Engine mount to subframe Engine support to engine mount...
Page 46 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB On vehicles equipped with Audi Telematics by OnStar, switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery --> 91 - COMMUNICATION After reconnecting vehicle battery, re-code and check operation of anti- theft radio.
Page 47 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 59: Lock Carrier In Service Position, Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - 45 Nm 2 - 45 Nm 3 - 10 Nm...
Page 48 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 7 - Hole in fender Removing Vehicles with auxiliary heater Fig. 60: Removing Bolts Securing Exhaust Pipe Of Auxiliary/Additional Heater To Sound Insulation Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 49 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 62: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - arrows -.  Disengage EVAP canister purge regulator valve N80 - 1 - from air duct.
Page 50 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Install in reverse order, paying attention to the following: Bolt lock carrier to longitudinal member (50 Nm) and to fenders (10 Nm).  Fig. 64: Bolt Lock Carrier To Longitudinal Member And To Fenders Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 51 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 65: Ribbed Belt For Generator, Vane Pump And Air Conditioner Compressor Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - 25 Nm 2 - Tensioning roller...
Page 52 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB For generator, power steering pump and air conditioning compressor  Removing and installing --> Bracket for generator, power steering pump and air conditioning  compressor, removing and installing...
Page 53 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Secured to bracket for generator, power steering pump and air conditioning compressor  18 - Special bolt, 25 Nm For idler wheel  Installing vibration damper/pulley Fig.
Page 54 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 67: Mandrel T10060 Courtesy of VOLKSWAGEN UNITED STATES, INC. Mandrel T10060  Removing NOTE: Mark direction of the ribbed belt with chalk or felt-tip pen prior to removal.
Page 55 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Install in reverse order.  NOTE: Before installing the ribbed belt, make sure that all mechanical units  (generator, air conditioning compressor, power steering pump) are securely attached.
Page 56 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB See Caution for disconnecting Telematics battery --> Engine, disassembling and assembling Disconnect battery Ground (GND) strap with ignition switched off.  Fig. 71: Disconnecting Top Coolant Hose From Radiator Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 57 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 73: Unbolting Power Steering Pump At Ribbed Belt Side Courtesy of VOLKSWAGEN UNITED STATES, INC. Unbolt power steering pump at ribbed belt side; bolts can be accessed through pulley. Do not disconnect ...
Page 58 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 75: Disconnecting Compressor Clutch Connector From Air Conditioning Compressor & Oil Level Gauge Connector From Oil Pan Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect air conditioning compressor connector - right arrow -.
Page 59 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 77: Removing/Installing Bracket For Generator, Power Steering Pump And A/C Compressor At Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bracket for generator, power steering pump and A/C compressor at bolts - 1 - through - 3 -.
Page 60 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 78: Removing/Installing Bracket For Generator, Power Steering Pump And A/C Compressor At Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Replace micro-encapsulated (threads coated with locking compound) collared bolts and position bracket ...
Page 61 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Then actuate all window lifter switches again for at least 1 second in "close" position to activate  automatic one-touch function. Set clock to correct time.
Page 62 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 79: Toothed Belt Drive, Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Toothed belt guard (lower) To remove, unbolt vibration damper  2 - 10 Nm Apply D 000 600 when installing ...
Page 63 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Carefully engage in center section of toothed belt guard when installing  5 - Toothed belt Mark direction of rotation with chalk or felt-tip pen before removing ...
Page 64 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 17 - 90 Nm + 1/4 turn (90 ° ) further Replace  Do not use oil  Use counterhold tool 3415 to loosen and tighten ...
Page 65 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Use counterhold tool 3415 to loosen and tighten central bolt.  Toothed drive belt, removing, installing and tensioning (Adjusting valve timing) Fig. 82: Identifying Special Tools - Toothed Drive Belt, Removing, Installing And Tensioning Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 66 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Removing With engine in vehicle.  Move lock carrier to service position --> Lock carrier in service position, overview.  Fig. 83: Removing Engine Cover By Lifting Up Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 67 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 85: Removing Upper Part Of Drive Belt Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove upper part of drive belt cover.  NOTE: Take special note of the installed position of the upper part of the drive ...
Page 68 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. Bring engine to TDC cylinder 1 by turning crankshaft in direction of engine rotation, using center  camshaft drive sprocket bolt on crankshaft. Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1 - arrows -.
Page 69 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 89: Inserting An Allen Wrench Into Socket-Head Courtesy of VOLKSWAGEN UNITED STATES, INC. Push pulley on counter-clockwise in direction of - arrow - with a socket head wrench using even but not ...
Page 70 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB cylinder. Risk of damaging valves/piston crown. Place drive belt on crankshaft sprocket (observe direction of rotation).  Install lower part of drive belt cover. ...
Page 71 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Align camshaft sprocket-to-cylinder head cover positioning marks and vibration damper-to-drive belt  cover positioning marks. Install drive belt in this order: water pump, tensioning pulley, camshaft sprocket.
Page 72 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 94: Adjusting Tensioning Roller Courtesy of VOLKSWAGEN UNITED STATES, INC. Turn eccentric bolt counter-clockwise in direction of - arrow - using special tool 3387.
Page 73 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Turn crankshaft two complete turns in direction of engine rotation until crankshaft is at TDC again.  Fig. 96: Identifying Marking On Camshaft Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 74 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB and with evenly applied force. When compressing the tensioner, excessive force can damage the tensioning pulley. Fig. 98: Inserting An Allen Wrench Into Socket-Head Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 75 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 100: Removing/Installing Ribbed Belt Tensioner Courtesy of VOLKSWAGEN UNITED STATES, INC. Install ribbed belt tensioner.  Install ribbed belt --> Ribbed belt, removing and installing.
Page 76 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 101: Identifying Torque Wrench V.A.G. 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC. torque wrench (5 to 50 Nm) VAG1331  Fig. 102: Identifying Marking Plate T10008 (For Engines With Hydraulic Tensioning Device) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 77 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 103: Removing Engine Cover By Lifting Up Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove engine cover by lifting up - arrows -.  Remove ribbed belt --> Ribbed belt, removing and installing.
Page 78 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 105: Identifying Marking On Camshaft Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Bring engine to TDC on cylinder 1 and turn crankshaft in direction of engine rotation using center ...
Page 79 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB excessive application of force until tensioner can be locked with locking plate T10008. NOTE: The stop tab of the eccentric bolt must not be bent.
Page 80 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB cover positioning marks. Install drive belt in this order: water pump, idler pulley, camshaft sprocket.  Tension drive belt.  Tightening Torques Component Drive belt cover at the cylinder block...
Page 81 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 109: Sealing Flanges And Flywheel/Drive Plate, Removing And Installing Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Oil seal Install with 10-203 ...
Page 82 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 5 - Gasket Replace  6 - Cylinder block Removing and installing crankshaft --> Crankshaft, removing and installing  Disassembling and assembling pistons and connecting rods --> Pistons and connecting rods, ...
Page 83 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Replace  15 - Sealing flange for intermediate shaft Crankshaft oil seal - pulley end, replacing Fig. 110: Identifying Special Tools - Crankshaft Oil Seal - Pulley End, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 84 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Engine in vehicle.  Lock carrier in service position --> Lock carrier, moving to service position.  Remove toothed belt --> Toothed drive belt, removing, installing and tensioning.
Page 85 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 113: Screwing Phillips-Head Bolt From 3083 Into Crankshaft Courtesy of VOLKSWAGEN UNITED STATES, INC. Before installing oil seal extractor, screw Phillips-head bolt from 3083 into crankshaft as far as it will go.
Page 86 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 115: Installing Guide Sleeve From 3083 Onto Crankshaft Journal Courtesy of VOLKSWAGEN UNITED STATES, INC. Install guide sleeve from 3083 onto crankshaft journal. ...
Page 87 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 117: Removing Crankshaft Toothed Belt Sprocket Courtesy of VOLKSWAGEN UNITED STATES, INC. Install crankshaft toothed belt sprocket. To do so, hold sprocket in position with counterhold 3415.
Page 88 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 119: Reversing Position Of Counterhold 10-201 To Loosen/Tighten Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Reverse position of counterhold 10-201 to loosen/tighten bolts. ...
Page 89 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 120: Identifying Counterhold VW 558 Courtesy of VOLKSWAGEN UNITED STATES, INC. Counterhold VW558  Hex bolt M8 x 45 and two M10 hex nuts ...
Page 90 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 122: Identifying Drive Plate, Grooved Washer And New Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC. Locate drive plate with shim - 2 - and packing plate - 1 -. Lug - arrow - must face toward torque ...
Page 91 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 124: Identifying Drive Plate, Grooved Washer And New Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove drive plate again and correct value by installing with/without shim - 2 -. Tighten bolts to 30 Nm ...
Page 92 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 125: Crankshaft, Removing And Installing Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Bearing shells 1, 2, 4 and 5 For bearing cap without oil groove ...
Page 93 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Bearing cap 1: pulley end  Bearing shell retaining lugs of cylinder block/bearing cap must be on same side  4 - Bearing shell 3 (top) For bearing cap without oil groove ...
Page 94 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB For bearing cap without oil groove  For cylinder block with oil groove  Do not interchange used bearing shells (mark)  11 - Chain sprocket Drive for oil pump ...
Page 95 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 127: Removing Engine Mount Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Top crankshaft bearing shells are graded at factory and identified on cylinder block as shown in ...
Page 96 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 128: Bearing Shell Identification By Color Codes Courtesy of VOLKSWAGEN UNITED STATES, INC. Lower crankshaft bearing shells supplied as replacement parts are always color-coded "yellow".
Page 97 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 129: Identifying Drift VW 207 C Courtesy of VOLKSWAGEN UNITED STATES, INC. Drift VW207C  Fig. 130: Kukko 21/2 Internal puller, Kukko 21/4 Internal puller, Kukko 22/2 Counter support Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 98 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 131: Pulling Out Pilot Needle Bearing Using Kukko 21/1 And Kukko 22/1 Courtesy of VOLKSWAGEN UNITED STATES, INC. Pull out pilot needle bearing using Kukko 21/1 and Kukko 22/1.
Page 99 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 133: Identifying Installation Depth Dimension Courtesy of VOLKSWAGEN UNITED STATES, INC. Installation depth for pilot needle bearing Distance a = 1.5 mm  Chain sprocket, removing and installing Special tools, testers and auxiliary items required Fig.
Page 100 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Oil pump chain sprocket, chain tensioner and chain, removing.  Fig. 135: Pulling Off Chain Sprocket From Crankshaft Courtesy of VOLKSWAGEN UNITED STATES, INC. Pull chain sprocket off crankshaft with puller - 2 - , use suitable washer - 1 - to protect end of crankshaft.
Page 101 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB drift sleeve 30-100. PISTONS AND CONNECTING RODS, DISASSEMBLING AND ASSEMBLING Pistons and connecting rods, disassembling and assembling Fig. 137: Pistons And Connecting Rods, Disassembling And Assembling Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 102 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Opens at: 2.5...3.2 bar  3 - Oil spray jet For piston cooling  4 - Connecting rod bearing cap Mark cylinder number - B - ...
Page 103 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 9 - Circlip 10 - Piston pin If difficult to move, heat piston to approx. 60 °C  Remove and install with VW222a  11 - Piston rings Offset gaps by 120 °...
Page 104 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB this use a piston without rings. Piston ring Dimensions in mm Wear limit Compression ring 1 0.20...0.40 Compression ring 2 0.20...0.40 Oil scraper ring 0.25...0.50 Checking ring to groove clearance Fig.
Page 105 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. Measure pistons approx. 10 mm from lower edge of skirt, at 90 ° to piston pin axis.  Deviation from nominal dimension: max. 0.04 mm ...
Page 106 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB CYLINDER HEAD, REMOVING AND INSTALLING Cylinder head, removing and installing CAUTION: Before beginning repairs on the electrical system: Obtain the anti-theft radio security code. Switch the ignition off.
Page 107 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 142: Cylinder Head, Removing And Installing Overview - Part I Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Cylinder head gasket Replace Removing cylinder head, --> Cylinder head, removing ...
Page 108 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB After replacing, fill with fresh coolant  3 - Oil deflector Note installed position  4 - Cylinder head bolt Replace  Note sequence when loosening ...
Page 109 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 14 - Coolant flange With coolant temperature sensor  15 - 10 Nm 16 - O-ring Replace  Part II Fig. 143: Cylinder Head, Removing And Installing Overview - Part II Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 110 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Note installed position  Replace  2 - 10 Nm 3 - 10 Nm 4 - O-ring For injector  Replace  5 - Fuel rail With injectors ...
Page 111 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 144: Checking Cylinder Head For Distortion Courtesy of VOLKSWAGEN UNITED STATES, INC. Check cylinder head for distortion at several points using knife-edge straightedge and feeler gauge.
Page 112 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 146: Sealing Transition Points Between Double Bearing Cap And Cylinder Head (2 Points) Courtesy of VOLKSWAGEN UNITED STATES, INC. Apply a small quantity of sealant Part No: AMV 174 004 01 to sides of joints - arrows - on upper sealing ...
Page 113 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 148: Loosening And Tightening Union Nut For Fuel Supply Line In Vehicles As Of 07.03 Courtesy of VOLKSWAGEN UNITED STATES, INC. CAUTION: Fuel system is under pressure! Before opening system, place rags around the connection point.
Page 114 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Remove engine cover - arrows -.  Fig. 150: Air Cleaner Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove air cleaner cover - arrow -.
Page 115 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 152: Crankcase Breather Line, Secondary Air Combination Valve Line And Heat Shield Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove crankcase breather line - 2 -.
Page 116 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 154: Cylinder Head Cover Nuts Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen nuts - arrows - on cylinder head cover and remove cylinder head cover.
Page 117 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Obtain and record radio anti-theft code for vehicles with coded radio.  See Caution for disconnecting Telematics battery --> Cylinder head, removing and installing Disconnect battery Ground strap with ignition switched off.
Page 118 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 2. Mass Air Flow (MAF) sensor G70 3. Wastegate bypass regulator valve N75 Disconnect hoses 4...7.  Disconnect hose to secondary air injection pump motor - 8 -.
Page 119 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Remove crankcase breather hose at cylinder head cover.  Remove line - 1 - on secondary air combination valve on cylinder head cover and heat shield - 3 -.
Page 120 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 161: Identifying Vacuum Hose, Oil Supply Line Bracket, Coolant Flange & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect vacuum hose - arrow - at combination valve.
Page 121 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 163: Cylinder Head Cover Nuts Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen nuts - arrows - on cylinder head cover and remove cylinder head cover.
Page 122 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Remove new cylinder head gasket from packaging just before installation.  Handle gasket extremely carefully. Damaging the silicone layer or indented  area will lead to leaks.
Page 123 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 166: Loosening Bolts On Turbocharger Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen bolts - 1 - and - 2 - on turbocharger bracket approx. 2 turns to avoid setting up stresses when ...
Page 124 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 168: Cylinder Head Bolt Tightening Sequence Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten cylinder head bolts in two stages in sequence shown as follows: ...
Page 125 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Perform adaptation of throttle valve control module: --> 24 - MULTIPORT FUEL INJECTION (MFI)  Tightening torques Component Intake manifold support to intake manifold to bracket...
Page 126 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 170: Compression Tester VAG1381 Or VAG1763 Courtesy of VOLKSWAGEN UNITED STATES, INC. Compression tester VAG1381 or VAG1763  Requirements Engine oil temperature at least 30 °C ...
Page 127 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 172: Ignition Coils, Ground Wire And Connectors Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connectors - 3 -.  Pull out ignition coils - 1 -.
Page 128 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Tightening torques Component Spark plugs in cylinder head VALVE GEAR, SERVICING Valve gear, servicing NOTE: Cylinder heads which have cracks between valve seats or between valve ...
Page 129 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 173: Valve Gear, Servicing Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - 65 Nm Use counterhold 3036 to loosen and tighten  2 - Camshaft sprocket For exhaust camshaft ...
Page 130 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Replacing --> Exhaust camshaft oil seal, replacing  4 - Cylinder head See note --> Valve gear, servicing  Checking valve guides --> Valve guides, checking ...
Page 131 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 12 - Bearing cap for intake camshaft Must be located on dowel sleeves  Dowel sleeves must be located in cylinder head  Note installed position ...
Page 132 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB With Valve 1 for camshaft adjustment N205  Checking --> Camshaft timing control, checking  Secure with retainer for chain tensioner 3366 before removing ...
Page 133 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Conical  Note installed position  27 - 25 Nm 28 - Housing for Camshaft Position (CMP) sensor G40 29 - 10 Nm Valve dimensions Fig.
Page 134 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Camshaft axial clearance, checking Special tools, testers and auxiliary items required Fig. 175: Identifying Dial Gauge Holder VW 387 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 135 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 177: Camshaft Axial Clearance, Checking - Exhaust Camshaft Courtesy of VOLKSWAGEN UNITED STATES, INC. Exhaust camshaft Wear limit for intake and exhaust camshafts: Axial clearance: max. 0.20 mm ...
Page 136 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 178: Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove engine cover - arrows -.  Remove top section of toothed belt guard --> Toothed drive belt, removing, installing and tensioning.
Page 137 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 180: Camshaft Gear Retaining Bolt Installed Into Camshaft To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC. To guide oil seal extractor, screw bolt for camshaft sprocket - arrow - into camshaft as far as it will go by ...
Page 138 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 182: Placing Guide Sleeve T10071/1 On Camshaft Pin Courtesy of VOLKSWAGEN UNITED STATES, INC. Install guide sleeve T10071/1 onto camshaft journal.  Slide oil seal over guide sleeve onto shaft journal.
Page 139 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 184: Identifying Camshaft Gear Thin Rib Toward Outside And TDC Marking Visible Courtesy of VOLKSWAGEN UNITED STATES, INC. Install camshaft sprocket.  Note installed position: ...
Page 140 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Intake camshaft oil seal, replacing Special tools, testers and auxiliary items required Fig. 186: Oil Seal Extractor 2085 Courtesy of VOLKSWAGEN UNITED STATES, INC. Oil seal extractor 2085 ...
Page 141 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 188: Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove engine cover - arrows -.  Remove top section of toothed belt guard --> Toothed drive belt, removing, installing and tensioning.
Page 142 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 190: Adapter 2085/1 Threaded In Camshaft Courtesy of VOLKSWAGEN UNITED STATES, INC. To guide oil seal extractor, screw bolt 2085/1 into camshaft as far as it will go by hand.
Page 143 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 192: Identifying A PTFE Seal (Teflon) & Inner Coil Spring Type Seal Courtesy of VOLKSWAGEN UNITED STATES, INC. Distinguishing features: Conventional shaft oil seal has just one sealing lip - arrow 1 - which is pressed ...
Page 144 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Installing oil seal with ring spring NOTE: Do not oil sealing lip of oil seal.  Fig. 194: Guide Sleeve 3241/2 On Camshaft Pin Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 145 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Component CMP sensor rotor ring to camshaft CMP sensor housing to cylinder head Camshafts and camshaft adjuster, removing and installing Special tools, testers and auxiliary items required Counterhold 3036 ...
Page 146 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 197: Disconnecting Connector At Camshaft Adjuster Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector - arrow - at camshaft adjuster.  Remove cylinder head cover --> Cylinder head cover, removing and installing.
Page 147 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 199: Checking Position Of Camshafts To Each Other Courtesy of VOLKSWAGEN UNITED STATES, INC. Re-check TDC position of camshafts:  Mark on two camshafts must be in line with - arrows - on bearing caps.
Page 148 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Do not mark chain with a center punch or by making a notch, etc.  Fig. 201: Identifying Bearing Cap Positions Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 149 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 203: Sealant Application Area Identified By Hatched Surface Courtesy of VOLKSWAGEN UNITED STATES, INC. Replace rubber/metal gasket for camshaft adjuster and apply a thin coat of sealant AMV 188 001 02 to ...
Page 150 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 205: First And Sixteenth Drive Chain Rollers Installed On Chain Gears Courtesy of VOLKSWAGEN UNITED STATES, INC. If new chain is installed, distance between notches - A - and - B - on camshafts must be 16 rollers on ...
Page 151 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 207: Checking Position Of Camshafts To Each Other Courtesy of VOLKSWAGEN UNITED STATES, INC. Two markings on camshafts must be in line with two - arrows - on bearing caps - arrows -.
Page 152 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 209: Identifying Double Bearing Cap Sealant Application Area Courtesy of VOLKSWAGEN UNITED STATES, INC. Apply thin coat of sealant AMV 188 001 02 to shaded area on double bearing cap and install bearing cap ...
Page 153 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 211: Identifying Marking On Camshaft Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Align marking on camshaft sprocket with marking on cylinder head cover.
Page 154 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Hydraulic valve lifters, checking Special tools, testers and auxiliary items required Feeler gauge  Wooden or plastic wedge  NOTE: Hydraulic valve lifters cannot be repaired.
Page 155 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Use wooden or plastic wedge to push down valve lifter. Replace valve lifter if an 0.20 mm feeler gauge  can be inserted between camshaft and valve lifter.
Page 156 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Pressure hose VW653/3  Spark plug wrench 3122B  Valve seal removal tool 3364 ...
Page 157 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Hammer jammed valve keepers on all five valves loose using a plastic hammer.  Exhaust side Fig. 215: Screwing Snap-In Device VAS5161/6 With Attaching Fork VAS5161/4 Onto Stud On Cylinder Head Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 158 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 216: Releasing Pressure Fork Courtesy of VOLKSWAGEN UNITED STATES, INC. Screw snap-in device VAS5161/6 with attaching fork VAS5161/4 onto stud on cylinder head. ...
Page 159 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 218: Identifying Valve Seal Removal Tool 3364 Courtesy of VOLKSWAGEN UNITED STATES, INC. Pull off valve stem seals with 3364.  Installing NOTE: A plastic sleeve - A - is included with new valve stem seals.
Page 160 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Push valve stem seal onto plastic sleeve.  Carefully press valve stem seal onto valve guide using seal driver 3365.  Remove plastic sleeve. ...
Page 161 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 222: Inserting Cartridge VAS5161/8 Back Into Guide Bushing VAS5161/13 Or VAS5161/14 Courtesy of VOLKSWAGEN UNITED STATES, INC. Insert cartridge VAS5161/8 back into guide bushing VAS5161/13 or VAS5161/14.
Page 162 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Universal dial indicator holder VW387  Dial indicator  Work sequence Fig. 224: Identifying Special Tool - VW 387 Installed Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 163 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB NOTE: When repairing engines with leaking valves, it is not sufficient to reface  valve seats and replace valves. Valve guides must also be checked for wear.
Page 164 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Outer intake valves Center intake valves Exhaust valves 31.0 mm 32.2 mm 31.9 mm Measured distance minus minimum dimension = maximum permissible refacing dimension. Example for outer intake valve: Measured distance 31.4 mm...
Page 165 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 45 ° Valve seat angle ß 30 ° Adjustment angle (top) gamma 60 ° Adjustment angle (bottom) CAMSHAFT TIMING CONTROL, CHECKING Camshaft timing control, checking The intake camshaft is adjusted according to load and engine speed.
Page 166 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 227: Identifying Special Tools - Camshaft Adjustment Valve, Checking Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Multimeter VAG1526A ...
Page 167 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector - arrow - at camshaft adjuster.  Fig. 229: Measuring Resistance Between Terminals Of Solenoid Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 168 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 230: Disconnecting Connector At Camshaft Adjuster Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector - arrow - at camshaft adjuster.  Fig. 231: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 169 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB If LED lights up: Check actuation.  Checking actuation Fig. 232: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect voltage tester VAG 1527B to contact 1 (positive) and 2 of connector.
Page 170 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 233: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Check for open circuit and short to Ground/positive in following wiring connection: ...
Page 171 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Refer to --> 01 - MAINTENANCE  01 - MAINTENANCE for CABRIOLET  Part I Fig. 234: Lubrication System Components, Removing And Installing - Part I Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 172 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Apply silicone sealant: D 176 404 A2 before installing  Removing and installing --> Oil pan, removing and installing  4 - Oil pump With pressure relief valve, 12 bar ...
Page 173 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 2 pcs.  13 - O-ring Always replace  14 - 16 Nm 15 - Suction line Clean strainer if soiled  16 - Baffle plate...
Page 174 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 235: Oil Spray Jet And Pressure Relief Valve Courtesy of VOLKSWAGEN UNITED STATES, INC. 1. Oil spray jet (for piston cooling) 2. Bolt with pressure relief valve, 27 Nm 3.
Page 175 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 236: Lubrication System Components, Removing And Installing - Part II Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Screw plug, 40 Nm 2 - Sealing ring Always replace ...
Page 176 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 5 - Gasket Always replace  6 - Oil retention valve Tighten to 8 Nm  Integrated in oil filter holder  7 - O-ring Always replace ...
Page 177 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 18 - Sealing ring If seal is leaking, cut open and replace  19 - 15 Nm plus additional 90 ° turn Always replace ...
Page 178 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 237: Identifying Special Tools - Oil Pan, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Support bar 10-222A ...
Page 179 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Lock carrier in service position --> Lock carrier, moving to service position.  Fig. 238: Removing Noise Insulation Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 180 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 240: Threaded Connections And Positioning Sleeves On Lower Engine Mounts Courtesy of VOLKSWAGEN UNITED STATES, INC. Mark positions of bolted connections - 1 - and locating sleeves - 2 - underneath right and left engine ...
Page 181 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 242: Installing Engine Support Bridge 10-222A Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove eye from lifting tackle 2024A.  Insert pin - 1 - back into center hole of lifting tackle and secure it using cotter pin.
Page 182 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 244: Disconnecting Connector For Oil Level Thermal Sensor -G266- Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector from oil level sensor - arrow -.
Page 183 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB NOTE: Please ignore items - 1 - and - 2 - in the illustration.  Unbolt holder for ATF line from engine.  Move ATF lines clear to one side.
Page 184 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 248: Subframe Supported Using Workshop Crane V.A.G 1202 A Courtesy of VOLKSWAGEN UNITED STATES, INC. Support subframe with workshop crane VAG1202A.  Fig. 249: Removing Front Bolts From Left And Right Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 185 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 250: Left Transmission Mount Nut Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen nuts - arrow - on left transmission mount until it is flush with end of bolt (approx. 4 turns on ...
Page 186 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 252: Right Transmission Mount Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen rear bolt - 2 - on right transmission mount a few turns, remove front bolt - 1 - on right ...
Page 187 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 254: M10 Bolts Removal Sequence Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove M10 bolts - arrows -.  Loosen bolts -1 to 18- in diagonal sequence.
Page 188 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Remove baffle plate and carefully remove sealant remaining on cylinder block.  Fig. 256: Removing Sealant Residue From Oil Pan With Rotating Brush Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 189 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Silicone sealant D 176 404 A2  Thickness of sealant bead: 2 to 3 mm  NOTE: The sealant bead must not be thicker than 3 mm, otherwise excess sealant ...
Page 190 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 259: M10 Bolts Removal Sequence Courtesy of VOLKSWAGEN UNITED STATES, INC. Pre-tighten bolts -1 to 18- to 5 Nm in diagonal sequence.  Tighten bolts securing oil pan to transmission to 45 Nm.
Page 191 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB should protrude by dimension - a - = 0.8 mm from cylinder block - 2 -. After installing oil pan, wait for approx. 30 minutes for sealant to dry ...
Page 192 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE  Tightening torques Component Oil pan to cylinder block Oil pan to transmission Torque reaction support stop to oil pan...
Page 193 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Install in reverse order, paying attention to the following: Insert dowel sleeves at top of oil pump:  Installed position of oil pump shaft/chain sprocket: Can only be installed in one position ...
Page 194 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 263: Identifying Special Tools - Oil Pressure And Oil Pressure Switch, Checking Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Oil pressure tester VAG1342 ...
Page 195 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Replace oil pressure switch.  Start engine.  NOTE: Switching point of oil pressure switch can be reached when engine is  cranked on starter motor, so watch tester and LED while starting engine.
Page 196 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Engine oil The vehicle is filled at the factory with a high-quality multi-grade oil which can be used all year round except in extremely cold climates.
Page 197 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB area). NOTE: Oil level must not be above mark - a - on dipstick.  19 - ENGINE - COOLING SYSTEM COOLING SYSTEM COMPONENTS, REMOVING AND INSTALLING Cooling system components, removing and installing CAUTION: Hot steam can escape when cap on expansion tank is opened.
Page 198 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 267: Cooling System Components, Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Heat exchanger for heater After replacing, fill with fresh coolant ...
Page 199 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 5 - Intake manifold 6 - Coolant hose (lower) 7 - Coolant hose (top) 8 - Radiator Removing and installing --> Radiator, removing and installing ...
Page 200 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 268: Identifying Special Tools - Cooling System, Draining And Filling Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Refractometer T10007 ...
Page 201 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Open cap on coolant expansion tank.  Fig. 269: Removing Sound Insulation Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove sound insulation - arrows -. ...
Page 202 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 271: Disconnecting Coolant Hose From Oil Cooler And Drain Off Remaining Coolant Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect coolant hose from oil cooler - arrow - and drain off remaining coolant.
Page 203 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Only use clean drinking water for mixing coolant.  If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
Page 204 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. Screw adapter VAG1274/8 onto coolant expansion tank.  Fit special tool VAG1274/10 onto adapter.  Fill cooling system with coolant.
Page 205 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 274: Identifying Special Tools - Cooling System Components, Servicing, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Refractometer T10007 ...
Page 206 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Drain coolant --> Cooling system, draining and filling.  Remove coolant hose couplers from top and bottom of radiator.  Fig. 275: Removing Air Ducts On Left/Right Of Radiator Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 207 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 277: Unbolting Condenser From Radiator Courtesy of VOLKSWAGEN UNITED STATES, INC. Unbolt condenser - arrows - from radiator.  NOTE: To prevent damage to condenser and refrigerant lines/hoses ensure that ...
Page 208 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 63 - BUMPERS for CABRIOLET  Coolant fan, removing and installing Fig. 279: Identifying Special Tools - Cooling System Components, Servicing, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 209 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB NOTE: Always replace gaskets and sealing rings.  Remove front bumper: -->  63 BUMPER  63 - BUMPERS for CABRIOLET  Move lock carrier to service position --> Lock carrier, moving to service position.
Page 210 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Install in reverse order, paying attention to the following: Install front bumper: -->  63 BUMPER  63 - BUMPERS for CABRIOLET  Coolant pump, removing and installing Fig.
Page 211 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Torque wrench (5 to 50 Nm) VAG1331  Assembly tools for spring clips VAS5024A  Removing NOTE: Always replace gaskets and sealing rings.  Remove toothed belt completely so that it cannot be damaged by coolant.
Page 212 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 284: Inserting Coolant Pump Into Cylinder Block And Securing Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Moisten new O-ring - 3 - with coolant.
Page 213 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 285: Identifying Special Tools - Cooling System, Checking For Leaks Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Cooling system tester VAG1274 ...
Page 214 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Open cap on coolant expansion tank.  Fig. 286: Installing Tester VAG1274 With Adapter VAG1274/8 Onto Expansion Tank Courtesy of VOLKSWAGEN UNITED STATES, INC. Install tester VAG1274 with adapter VAG1274/8 onto expansion tank.
Page 215 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Pressure relief valve must open at pressure of 1.4 to 1.6 bar.  21 - TURBOCHARGER, G-CHARGER CHARGE AIR PRESSURE SYSTEM WITH TURBOCHARGER, CHECKING Charge air pressure system with turbocharger, checking NOTE: Observe rules for cleanliness -->...
Page 216 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 288: Boost Pressure Regulation And Vacuum Control System, Connection Diagram For Vehicles Up To 06.03 Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Mechanical recirculation valve...
Page 217 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 6 - Check valve Installed position: Arrow on valve points in direction of flow, as shown in illustration  7 - To EVAP canister 8 - Evaporative Emission (EVAP) Canister Purge Regulator Valve N80...
Page 218 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 21 - Recirculating valve for turbocharger N249 Component location: Below intake manifold  22 - Vacuum diaphragm for boost pressure regulation When combination valve is opened, mechanical boost pressure regulation valve in turbocharger is opened ...
Page 219 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 4 - Wastegate Bypass Regulator Valve N75 5 - Air filter With Mass Air Flow (MAF) Sensor G70  6 - Check valve Installed position: Arrow on valve points in direction of flow, as shown in illustration ...
Page 220 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Installed position: Arrow on valve points in direction of flow, as shown in illustration  21 - Secondary Air Injection (AIR) Solenoid Valve N112 Component location: Below intake manifold ...
Page 221 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 291: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051 Courtesy of VOLKSWAGEN UNITED STATES, INC. VAS5051 with VAS5051/1  VAG1551 with VAG1551/3A ...
Page 222 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 292: Connecting T-Piece And Measuring Hose Of Turbocharger Tester VAG1397A To Intake Manifold Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect T-piece and measuring hose of turbocharger tester VAG1397A to intake manifold (front).
Page 223 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Before performing test, drive vehicle at brisk speed for at least 3 km  without stopping (i.e. along route without traffic lights, etc.). A second mechanic is required to note readings on tester when vehicle is ...
Page 224 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Charge air pressure below specification Wastegate bypass regulator valve N75 faulty -  -> Wastegate bypass regulator valve N75 , checking , checking Hoses to Wastegate bypass regulator valve ...
Page 225 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB misfiring at high engine speeds. Effects of leakage at intake and exhaust end Leakage downstream of Mass Air Flow sensor Effect: Loss of power ...
Page 226 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 295: Checking Charge Air Pressure System Using Vag1687 Charge Air System Tester Courtesy of VOLKSWAGEN UNITED STATES, INC. Check the charge air pressure system using the VAG1687 Charge air system tester.
Page 227 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Special tool VAG 1687/1 pressure adapter, installing (1.8L Turbo) Separate intake hose from Mass Air Flow (MAF) sensor assembly.  Fig. 297: Special Tool VAG 1687/1 Pressure Adapter, Installing (1.8L Turbo) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 228 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Turbo). Special tool LKI9210 (Evaporative system leak detector), preliminary set-up Connect smoke generator leads to vehicle battery.  Fig. 299: Special Tool LKI9210 (Evaporative System Leak Detector), Preliminary Set-Up Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 229 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 300: Special Tool VAG1687 , Connecting To Pressure Adapter VAG1687/1 (1.8L Turbo) Courtesy of VOLKSWAGEN UNITED STATES, INC. VAG1687 is shown connected to VAG1687/1 - black arrow - Shop air supply will be connected to VAG1687 at - white arrow - Perform pressure test.
Page 230 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB CAUTION: DO NOT pressurize the system above 0.5 bar! Doing so may force oil into the intake system which can damage the engine. Slowly open outlet valve - 4 - (after gauge) to test hose connections.
Page 231 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB With VAS5051 diagnostic tool connected: Erase DTC memory.  Effects of leakage at exhaust end Effect: Charge air pressure too low, possible exhaust smell, soot traces in engine compartment ...
Page 232 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Vacuum hand pump VAG1390  Work sequence Fig. 304: Connecting Hand Vacuum Pump V.A.G 1390 To Vacuum Connection Of Charge Pressure Bypass Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 233 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 305: Identifying Special Tools - Recirculating Valve For Turbocharger N249 , Checking Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Multimeter VAG1526A or equivalent ...
Page 234 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Requirement Vehicle Diagnostic, Testing and Information System VAS5051 or Scan Tool VAG1551 must be  connected. Work sequence NOTE: The Recirculating valve for turbocharger N249 and its wiring are monitored ...
Page 235 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 307: Connect Test Hose To Valve Connection Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect test hose to valve connection marked with - arrow -.
Page 236 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 308: Identifying Secondary Air Injection (AIR) Solenoid Valve -N112- Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector from Recirculating valve for turbocharger N249- - 1 -.
Page 237 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Requirements Fuse for recirculating valve OK --> Electrical Wiring Diagrams, Troubleshooting and Component  Locations Fuel pump relay OK --> 24 - MULTIPORT FUEL INJECTION (MFI) ...
Page 238 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 311: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect voltage tester VAG1527B to contact 1 (positive) and 2 of connector.
Page 239 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB If wiring is OK: Replace engine control module.  Wastegate bypass regulator valve N75 , checking Fig. 313: Identifying Special Tools - Wastegate Bypass Regulator Valve N75 , Checking Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 240 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Vehicle Diagnostic, Testing and Information System VAS5051 VAS5051 with VAS5051/1  Scan Tool VAG1551 with VAG1551/3A  Requirement Vehicle Diagnostic, Testing and Information System VAS5051 or Scan Tool VAG1551 must be ...
Page 241 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB ..and must open and close (can be checked by blowing into test hose).  If valve does not click: Check internal resistance of valve. ...
Page 242 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fuel pump relay OK --> 24 - MULTIPORT FUEL INJECTION (MFI)  Fig. 316: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 243 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 317: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect voltage tester VAG1527B to contact 1 (positive) and 2 of connector.
Page 244 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Connector contact Test box VAG1598/31 socket If necessary, eliminate open circuit/short circuit.  If wiring is OK: Replace engine control module.  Charge air pressure sensor G31 , checking Fig.
Page 245 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Multimeter VAG1526A or equivalent  Connector test set VAG1594A  Adapter VAG1598/31  Vehicle Diagnostic, Testing and Information System VAS5051 VAS5051 with VAS5051/1  Scan Tool VAG1551 with VAG1551/3A ...
Page 246 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 321: Identifying Connector Terminals 1 And 4 Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect multimeter and measure voltage between contacts 1 and 3 of connector.
Page 247 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 323: Identifying Connector Terminals 1 And 4 Courtesy of VOLKSWAGEN UNITED STATES, INC. Check for open circuit and short to Ground/positive in following wiring: ...
Page 248 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 324: Identifying Connector Terminals 1 And 4 Courtesy of VOLKSWAGEN UNITED STATES, INC. Check for open circuit and short to Ground/positive in following wiring connection: ...
Page 249 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 325: Turbocharger, Removing And Installing - Overview (Part I) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - 30 Nm Only use genuine bolt ...
Page 250 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 5 - 30 Nm 6 - 35 Nm 7 - Oil supply line Tighten union nut to 23 Nm  8 - 3.5 Nm 9 - Heat shield...
Page 251 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 20 - Coolant supply line 21 - Banjo bolt, 35 Nm Apply D 000 600 when installing  22 - 10 Nm Apply D 000 600 when installing ...
Page 252 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 326: Turbocharger, Removing And Installing - Overview (Part II) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Vacuum hose To Recirculating valve for turbocharger N249 ...
Page 253 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB To turbocharger connection  5 - Hose To EVAP valve  6 - Line To crankcase breather  7 - 10 Nm 8 - Hose To crankcase breather line ...
Page 254 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 327: Identifying Hose Clamps 3094 Courtesy of VOLKSWAGEN UNITED STATES, INC. Hose clamps 3094  Removing Fig. 328: Noise Insulation Tray Retainers Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 255 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 329: Locating Securing Bolts For Ribbed Belt Tensioner For A/C Compressor Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen securing bolts of tensioning roller for ribbed belt of air conditioning compressor - arrows - , ...
Page 256 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 331: Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove engine cover - arrows -.  Fig. 332: Air Cleaner Cover Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 257 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Remove bolts - arrows -.  Remove air duct - 1 - and - 2 -.  Fig. 334: Disconnecting Wiring Connectors From Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 258 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 335: Removing Secondary Air Line Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove secondary air line. To do so, pull off hoses - arrows - and remove bolts - 1 -.
Page 259 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 337: Using Hose Clamp 3094 To Clamp Off Coolant Return Hose To Turbocharger Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - 1 - and - 3 - of oil supply line.
Page 260 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Top off cooling system --> Cooling system, draining and filling.  Check oil level --> Oil level, checking.  NOTE: After installing turbocharger, run engine for approx. 1 minute at idling ...
Page 261 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 338: Charge Air Cooling Components, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Air duct 2 - Rubber grommet 3 - Air hose Between charge air cooler and air duct in lock carrier ...
Page 262 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Replace if damaged  6 - Charge air pressure sensor G31 7 - 3 Nm 8 - Rubber grommet 9 - Bracket Riveted to body ...
Page 263 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 340: Removing Air Duct In Front Of Charge Air Cooler Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove air duct in front of charge air cooler - arrows -.
Page 264 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Exhaust system components, removing and installing (Front wheel drive vehicles) Fig. 341: Exhaust System Components, Removing And Installing (Front Wheel Drive Vehicles) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 265 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Grease threads only with hot bolt paste G 052 112 A3; paste must not be allowed to come into contact  with slits in sensor body Checking: -->...
Page 266 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 16 - Mounting 17 - 25 Nm 18 - Rear muffler (left) Tailpipe can be replaced  Rear muffler and center muffler are one unit as original equipment but can be replaced separately for ...
Page 267 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 23 - 25 Nm 24 - Mounting 25 - 25 Nm 26 - Mounting 27 - M8 bolt 28 - Washer 29 - Spring 30 - Lug...
Page 268 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Installed position of rear clamps Fig. 343: Installed Position Of Rear Clamps Courtesy of VOLKSWAGEN UNITED STATES, INC. Install clamps so that ends of bolts are not below bottom circumference of clamps.
Page 269 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Exhaust system components, removing and installing (All wheel drive vehicles) Fig. 345: Exhaust System Components, Removing And Installing (All Wheel Drive Vehicles) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 270 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Grease threads only with hot bolt paste G 052 112 A3; paste must not be allowed to come into contact  with slits in sensor body Checking: -->...
Page 271 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 16 - Rear muffler (left) Tailpipe can be replaced  Rear muffler and center muffler are one unit as original equipment but can be replaced separately for ...
Page 272 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 23 - 25 Nm 24 - Mounting 25 - M8 bolt 26 - Washer 27 - Spring 28 - Lug 29 - Spacer sleeve 30 - 25 Nm...
Page 273 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 347: Installed Position Of Rear Clamp Courtesy of VOLKSWAGEN UNITED STATES, INC. Install clamps so that ends of bolts are not below bottom circumference of clamps.
Page 274 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Connecting pipe can be cut through at point marked to allow center and rear mufflers to be replaced  separately. Cutting point is marked with indentation on outside of exhaust pipe.
Page 275 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 350: Position Center Of Clamp Strap Over Saw-Cut Courtesy of VOLKSWAGEN UNITED STATES, INC. When installing, position center of clamp strap over saw-cut. ...
Page 276 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Installed position of clamp Installed position of rear clamps  Align exhaust system stress-free --> Exhaust system - vehicles with all wheel drive, aligning stress- ...
Page 277 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 354: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - arrows -.  Disengage EVAP canister purge regulator valve N80 - 1 - from air duct - 2 -.
Page 278 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 356: Disconnect Wires/Unplug Connectors From Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect hose to secondary air injection pump motor - 8 -.  Move wiring clear.
Page 279 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 358: Loosening Bolts On Turbocharger Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen bolts - 1 - and - 2 - a few turns.
Page 280 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 360: Removing Bolts Of Oil Supply Line & For Turbocharger Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - 1 - and - 2 - of oil supply line.
Page 281 Fig. 362: Disconnecting 4-Pin Connectors Of Oxygen Sensors Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect 4-pin connectors of oxygen sensors and move wires clear.  1. (Brown) to O2S Behind TWC G130 (only with engine code AMB) 1:01:29 AM Page 269...
Page 282 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 2. (Black) to HO2S G39 Fig. 363: Air Cleaner Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove air cleaner cover - arrow -.  Fig. 364: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 283 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 365: Disconnect Wires/Unplug Connectors From Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect wiring connectors from:  1. EVAP valve 2. Mass Air Flow sensor 3.
Page 284 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 367: Removing Bolts Securing Turbocharger To Catalytic Converter Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - arrows - securing turbocharger to catalytic converter.
Page 285 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Loosen bolts securing front exhaust pipe to catalytic converter, accessible from above.  Fig. 368: Removing Heat Shield Above Right Side Drive Axle Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 286 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 370: Removing Bolts Securing Catalytic Converter To Front Exhaust Pipe Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - arrows - securing catalytic converter to front exhaust pipe.
Page 287 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Loosen bolted connections on front clamp.  Fig. 372: Pushing Exhaust System Toward Front Of Vehicle Courtesy of VOLKSWAGEN UNITED STATES, INC. Push exhaust system toward front of vehicle - arrow - until preloading at right side mounting of center ...
Page 288 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 374: Pushing Exhaust System Toward Front Of Vehicle Courtesy of VOLKSWAGEN UNITED STATES, INC. Push front section of exhaust system toward front of vehicle - arrow - until preloading at right side ...
Page 289 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 376: Aligning Tailpipes Courtesy of VOLKSWAGEN UNITED STATES, INC. Check to make sure that distances - a - and - b - between tailpipe and bumper are equal.
Page 290 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 378: Pushing Exhaust System Toward Front Of Vehicle Courtesy of VOLKSWAGEN UNITED STATES, INC. Push exhaust system toward front of vehicle - arrow - until preloading at right side mounting of center ...
Page 291 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 380: Pushing Rear Section Of Exhaust System Toward Front Of Vehicle Courtesy of VOLKSWAGEN UNITED STATES, INC. Push rear section of exhaust system toward front of vehicle - arrow - until preloading at rear mounting of ...
Page 292 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Listen for noise at connection points of cylinder head/manifold, manifold/turbocharger,  turbocharger/catalytic converter etc., to locate any leaks. Correct any leaks that are found. ...
Page 293 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 382: Secondary Air System, Checking Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Secondary Air Injection (AIR) pump motor V101 Location --> Location of Secondary Air Injection (AIR) pump motor V101 ...
Page 294 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB direction of flow. 5 - Secondary Air Injection (AIR) pump relay J299 Location Location of Secondary Air Injection (AIR) pump relay J299  6 - Engine Control Module (ECM) J220...
Page 295 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 384: Disconnecting Connector From Secondary AIR Pump Motor V101 Courtesy of VOLKSWAGEN UNITED STATES, INC. Front right in engine compartment below air cleaner housing ...
Page 296 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 386: Vacuum Hose Disconnected At Combination Valve Courtesy of VOLKSWAGEN UNITED STATES, INC. Right rear on cylinder head  Secondary Air Injection (AIR) solenoid valve N112 , checking...
Page 297 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 387: Identifying Special Tools - Secondary Air Injection (AIR) Solenoid Valve N112 , Checking Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Multimeter VAG1526A or equivalent ...
Page 298 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Requirement Vehicle Diagnostic, Testing and Information System VAS5051 or Scan Tool VAG1551 must be  connected. Work sequence NOTE: The Secondary Air Injection (AIR) solenoid valve N112 and its wiring are ...
Page 299 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 389: Connect Test Hose To Valve Connection Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect test hose to valve connection marked with an - arrow -.
Page 300 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 390: Identifying Secondary Air Injection (AIR) Solenoid Valve -N112- Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector at Secondary Air Injection (AIR) solenoid valve N112 - 2 -.
Page 301 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB via fuel pump relay. Requirements Fuse for secondary air injection solenoid valve OK --> Electrical Wiring Diagrams, Troubleshooting and  Component Locations Fuel pump relay OK --> 24 - MULTIPORT FUEL INJECTION (MFI) ...
Page 302 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 393: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect voltage tester VAG1527B to contact 1 (positive) and 2 of connector.
Page 303 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB If wiring is OK: Replace engine control module.  Secondary Air Injection (AIR) pump relay J299 and Secondary Air Injection (AIR) pump motor V101 , checking Fig.
Page 304 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Requirement Vehicle Diagnostic, Testing and Information System VAS5051 or Scan Tool VAG1551 must be  connected. Work sequence Fig. 396: Identifying Plenum Chamber Cover & Removing Rubber Seal Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 305 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 398: Location Of Secondary Air Injection (AIR) Pump Relay J299 Courtesy of VOLKSWAGEN UNITED STATES, INC. Secondary AIR pump relay - 2 - (in 3-way relay carrier of electronics box at left side of plenum chamber, ...
Page 306 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Connect multimeter and measure voltage as follows.  3-way relay carrier in electronics box in plenum Measure to chamber, position 2, contact Engine Ground Specification: approx. battery voltage ...
Page 307 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Connect multimeter and measure voltage as follows.  3-way relay carrier in electronics box in plenum Measure to chamber, position 2, contact Engine Ground Briefly operate starter.
Page 308 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 403: Identifying Secondary Air Pump Relay Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect voltage tester VAG1527B as follows:  3-way relay carrier in electronics box in plenum...
Page 309 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 3-way relay carrier in electronics box in plenum Test box VAG1598/31 ocket chamber, position 2, contact If necessary, eliminate open circuit/short circuit.  If no fault is found: Replace Secondary AIR pump relay J299.
Page 310 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 407: Identifying 2-Pin Electrical Harness Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect voltage tester VAG1527B between contacts 1 and 2. ...
Page 311 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 408: Identifying Hand Vacuum Pump V.A.G. 1390 Courtesy of VOLKSWAGEN UNITED STATES, INC. Vacuum hand pump VAG1390  Requirements No leaks along vacuum hoses or at hose connections.
Page 312 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 410: Vacuum Hose Disconnected At Combination Valve Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect vacuum hose - arrow - at combination valve.  Connect vacuum hand pump VAG1390 to vacuum hose of combination valve.
Page 313 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect hose - arrow - at line for secondary air combination valve.  Connect test hose to line... ...
Page 314 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 414: Disconnecting Connector At Engine Coolant Temperature (ECT) Sensor G2/G62 Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector - arrow - at Engine Coolant Temperature (ECT) sensor G2/G62.
Page 315 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Secondary air line to cylinder head cover Secondary air line to secondary air combination valve 1:01:38 AM Page 303...
Page 316 2005 Audi A4 Quattro 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE The manufacturer suggests the belt be replaced at 105,000 mile intervals under normal driving conditions, 52,500 mile intervals under severe driving conditions.
Page 317 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 NOTE: Mark direction of ribbed belt with chalk or felt-tip pen prior to removal. Running a used belt in the opposite direction could destroy it. 13. Remove engine cover by lifting up. Swivel tensioning element in direction of arrow to slacken off ribbed belt.
Page 318 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 1: Removing Under-Car Noise Insulation (Avant & Sedan) Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 3...
Page 319 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 2: Identifying Auxiliary Heater Exhaust Pipe Bolts (Avant & Sedan) Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 4...
Page 320 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 3: Locating Wheelhousing Fasteners (Avant & Sedan) Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 5...
Page 321 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 4: Identifying Front Bumper-To-Fender Fasteners (Avant & Sedan) Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 6...
Page 322 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 5: Removing Grilles (Avant & Sedan) Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 7...
Page 323 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 6: Identifying Bumper Fasteners (Avant & Sedan) Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 8...
Page 324 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 7: Identifying Washer Hoses & Harness Connectors (Avant & Sedan) Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 9...
Page 325 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 8: Identifying Lock Carrier Components (Avant & Sedan) Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 10...
Page 326 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 9: Identifying Support Tool (Part No. 3369) Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 11...
Page 327 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 10: Installing Support Tool (3369) Into Chassis (Avant & Sedan) Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 12...
Page 328 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 11: Securing Lock Carrier In Service Position Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 13...
Page 329 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 12: Removing/Installing Ribbed Belt Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 14...
Page 330 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 13: Locking Ribbed Belt Tensioner Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 15...
Page 331 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 14: Identifying Top Dead Center (TDC) Position Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 16...
Page 332 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 15: Compressing Timing Belt Tensioner Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 17...
Page 333 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 16: Releasing Timing Belt Tension Courtesy of AUDI OF AMERICA, INC. 16. To release tension from timing belt, loosen nut on pulley and rotate eccentric bolt clockwise in direction of arrow using special tool (3387).
Page 334 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 5. Remove left and right engine compartment covers. Remove air duct between lock carrier and air cleaner (air duct is bolted to lock carrier). Install Lock Carrier Support Tool (3369) into thread on left and right side near impact absorbers.
Page 335 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 17: Identifying Bumper Cover Fasteners (Cabriolet) Courtesy of AUDI OF AMERICA, INC. 12:44:06 AM Page 20...
Page 336 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 18: Identifying Bumper Cover Fasteners At Wheel Opening (Cabriolet) Courtesy of AUDI OF AMERICA, INC. 12:44:07 AM Page 21...
Page 337 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 19: Removing Bumper Cover (Cabriolet) Courtesy of AUDI OF AMERICA, INC. 12:44:07 AM Page 22...
Page 338 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 20: Exploded View Of Lock Carrier Components (Cabriolet) Courtesy of AUDI OF AMERICA, INC. Installation (Avant & Sedan) CAUTION: To prevent pistons from hitting valves, make sure crankshaft is NOT at TDC for any piston before turning camshaft.
Page 339 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 1. Place timing belt on crankshaft sprocket (if reusing belt, observe direction of rotation). Install lower part of timing belt cover. Install vibration dampener. The hole in the vibration damper must be located over the raised part on the crankshaft timing belt sprocket.
Page 340 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 21: Releasing Locking Plate From Tensioner Courtesy of AUDI OF AMERICA, INC. 12:44:07 AM Page 25...
Page 341 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 22: Adjusting Timing Belt Tensioner Courtesy of AUDI OF AMERICA, INC. 12:44:07 AM Page 26...
Page 342 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 23: Identifying Torque Support Bolts (Avant & Sedan) Courtesy of AUDI OF AMERICA, INC. Installation (Cabriolet) 1. Place timing belt on crankshaft sprocket (if reusing belt, observe direction of rotation). Install lower part of timing belt cover.
Page 343 9. Verify fender gaps are as follow: A = 2 mm +/- 0.5 mm, B = 0 mm +/- 0.5 mm and C = 0 mm +/- 0.5 mm. See Fig. 24 . Gap dimensions can be checked using Audi special tool (3371). Adjust gaps as necessary.
Page 344 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 Fig. 24: Bumper Cover Gaps (Cabriolet) Courtesy of AUDI OF AMERICA, INC. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Component Ft. Lbs. (N.m) Camshaft Gear Bolt 48 (65) Crankshaft Gear Bolt...
Page 345 2005 Audi A4 Quattro AUDI 1.8L 4-Cylinder Turbo - AMB Engine - 2002-04 A4 After achieving torque, tighten an additional quarter turn (90°). Install with Locking Fluid (D 000 600 A2). Replace bolts. 12:44:07 AM Page 30...
Page 346 2005 Audi A4 Quattro 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 10 - ENGINE - ASSEMBLY ENGINE, REMOVING AND INSTALLING Engine, removing and installing CAUTION: Before beginning repairs on the electrical system: Obtain the anti-theft radio security code.
Page 347 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 2: Identifying Special Tools - Engine, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Support bar 10-222A ...
Page 348 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 3: Identifying Hose Clip Pliers VAG 1921 Courtesy of VOLKSWAGEN UNITED STATES, INC. Hose clip pliers VAG5024  Engine, removing NOTE: All cable ties unfastened or cut when removing engine are to be ...
Page 349 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Remove rubber seal from plenum chamber cover in direction of - arrow -.  Pull plenum chamber cover - 1 - toward front and remove.
Page 350 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 7: Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove engine cover - arrows -.  Fig. 8: Air Cleaner Cover Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 351 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Remove bolts - arrows -.  Disengage EVAP canister purge regulator valve N80 - 1 - from air duct - 2 -.  Remove both screws - arrows - for air duct - 2 -.
Page 352 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 12: Unbolting Sound Insulation Holder Courtesy of VOLKSWAGEN UNITED STATES, INC. Unbolt sound insulation holder.  Fig. 13: Removing Air Duct In Front Of Charge Air Cooler Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 353 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Hose And Drain Coolant From Radiator Courtesy of VOLKSWAGEN UNITED STATES, INC. Pull retaining clip - 1 - for Engine Coolant Temperature (ECT) sensor G2 - 2 - off lower coolant hose and ...
Page 354 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 17: Removing Lower Air Hose Between Turbocharger And Lock Carrier Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove lower air hose - arrow - between turbocharger and lock carrier.
Page 355 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 19: Removing Air Ducts On Left/Right Of Radiator Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove air ducts on left and right of radiator - arrows -.
Page 356 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 21: Removing Impact Absorber Bolts On Left/Right Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove impact absorber bolts on left and right - arrows -.
Page 357 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 23: Unbolting Lock Carrier On Left/Right Courtesy of VOLKSWAGEN UNITED STATES, INC. Unbolt lock carrier on left and right - arrows -.  NOTE: A second technician is required to remove the lock carrier.
Page 358 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 24: Disconnecting ATF Lines Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect ATF lines - arrows -.  Unbolt bracket for ATF lines on left of engine.
Page 359 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB the connection point. Then release pressure by carefully loosening connection. Fig. 26: Counterholding Using An Open-End Wrench At Each Hex Head & Unscrew Union Nut Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 360 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Unbolt Ground connection from plenum chamber.  Remove vacuum line to brake servo from plenum chamber.  Fig. 28: Disconnect Wires/Unplug Connectors From Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 361 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 29: Removing Both Coolant Hoses From Coolant Expansion Tank Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove both coolant hoses from coolant expansion tank. ...
Page 362 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 31: Removing Engine Control Module Courtesy of VOLKSWAGEN UNITED STATES, INC. Carefully pry off retainer bar with screwdriver - arrow -.  Fig. 32: Disengaging Electrical Connector Retainers And Disconnecting Electrical Connectors From Engine Control Module (ECM) J623 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 363 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 34: Releasing Catches, Lifting Off Control Module Support & Pulling Auxiliary Relay Carrier In Electronics Box Upward To Remove Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 364 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 36: Disconnecting Connector From Secondary Air Injection (AIR) Pump Motor V101 & Hose From Pipe To Secondary Air Combination Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 365 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 38: Guiding Tube For Positive Wire To Starter Is Attached Using Bolt Securing Engine To Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC. Guide tube for positive wire to starter is attached using bolt securing engine to transmission.
Page 366 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 40: Separating Exhaust System At Clamp Courtesy of VOLKSWAGEN UNITED STATES, INC. Separate exhaust system at clamp.  Fig. 41: Removing Bolts Securing Catalytic Converter To Front Exhaust Pipe Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 367 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 42: Disconnecting Connectors From Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect both connectors - arrows - from transmission.  Fig. 43: Swiveling Tensioner In To Loosen Ribbed Belt Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 368 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Gauge Connector From Oil Pan Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect compressor clutch connector from air conditioning compressor.  Disconnect oil level gauge connector from oil pan.
Page 369 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB NOTE: Differing mounting holes are provided for different engine versions.  Fig. 47: Threaded Connections And Positioning Sleeves On Lower Engine Mounts Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 370 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Attach transmission support 3147 to support bar 10-222A.  Use support bar 10-222A to lift engine/transmission assembly until engine mount bolts are positioned  approx. 1 cm above engine supports.
Page 371 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 50: Separating Transmission From Engine And At Same Time Remove Torque Converter From Drive Plate Courtesy of VOLKSWAGEN UNITED STATES, INC. Separate transmission from engine and at same time remove torque converter from drive plate.
Page 372 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 52: Identifying Engine Transmission Bracket VW540 Courtesy of VOLKSWAGEN UNITED STATES, INC. When working on the engine, secure it to the engine stand using engine bracket VW540.
Page 373 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 53: Checking Torque Converter Is Correctly Positioned Courtesy of VOLKSWAGEN UNITED STATES, INC. If the torque converter has been correctly installed, the distance between bottom contact surfaces at threaded holes in torque converter and joint surface on torque converter bell housing with automatic transmission 01V, is approx.
Page 374 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 54: Disconnecting Fuel Supply Line And Set Aside Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten union nut of fuel supply line - 1 - to 22 Nm.
Page 375 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB After connecting battery, enter radio anti-theft code. Radio operating instructions.  Use electric window lifters to completely close door windows.  Then actuate all window lifter switches again for at least 1 second in "close" position to activate ...
Page 376 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 56: Identifying Engine/Transmission Mountings (Automatic/Manual Transmission) Courtesy of VOLKSWAGEN UNITED STATES, INC. Engine/transmission mountings (manual transmission) Item Bolt 1, 3, 4 M12 x 67...
Page 377 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB M12 x 90 M10 x 60 A: Dowel sleeves for centering Component Bolts/nuts except the following: Engine mount to subframe Engine support to engine mount...
Page 378 2005 Audi A4 Quattro 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK ENGINE, DISASSEMBLING AND ASSEMBLING...
Page 379 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Lock carrier in service position, overview Fig. 59: Lock Carrier In Service Position, Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - 45 Nm 2 - 45 Nm...
Page 380 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 6 - Hole in lock carrier 7 - Hole in fender Removing Vehicles with auxiliary heater Fig. 60: Removing Bolts Securing Exhaust Pipe Of Auxiliary/Additional Heater To Sound Insulation Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 381 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 62: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - arrows -.  Disengage EVAP canister purge regulator valve N80 - 1 - from air duct.
Page 382 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Install in reverse order, paying attention to the following: Bolt lock carrier to longitudinal member (50 Nm) and to fenders (10 Nm).  Fig. 64: Bolt Lock Carrier To Longitudinal Member And To Fenders Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 383 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 65: Ribbed Belt For Generator, Vane Pump And Air Conditioner Compressor Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - 25 Nm 2 - Tensioning roller...
Page 384 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB For generator, power steering pump and air conditioning compressor  Removing and installing --> Bracket for generator, power steering pump and air conditioning  compressor, removing and installing...
Page 385 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Secured to bracket for generator, power steering pump and air conditioning compressor  18 - Special bolt, 25 Nm For idler wheel  Installing vibration damper/pulley Fig.
Page 386 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 67: Mandrel T10060 Courtesy of VOLKSWAGEN UNITED STATES, INC. Mandrel T10060  Removing NOTE: Mark direction of the ribbed belt with chalk or felt-tip pen prior to removal.
Page 387 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Install in reverse order.  NOTE: Before installing the ribbed belt, make sure that all mechanical units  (generator, air conditioning compressor, power steering pump) are securely attached.
Page 388 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB See Caution for disconnecting Telematics battery --> Engine, disassembling and assembling Disconnect battery Ground (GND) strap with ignition switched off.  Fig. 71: Disconnecting Top Coolant Hose From Radiator Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 389 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 73: Unbolting Power Steering Pump At Ribbed Belt Side Courtesy of VOLKSWAGEN UNITED STATES, INC. Unbolt power steering pump at ribbed belt side; bolts can be accessed through pulley. Do not disconnect ...
Page 390 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 75: Disconnecting Compressor Clutch Connector From Air Conditioning Compressor & Oil Level Gauge Connector From Oil Pan Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect air conditioning compressor connector - right arrow -.
Page 391 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 77: Removing/Installing Bracket For Generator, Power Steering Pump And A/C Compressor At Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bracket for generator, power steering pump and A/C compressor at bolts - 1 - through - 3 -.
Page 392 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 78: Removing/Installing Bracket For Generator, Power Steering Pump And A/C Compressor At Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Replace micro-encapsulated (threads coated with locking compound) collared bolts and position bracket ...
Page 393 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Then actuate all window lifter switches again for at least 1 second in "close" position to activate  automatic one-touch function. Set clock to correct time.
Page 394 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 79: Toothed Belt Drive, Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Toothed belt guard (lower) To remove, unbolt vibration damper  2 - 10 Nm Apply D 000 600 when installing ...
Page 395 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Carefully engage in center section of toothed belt guard when installing  5 - Toothed belt Mark direction of rotation with chalk or felt-tip pen before removing ...
Page 396 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 17 - 90 Nm + 1/4 turn (90 ° ) further Replace  Do not use oil  Use counterhold tool 3415 to loosen and tighten ...
Page 397 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Use counterhold tool 3415 to loosen and tighten central bolt.  Toothed drive belt, removing, installing and tensioning (Adjusting valve timing) Fig. 82: Identifying Special Tools - Toothed Drive Belt, Removing, Installing And Tensioning Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 398 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Removing With engine in vehicle.  Move lock carrier to service position --> Lock carrier in service position, overview.  Fig. 83: Removing Engine Cover By Lifting Up Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 399 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 85: Removing Upper Part Of Drive Belt Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove upper part of drive belt cover.  NOTE: Take special note of the installed position of the upper part of the drive ...
Page 400 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. Bring engine to TDC cylinder 1 by turning crankshaft in direction of engine rotation, using center  camshaft drive sprocket bolt on crankshaft. Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1 - arrows -.
Page 401 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 89: Inserting An Allen Wrench Into Socket-Head Courtesy of VOLKSWAGEN UNITED STATES, INC. Push pulley on counter-clockwise in direction of - arrow - with a socket head wrench using even but not ...
Page 402 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB cylinder. Risk of damaging valves/piston crown. Place drive belt on crankshaft sprocket (observe direction of rotation).  Install lower part of drive belt cover. ...
Page 403 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Align camshaft sprocket-to-cylinder head cover positioning marks and vibration damper-to-drive belt  cover positioning marks. Install drive belt in this order: water pump, tensioning pulley, camshaft sprocket.
Page 404 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 94: Adjusting Tensioning Roller Courtesy of VOLKSWAGEN UNITED STATES, INC. Turn eccentric bolt counter-clockwise in direction of - arrow - using special tool 3387.
Page 405 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Turn crankshaft two complete turns in direction of engine rotation until crankshaft is at TDC again.  Fig. 96: Identifying Marking On Camshaft Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 406 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB and with evenly applied force. When compressing the tensioner, excessive force can damage the tensioning pulley. Fig. 98: Inserting An Allen Wrench Into Socket-Head Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 407 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 100: Removing/Installing Ribbed Belt Tensioner Courtesy of VOLKSWAGEN UNITED STATES, INC. Install ribbed belt tensioner.  Install ribbed belt --> Ribbed belt, removing and installing.
Page 408 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 101: Identifying Torque Wrench V.A.G. 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC. torque wrench (5 to 50 Nm) VAG1331  Fig. 102: Identifying Marking Plate T10008 (For Engines With Hydraulic Tensioning Device) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 409 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 103: Removing Engine Cover By Lifting Up Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove engine cover by lifting up - arrows -.  Remove ribbed belt --> Ribbed belt, removing and installing.
Page 410 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 105: Identifying Marking On Camshaft Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Bring engine to TDC on cylinder 1 and turn crankshaft in direction of engine rotation using center ...
Page 411 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB excessive application of force until tensioner can be locked with locking plate T10008. NOTE: The stop tab of the eccentric bolt must not be bent.
Page 412 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB cover positioning marks. Install drive belt in this order: water pump, idler pulley, camshaft sprocket.  Tension drive belt.  Tightening Torques Component Drive belt cover at the cylinder block...
Page 413 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 109: Sealing Flanges And Flywheel/Drive Plate, Removing And Installing Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Oil seal Install with 10-203 ...
Page 414 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 5 - Gasket Replace  6 - Cylinder block Removing and installing crankshaft --> Crankshaft, removing and installing  Disassembling and assembling pistons and connecting rods --> Pistons and connecting rods, ...
Page 415 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Replace  15 - Sealing flange for intermediate shaft Crankshaft oil seal - pulley end, replacing Fig. 110: Identifying Special Tools - Crankshaft Oil Seal - Pulley End, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 416 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Engine in vehicle.  Lock carrier in service position --> Lock carrier, moving to service position.  Remove toothed belt --> Toothed drive belt, removing, installing and tensioning.
Page 417 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 113: Screwing Phillips-Head Bolt From 3083 Into Crankshaft Courtesy of VOLKSWAGEN UNITED STATES, INC. Before installing oil seal extractor, screw Phillips-head bolt from 3083 into crankshaft as far as it will go.
Page 418 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 115: Installing Guide Sleeve From 3083 Onto Crankshaft Journal Courtesy of VOLKSWAGEN UNITED STATES, INC. Install guide sleeve from 3083 onto crankshaft journal. ...
Page 419 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 117: Removing Crankshaft Toothed Belt Sprocket Courtesy of VOLKSWAGEN UNITED STATES, INC. Install crankshaft toothed belt sprocket. To do so, hold sprocket in position with counterhold 3415.
Page 420 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 119: Reversing Position Of Counterhold 10-201 To Loosen/Tighten Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Reverse position of counterhold 10-201 to loosen/tighten bolts. ...
Page 421 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 120: Identifying Counterhold VW 558 Courtesy of VOLKSWAGEN UNITED STATES, INC. Counterhold VW558  Hex bolt M8 x 45 and two M10 hex nuts ...
Page 422 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 122: Identifying Drive Plate, Grooved Washer And New Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC. Locate drive plate with shim - 2 - and packing plate - 1 -. Lug - arrow - must face toward torque ...
Page 423 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 124: Identifying Drive Plate, Grooved Washer And New Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove drive plate again and correct value by installing with/without shim - 2 -. Tighten bolts to 30 Nm ...
Page 424 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 125: Crankshaft, Removing And Installing Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Bearing shells 1, 2, 4 and 5 For bearing cap without oil groove ...
Page 425 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Bearing cap 1: pulley end  Bearing shell retaining lugs of cylinder block/bearing cap must be on same side  4 - Bearing shell 3 (top) For bearing cap without oil groove ...
Page 426 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB For bearing cap without oil groove  For cylinder block with oil groove  Do not interchange used bearing shells (mark)  11 - Chain sprocket Drive for oil pump ...
Page 427 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 127: Removing Engine Mount Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Top crankshaft bearing shells are graded at factory and identified on cylinder block as shown in ...
Page 428 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 128: Bearing Shell Identification By Color Codes Courtesy of VOLKSWAGEN UNITED STATES, INC. Lower crankshaft bearing shells supplied as replacement parts are always color-coded "yellow".
Page 429 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 129: Identifying Drift VW 207 C Courtesy of VOLKSWAGEN UNITED STATES, INC. Drift VW207C  Fig. 130: Kukko 21/2 Internal puller, Kukko 21/4 Internal puller, Kukko 22/2 Counter support Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 430 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 131: Pulling Out Pilot Needle Bearing Using Kukko 21/1 And Kukko 22/1 Courtesy of VOLKSWAGEN UNITED STATES, INC. Pull out pilot needle bearing using Kukko 21/1 and Kukko 22/1.
Page 431 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 133: Identifying Installation Depth Dimension Courtesy of VOLKSWAGEN UNITED STATES, INC. Installation depth for pilot needle bearing Distance a = 1.5 mm  Chain sprocket, removing and installing Special tools, testers and auxiliary items required Fig.
Page 432 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Oil pump chain sprocket, chain tensioner and chain, removing.  Fig. 135: Pulling Off Chain Sprocket From Crankshaft Courtesy of VOLKSWAGEN UNITED STATES, INC. Pull chain sprocket off crankshaft with puller - 2 - , use suitable washer - 1 - to protect end of crankshaft.
Page 433 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB drift sleeve 30-100. PISTONS AND CONNECTING RODS, DISASSEMBLING AND ASSEMBLING Pistons and connecting rods, disassembling and assembling Fig. 137: Pistons And Connecting Rods, Disassembling And Assembling Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 434 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Opens at: 2.5...3.2 bar  3 - Oil spray jet For piston cooling  4 - Connecting rod bearing cap Mark cylinder number - B - ...
Page 435 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 9 - Circlip 10 - Piston pin If difficult to move, heat piston to approx. 60 °C  Remove and install with VW222a  11 - Piston rings Offset gaps by 120 °...
Page 436 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB this use a piston without rings. Piston ring Dimensions in mm Wear limit Compression ring 1 0.20...0.40 Compression ring 2 0.20...0.40 Oil scraper ring 0.25...0.50 Checking ring to groove clearance Fig.
Page 437 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. Measure pistons approx. 10 mm from lower edge of skirt, at 90 ° to piston pin axis.  Deviation from nominal dimension: max. 0.04 mm ...
Page 438 2005 Audi A4 Quattro 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 15 - ENGINE - CYLINDER HEAD, VALVETRAIN CYLINDER HEAD, REMOVING AND INSTALLING...
Page 439 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB cracked. Part I Fig. 142: Cylinder Head, Removing And Installing Overview - Part I Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Cylinder head gasket Replace Removing cylinder head, -->...
Page 440 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Checking for distortion Checking cylinder head for distortion  Resurfacing limit Cylinder head resurfacing limit  Installing --> Cylinder head, installing  After replacing, fill with fresh coolant ...
Page 441 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB With screw connection  13 - 10 Nm 14 - Coolant flange With coolant temperature sensor  15 - 10 Nm 16 - O-ring Replace ...
Page 442 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Gasket Note installed position  Replace  2 - 10 Nm 3 - 10 Nm 4 - O-ring For injector ...
Page 443 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 144: Checking Cylinder Head For Distortion Courtesy of VOLKSWAGEN UNITED STATES, INC. Check cylinder head for distortion at several points using knife-edge straightedge and feeler gauge.
Page 444 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 146: Sealing Transition Points Between Double Bearing Cap And Cylinder Head (2 Points) Courtesy of VOLKSWAGEN UNITED STATES, INC. Apply a small quantity of sealant Part No: AMV 174 004 01 to sides of joints - arrows - on upper sealing ...
Page 445 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 148: Loosening And Tightening Union Nut For Fuel Supply Line In Vehicles As Of 07.03 Courtesy of VOLKSWAGEN UNITED STATES, INC. CAUTION: Fuel system is under pressure! Before opening system, place rags around the connection point.
Page 446 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Remove engine cover - arrows -.  Fig. 150: Air Cleaner Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove air cleaner cover - arrow -.
Page 447 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 152: Crankcase Breather Line, Secondary Air Combination Valve Line And Heat Shield Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove crankcase breather line - 2 -.
Page 448 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 154: Cylinder Head Cover Nuts Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen nuts - arrows - on cylinder head cover and remove cylinder head cover.
Page 449 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Obtain and record radio anti-theft code for vehicles with coded radio.  See Caution for disconnecting Telematics battery --> Cylinder head, removing and installing Disconnect battery Ground strap with ignition switched off.
Page 450 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 2. Mass Air Flow (MAF) sensor G70 3. Wastegate bypass regulator valve N75 Disconnect hoses 4...7.  Disconnect hose to secondary air injection pump motor - 8 -.
Page 451 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Remove crankcase breather hose at cylinder head cover.  Remove line - 1 - on secondary air combination valve on cylinder head cover and heat shield - 3 -.
Page 452 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 161: Identifying Vacuum Hose, Oil Supply Line Bracket, Coolant Flange & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect vacuum hose - arrow - at combination valve.
Page 453 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 163: Cylinder Head Cover Nuts Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen nuts - arrows - on cylinder head cover and remove cylinder head cover.
Page 454 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Remove new cylinder head gasket from packaging just before installation.  Handle gasket extremely carefully. Damaging the silicone layer or indented  area will lead to leaks.
Page 455 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 166: Loosening Bolts On Turbocharger Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen bolts - 1 - and - 2 - on turbocharger bracket approx. 2 turns to avoid setting up stresses when ...
Page 456 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 168: Cylinder Head Bolt Tightening Sequence Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten cylinder head bolts in two stages in sequence shown as follows: ...
Page 457 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Perform adaptation of throttle valve control module: --> 24 - MULTIPORT FUEL INJECTION (MFI)  Tightening torques Component Intake manifold support to intake manifold to bracket...
Page 458 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 170: Compression Tester VAG1381 Or VAG1763 Courtesy of VOLKSWAGEN UNITED STATES, INC. Compression tester VAG1381 or VAG1763  Requirements Engine oil temperature at least 30 °C ...
Page 459 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 172: Ignition Coils, Ground Wire And Connectors Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connectors - 3 -.  Pull out ignition coils - 1 -.
Page 460 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Tightening torques Component Spark plugs in cylinder head VALVE GEAR, SERVICING Valve gear, servicing NOTE: Cylinder heads which have cracks between valve seats or between valve ...
Page 461 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 173: Valve Gear, Servicing Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - 65 Nm Use counterhold 3036 to loosen and tighten  2 - Camshaft sprocket For exhaust camshaft ...
Page 462 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Replacing --> Exhaust camshaft oil seal, replacing  4 - Cylinder head See note --> Valve gear, servicing  Checking valve guides --> Valve guides, checking ...
Page 463 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 12 - Bearing cap for intake camshaft Must be located on dowel sleeves  Dowel sleeves must be located in cylinder head  Note installed position ...
Page 464 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB With Valve 1 for camshaft adjustment N205  Checking --> Camshaft timing control, checking  Secure with retainer for chain tensioner 3366 before removing ...
Page 465 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Conical  Note installed position  27 - 25 Nm 28 - Housing for Camshaft Position (CMP) sensor G40 29 - 10 Nm Valve dimensions Fig.
Page 466 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Camshaft axial clearance, checking Special tools, testers and auxiliary items required Fig. 175: Identifying Dial Gauge Holder VW 387 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 467 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 177: Camshaft Axial Clearance, Checking - Exhaust Camshaft Courtesy of VOLKSWAGEN UNITED STATES, INC. Exhaust camshaft Wear limit for intake and exhaust camshafts: Axial clearance: max. 0.20 mm ...
Page 468 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 178: Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove engine cover - arrows -.  Remove top section of toothed belt guard --> Toothed drive belt, removing, installing and tensioning.
Page 469 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 180: Camshaft Gear Retaining Bolt Installed Into Camshaft To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC. To guide oil seal extractor, screw bolt for camshaft sprocket - arrow - into camshaft as far as it will go by ...
Page 470 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 182: Placing Guide Sleeve T10071/1 On Camshaft Pin Courtesy of VOLKSWAGEN UNITED STATES, INC. Install guide sleeve T10071/1 onto camshaft journal.  Slide oil seal over guide sleeve onto shaft journal.
Page 471 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 184: Identifying Camshaft Gear Thin Rib Toward Outside And TDC Marking Visible Courtesy of VOLKSWAGEN UNITED STATES, INC. Install camshaft sprocket.  Note installed position: ...
Page 472 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Intake camshaft oil seal, replacing Special tools, testers and auxiliary items required Fig. 186: Oil Seal Extractor 2085 Courtesy of VOLKSWAGEN UNITED STATES, INC. Oil seal extractor 2085 ...
Page 473 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 188: Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove engine cover - arrows -.  Remove top section of toothed belt guard --> Toothed drive belt, removing, installing and tensioning.
Page 474 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 190: Adapter 2085/1 Threaded In Camshaft Courtesy of VOLKSWAGEN UNITED STATES, INC. To guide oil seal extractor, screw bolt 2085/1 into camshaft as far as it will go by hand.
Page 475 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 192: Identifying A PTFE Seal (Teflon) & Inner Coil Spring Type Seal Courtesy of VOLKSWAGEN UNITED STATES, INC. Distinguishing features: Conventional shaft oil seal has just one sealing lip - arrow 1 - which is pressed ...
Page 476 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Installing oil seal with ring spring NOTE: Do not oil sealing lip of oil seal.  Fig. 194: Guide Sleeve 3241/2 On Camshaft Pin Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 477 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Component CMP sensor rotor ring to camshaft CMP sensor housing to cylinder head Camshafts and camshaft adjuster, removing and installing Special tools, testers and auxiliary items required Counterhold 3036 ...
Page 478 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 197: Disconnecting Connector At Camshaft Adjuster Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector - arrow - at camshaft adjuster.  Remove cylinder head cover --> Cylinder head cover, removing and installing.
Page 479 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 199: Checking Position Of Camshafts To Each Other Courtesy of VOLKSWAGEN UNITED STATES, INC. Re-check TDC position of camshafts:  Mark on two camshafts must be in line with - arrows - on bearing caps.
Page 480 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Do not mark chain with a center punch or by making a notch, etc.  Fig. 201: Identifying Bearing Cap Positions Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 481 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 203: Sealant Application Area Identified By Hatched Surface Courtesy of VOLKSWAGEN UNITED STATES, INC. Replace rubber/metal gasket for camshaft adjuster and apply a thin coat of sealant AMV 188 001 02 to ...
Page 482 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 205: First And Sixteenth Drive Chain Rollers Installed On Chain Gears Courtesy of VOLKSWAGEN UNITED STATES, INC. If new chain is installed, distance between notches - A - and - B - on camshafts must be 16 rollers on ...
Page 483 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 207: Checking Position Of Camshafts To Each Other Courtesy of VOLKSWAGEN UNITED STATES, INC. Two markings on camshafts must be in line with two - arrows - on bearing caps - arrows -.
Page 484 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 209: Identifying Double Bearing Cap Sealant Application Area Courtesy of VOLKSWAGEN UNITED STATES, INC. Apply thin coat of sealant AMV 188 001 02 to shaded area on double bearing cap and install bearing cap ...
Page 485 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 211: Identifying Marking On Camshaft Gear Aligned With Marking On Cylinder Head Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Align marking on camshaft sprocket with marking on cylinder head cover.
Page 486 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Hydraulic valve lifters, checking Special tools, testers and auxiliary items required Feeler gauge  Wooden or plastic wedge  NOTE: Hydraulic valve lifters cannot be repaired.
Page 487 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Use wooden or plastic wedge to push down valve lifter. Replace valve lifter if an 0.20 mm feeler gauge  can be inserted between camshaft and valve lifter.
Page 488 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Pressure hose VW653/3  Spark plug wrench 3122B  Valve seal removal tool 3364 ...
Page 489 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Hammer jammed valve keepers on all five valves loose using a plastic hammer.  Exhaust side Fig. 215: Screwing Snap-In Device VAS5161/6 With Attaching Fork VAS5161/4 Onto Stud On Cylinder Head Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 490 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 216: Releasing Pressure Fork Courtesy of VOLKSWAGEN UNITED STATES, INC. Screw snap-in device VAS5161/6 with attaching fork VAS5161/4 onto stud on cylinder head. ...
Page 491 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 218: Identifying Valve Seal Removal Tool 3364 Courtesy of VOLKSWAGEN UNITED STATES, INC. Pull off valve stem seals with 3364.  Installing NOTE: A plastic sleeve - A - is included with new valve stem seals.
Page 492 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Push valve stem seal onto plastic sleeve.  Carefully press valve stem seal onto valve guide using seal driver 3365.  Remove plastic sleeve. ...
Page 493 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 222: Inserting Cartridge VAS5161/8 Back Into Guide Bushing VAS5161/13 Or VAS5161/14 Courtesy of VOLKSWAGEN UNITED STATES, INC. Insert cartridge VAS5161/8 back into guide bushing VAS5161/13 or VAS5161/14.
Page 494 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Universal dial indicator holder VW387  Dial indicator  Work sequence Fig. 224: Identifying Special Tool - VW 387 Installed Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 495 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB NOTE: When repairing engines with leaking valves, it is not sufficient to reface  valve seats and replace valves. Valve guides must also be checked for wear.
Page 496 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Outer intake valves Center intake valves Exhaust valves 31.0 mm 32.2 mm 31.9 mm Measured distance minus minimum dimension = maximum permissible refacing dimension. Example for outer intake valve: Measured distance 31.4 mm...
Page 497 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 45 ° Valve seat angle ß 30 ° Adjustment angle (top) gamma 60 ° Adjustment angle (bottom) CAMSHAFT TIMING CONTROL, CHECKING Camshaft timing control, checking The intake camshaft is adjusted according to load and engine speed.
Page 498 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 227: Identifying Special Tools - Camshaft Adjustment Valve, Checking Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Multimeter VAG1526A ...
Page 499 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector - arrow - at camshaft adjuster.  Fig. 229: Measuring Resistance Between Terminals Of Solenoid Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 500 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 230: Disconnecting Connector At Camshaft Adjuster Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector - arrow - at camshaft adjuster.  Fig. 231: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 501 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB If LED lights up: Check actuation.  Checking actuation Fig. 232: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect voltage tester VAG 1527B to contact 1 (positive) and 2 of connector.
Page 502 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 233: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Check for open circuit and short to Ground/positive in following wiring connection: ...
Page 503 2005 Audi A4 Quattro 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 17 - ENGINE - LUBRICATION LUBRICATION SYSTEM COMPONENTS, REMOVING AND INSTALLING...
Page 504 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 234: Lubrication System Components, Removing And Installing - Part I Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - 28 Nm 2 - Stop for torque reaction support...
Page 505 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Replace pump if there is scoring on moving surfaces and gear teeth  Tightening torque for oil pump cover to oil pump housing: 10 Nm ...
Page 506 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 15 - Suction line Clean strainer if soiled  16 - Baffle plate 17 - 16 Nm 18 - 15 Nm Tighten in stages and diagonally ...
Page 507 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. 1. Oil spray jet (for piston cooling) 2. Bolt with pressure relief valve, 27 Nm 3. Opening pressure 1.3 to 1.6 bar Part II Fig.
Page 508 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 3 - Spring For pressure relief valve, approx. 4 bar  4 - Piston For pressure relief valve, approx. 4 bar  5 - Gasket Always replace ...
Page 509 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Always replace  17 - Oil pressure switch F1 , 1.4 bar, 25 Nm Black insulation  Checking --> Oil pressure and oil pressure switch, checking ...
Page 510 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 237: Identifying Special Tools - Oil Pan, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Support bar 10-222A ...
Page 511 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Lock carrier in service position --> Lock carrier, moving to service position.  Fig. 238: Removing Noise Insulation Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 512 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 240: Threaded Connections And Positioning Sleeves On Lower Engine Mounts Courtesy of VOLKSWAGEN UNITED STATES, INC. Mark positions of bolted connections - 1 - and locating sleeves - 2 - underneath right and left engine ...
Page 513 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 242: Installing Engine Support Bridge 10-222A Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove eye from lifting tackle 2024A.  Insert pin - 1 - back into center hole of lifting tackle and secure it using cotter pin.
Page 514 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 244: Disconnecting Connector For Oil Level Thermal Sensor -G266- Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector from oil level sensor - arrow -.
Page 515 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB NOTE: Please ignore items - 1 - and - 2 - in the illustration.  Unbolt holder for ATF line from engine.  Move ATF lines clear to one side.
Page 516 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 248: Subframe Supported Using Workshop Crane V.A.G 1202 A Courtesy of VOLKSWAGEN UNITED STATES, INC. Support subframe with workshop crane VAG1202A.  Fig. 249: Removing Front Bolts From Left And Right Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 517 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 250: Left Transmission Mount Nut Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen nuts - arrow - on left transmission mount until it is flush with end of bolt (approx. 4 turns on ...
Page 518 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 252: Right Transmission Mount Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen rear bolt - 2 - on right transmission mount a few turns, remove front bolt - 1 - on right ...
Page 519 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 254: M10 Bolts Removal Sequence Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove M10 bolts - arrows -.  Loosen bolts -1 to 18- in diagonal sequence.
Page 520 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Remove baffle plate and carefully remove sealant remaining on cylinder block.  Fig. 256: Removing Sealant Residue From Oil Pan With Rotating Brush Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 521 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Silicone sealant D 176 404 A2  Thickness of sealant bead: 2 to 3 mm  NOTE: The sealant bead must not be thicker than 3 mm, otherwise excess sealant ...
Page 522 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 259: M10 Bolts Removal Sequence Courtesy of VOLKSWAGEN UNITED STATES, INC. Pre-tighten bolts -1 to 18- to 5 Nm in diagonal sequence.  Tighten bolts securing oil pan to transmission to 45 Nm.
Page 523 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB should protrude by dimension - a - = 0.8 mm from cylinder block - 2 -. After installing oil pan, wait for approx. 30 minutes for sealant to dry ...
Page 524 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE  Tightening torques Component Oil pan to cylinder block Oil pan to transmission Torque reaction support stop to oil pan...
Page 525 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Install in reverse order, paying attention to the following: Insert dowel sleeves at top of oil pump:  Installed position of oil pump shaft/chain sprocket: Can only be installed in one position ...
Page 526 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 263: Identifying Special Tools - Oil Pressure And Oil Pressure Switch, Checking Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Oil pressure tester VAG1342 ...
Page 527 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Replace oil pressure switch.  Start engine.  NOTE: Switching point of oil pressure switch can be reached when engine is  cranked on starter motor, so watch tester and LED while starting engine.
Page 528 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Engine oil The vehicle is filled at the factory with a high-quality multi-grade oil which can be used all year round except in extremely cold climates.
Page 529 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB area). NOTE: Oil level must not be above mark - a - on dipstick.  2:35:34 AM Page 27...
Page 530 2005 Audi A4 Quattro 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 19 - ENGINE - COOLING SYSTEM COOLING SYSTEM COMPONENTS, REMOVING AND INSTALLING Cooling system components, removing and installing CAUTION: Hot steam can escape when cap on expansion tank is opened.
Page 531 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 267: Cooling System Components, Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Heat exchanger for heater After replacing, fill with fresh coolant ...
Page 532 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 5 - Intake manifold 6 - Coolant hose (lower) 7 - Coolant hose (top) 8 - Radiator Removing and installing --> Radiator, removing and installing ...
Page 533 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 268: Identifying Special Tools - Cooling System, Draining And Filling Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Refractometer T10007 ...
Page 534 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Open cap on coolant expansion tank.  Fig. 269: Removing Sound Insulation Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove sound insulation - arrows -. ...
Page 535 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 271: Disconnecting Coolant Hose From Oil Cooler And Drain Off Remaining Coolant Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect coolant hose from oil cooler - arrow - and drain off remaining coolant.
Page 536 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Only use clean drinking water for mixing coolant.  If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
Page 537 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. Screw adapter VAG1274/8 onto coolant expansion tank.  Fit special tool VAG1274/10 onto adapter.  Fill cooling system with coolant.
Page 538 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 274: Identifying Special Tools - Cooling System Components, Servicing, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Refractometer T10007 ...
Page 539 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Drain coolant --> Cooling system, draining and filling.  Remove coolant hose couplers from top and bottom of radiator.  Fig. 275: Removing Air Ducts On Left/Right Of Radiator Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 540 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 277: Unbolting Condenser From Radiator Courtesy of VOLKSWAGEN UNITED STATES, INC. Unbolt condenser - arrows - from radiator.  NOTE: To prevent damage to condenser and refrigerant lines/hoses ensure that ...
Page 541 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 63 - BUMPERS for CABRIOLET  Coolant fan, removing and installing Fig. 279: Identifying Special Tools - Cooling System Components, Servicing, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 542 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB NOTE: Always replace gaskets and sealing rings.  Remove front bumper: -->  63 BUMPER  63 - BUMPERS for CABRIOLET  Move lock carrier to service position --> Lock carrier, moving to service position.
Page 543 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Install in reverse order, paying attention to the following: Install front bumper: -->  63 BUMPER  63 - BUMPERS for CABRIOLET  Coolant pump, removing and installing Fig.
Page 544 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Torque wrench (5 to 50 Nm) VAG1331  Assembly tools for spring clips VAS5024A  Removing NOTE: Always replace gaskets and sealing rings.  Remove toothed belt completely so that it cannot be damaged by coolant.
Page 545 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 284: Inserting Coolant Pump Into Cylinder Block And Securing Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Moisten new O-ring - 3 - with coolant.
Page 546 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 285: Identifying Special Tools - Cooling System, Checking For Leaks Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Cooling system tester VAG1274 ...
Page 547 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Open cap on coolant expansion tank.  Fig. 286: Installing Tester VAG1274 With Adapter VAG1274/8 Onto Expansion Tank Courtesy of VOLKSWAGEN UNITED STATES, INC. Install tester VAG1274 with adapter VAG1274/8 onto expansion tank.
Page 548 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Pressure relief valve must open at pressure of 1.4 to 1.6 bar.  2:36:19 AM Page 19...
Page 549 2005 Audi A4 Quattro 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 26 - EXHAUST SYSTEM, EMISSION CONTROLS EXHAUST SYSTEM COMPONENTS, SERVICING...
Page 550 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 341: Exhaust System Components, Removing And Installing (Front Wheel Drive Vehicles) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Turbocharger Removing and installing --> Turbocharger, removing and installing ...
Page 551 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Checking: --> 24 - MULTIPORT FUEL INJECTION (MFI)  4 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 , 50 Nm Brown connector ...
Page 552 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 17 - 25 Nm 18 - Rear muffler (left) Tailpipe can be replaced  Rear muffler and center muffler are one unit as original equipment but can be replaced separately for ...
Page 553 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 24 - Mounting 25 - 25 Nm 26 - Mounting 27 - M8 bolt 28 - Washer 29 - Spring 30 - Lug 31 - Spacer sleeve...
Page 554 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 343: Installed Position Of Rear Clamps Courtesy of VOLKSWAGEN UNITED STATES, INC. Install clamps so that ends of bolts are not below bottom circumference of clamps.
Page 555 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 345: Exhaust System Components, Removing And Installing (All Wheel Drive Vehicles) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Turbocharger Removing and installing --> Turbocharger, removing and installing ...
Page 556 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Checking: --> 24 - MULTIPORT FUEL INJECTION (MFI)  4 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 , 50 Nm Brown connector ...
Page 557 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Tailpipe can be replaced  Rear muffler and center muffler are one unit as original equipment but can be replaced separately for  repair purposes.
Page 558 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 24 - Mounting 25 - M8 bolt 26 - Washer 27 - Spring 28 - Lug 29 - Spacer sleeve 30 - 25 Nm 31 - 40 Nm Installed position of front clamp Fig.
Page 559 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 347: Installed Position Of Rear Clamp Courtesy of VOLKSWAGEN UNITED STATES, INC. Install clamps so that ends of bolts are not below bottom circumference of clamps.
Page 560 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Connecting pipe can be cut through at point marked to allow center and rear mufflers to be replaced  separately. Cutting point is marked with indentation on outside of exhaust pipe.
Page 561 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 350: Position Center Of Clamp Strap Over Saw-Cut Courtesy of VOLKSWAGEN UNITED STATES, INC. When installing, position center of clamp strap over saw-cut. ...
Page 562 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Installed position of clamp Installed position of rear clamps  Align exhaust system stress-free --> Exhaust system - vehicles with all wheel drive, aligning stress- ...
Page 563 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 354: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - arrows -.  Disengage EVAP canister purge regulator valve N80 - 1 - from air duct - 2 -.
Page 564 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 356: Disconnect Wires/Unplug Connectors From Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect hose to secondary air injection pump motor - 8 -.  Move wiring clear.
Page 565 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 358: Loosening Bolts On Turbocharger Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen bolts - 1 - and - 2 - a few turns.
Page 566 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 360: Removing Bolts Of Oil Supply Line & For Turbocharger Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - 1 - and - 2 - of oil supply line.
Page 567 Fig. 362: Disconnecting 4-Pin Connectors Of Oxygen Sensors Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect 4-pin connectors of oxygen sensors and move wires clear.  1. (Brown) to O2S Behind TWC G130 (only with engine code AMB) 2:39:05 AM Page 19...
Page 568 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 2. (Black) to HO2S G39 Fig. 363: Air Cleaner Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove air cleaner cover - arrow -.  Fig. 364: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 569 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 365: Disconnect Wires/Unplug Connectors From Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect wiring connectors from:  1. EVAP valve 2. Mass Air Flow sensor 3.
Page 570 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 367: Removing Bolts Securing Turbocharger To Catalytic Converter Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - arrows - securing turbocharger to catalytic converter.
Page 571 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Loosen bolts securing front exhaust pipe to catalytic converter, accessible from above.  Fig. 368: Removing Heat Shield Above Right Side Drive Axle Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 572 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 370: Removing Bolts Securing Catalytic Converter To Front Exhaust Pipe Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - arrows - securing catalytic converter to front exhaust pipe.
Page 573 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Loosen bolted connections on front clamp.  Fig. 372: Pushing Exhaust System Toward Front Of Vehicle Courtesy of VOLKSWAGEN UNITED STATES, INC. Push exhaust system toward front of vehicle - arrow - until preloading at right side mounting of center ...
Page 574 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 374: Pushing Exhaust System Toward Front Of Vehicle Courtesy of VOLKSWAGEN UNITED STATES, INC. Push front section of exhaust system toward front of vehicle - arrow - until preloading at right side ...
Page 575 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 376: Aligning Tailpipes Courtesy of VOLKSWAGEN UNITED STATES, INC. Check to make sure that distances - a - and - b - between tailpipe and bumper are equal.
Page 576 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 378: Pushing Exhaust System Toward Front Of Vehicle Courtesy of VOLKSWAGEN UNITED STATES, INC. Push exhaust system toward front of vehicle - arrow - until preloading at right side mounting of center ...
Page 577 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 380: Pushing Rear Section Of Exhaust System Toward Front Of Vehicle Courtesy of VOLKSWAGEN UNITED STATES, INC. Push rear section of exhaust system toward front of vehicle - arrow - until preloading at rear mounting of ...
Page 578 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Listen for noise at connection points of cylinder head/manifold, manifold/turbocharger,  turbocharger/catalytic converter etc., to locate any leaks. Correct any leaks that are found. ...
Page 579 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 382: Secondary Air System, Checking Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Secondary Air Injection (AIR) pump motor V101 Location --> Location of Secondary Air Injection (AIR) pump motor V101 ...
Page 580 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB direction of flow. 5 - Secondary Air Injection (AIR) pump relay J299 Location Location of Secondary Air Injection (AIR) pump relay J299  6 - Engine Control Module (ECM) J220...
Page 581 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 384: Disconnecting Connector From Secondary AIR Pump Motor V101 Courtesy of VOLKSWAGEN UNITED STATES, INC. Front right in engine compartment below air cleaner housing ...
Page 582 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 386: Vacuum Hose Disconnected At Combination Valve Courtesy of VOLKSWAGEN UNITED STATES, INC. Right rear on cylinder head  Secondary Air Injection (AIR) solenoid valve N112 , checking...
Page 583 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 387: Identifying Special Tools - Secondary Air Injection (AIR) Solenoid Valve N112 , Checking Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Multimeter VAG1526A or equivalent ...
Page 584 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Requirement Vehicle Diagnostic, Testing and Information System VAS5051 or Scan Tool VAG1551 must be  connected. Work sequence NOTE: The Secondary Air Injection (AIR) solenoid valve N112 and its wiring are ...
Page 585 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 389: Connect Test Hose To Valve Connection Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect test hose to valve connection marked with an - arrow -.
Page 586 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 390: Identifying Secondary Air Injection (AIR) Solenoid Valve -N112- Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector at Secondary Air Injection (AIR) solenoid valve N112 - 2 -.
Page 587 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB via fuel pump relay. Requirements Fuse for secondary air injection solenoid valve OK --> Electrical Wiring Diagrams, Troubleshooting and  Component Locations Fuel pump relay OK --> 24 - MULTIPORT FUEL INJECTION (MFI) ...
Page 588 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 393: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect voltage tester VAG1527B to contact 1 (positive) and 2 of connector.
Page 589 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB If wiring is OK: Replace engine control module.  Secondary Air Injection (AIR) pump relay J299 and Secondary Air Injection (AIR) pump motor V101 , checking Fig.
Page 590 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Requirement Vehicle Diagnostic, Testing and Information System VAS5051 or Scan Tool VAG1551 must be  connected. Work sequence Fig. 396: Identifying Plenum Chamber Cover & Removing Rubber Seal Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 591 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 398: Location Of Secondary Air Injection (AIR) Pump Relay J299 Courtesy of VOLKSWAGEN UNITED STATES, INC. Secondary AIR pump relay - 2 - (in 3-way relay carrier of electronics box at left side of plenum chamber, ...
Page 592 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Connect multimeter and measure voltage as follows.  3-way relay carrier in electronics box in plenum Measure to chamber, position 2, contact Engine Ground Specification: approx. battery voltage ...
Page 593 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Connect multimeter and measure voltage as follows.  3-way relay carrier in electronics box in plenum Measure to chamber, position 2, contact Engine Ground Briefly operate starter.
Page 594 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 403: Identifying Secondary Air Pump Relay Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect voltage tester VAG1527B as follows:  3-way relay carrier in electronics box in plenum...
Page 595 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 3-way relay carrier in electronics box in plenum Test box VAG1598/31 ocket chamber, position 2, contact If necessary, eliminate open circuit/short circuit.  If no fault is found: Replace Secondary AIR pump relay J299.
Page 596 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 407: Identifying 2-Pin Electrical Harness Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect voltage tester VAG1527B between contacts 1 and 2. ...
Page 597 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 408: Identifying Hand Vacuum Pump V.A.G. 1390 Courtesy of VOLKSWAGEN UNITED STATES, INC. Vacuum hand pump VAG1390  Requirements No leaks along vacuum hoses or at hose connections.
Page 598 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 410: Vacuum Hose Disconnected At Combination Valve Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect vacuum hose - arrow - at combination valve.  Connect vacuum hand pump VAG1390 to vacuum hose of combination valve.
Page 599 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect hose - arrow - at line for secondary air combination valve.  Connect test hose to line... ...
Page 600 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 414: Disconnecting Connector At Engine Coolant Temperature (ECT) Sensor G2/G62 Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector - arrow - at Engine Coolant Temperature (ECT) sensor G2/G62.
Page 601 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Secondary air line to cylinder head cover Secondary air line to secondary air combination valve 2:39:06 AM Page 53...
Page 602 2005 Audi A4 Quattro 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 21 - TURBOCHARGER, G-CHARGER CHARGE AIR PRESSURE SYSTEM WITH TURBOCHARGER, CHECKING...
Page 603 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 288: Boost Pressure Regulation And Vacuum Control System, Connection Diagram For Vehicles Up To 06.03 Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Mechanical recirculation valve...
Page 604 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 6 - Check valve Installed position: Arrow on valve points in direction of flow, as shown in illustration  7 - To EVAP canister 8 - Evaporative Emission (EVAP) Canister Purge Regulator Valve N80...
Page 605 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 21 - Recirculating valve for turbocharger N249 Component location: Below intake manifold  22 - Vacuum diaphragm for boost pressure regulation When combination valve is opened, mechanical boost pressure regulation valve in turbocharger is opened ...
Page 606 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 4 - Wastegate Bypass Regulator Valve N75 5 - Air filter With Mass Air Flow (MAF) Sensor G70  6 - Check valve Installed position: Arrow on valve points in direction of flow, as shown in illustration ...
Page 607 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Installed position: Arrow on valve points in direction of flow, as shown in illustration  21 - Secondary Air Injection (AIR) Solenoid Valve N112 Component location: Below intake manifold ...
Page 608 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 291: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051 Courtesy of VOLKSWAGEN UNITED STATES, INC. VAS5051 with VAS5051/1  VAG1551 with VAG1551/3A ...
Page 609 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 292: Connecting T-Piece And Measuring Hose Of Turbocharger Tester VAG1397A To Intake Manifold Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect T-piece and measuring hose of turbocharger tester VAG1397A to intake manifold (front).
Page 610 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Before performing test, drive vehicle at brisk speed for at least 3 km  without stopping (i.e. along route without traffic lights, etc.). A second mechanic is required to note readings on tester when vehicle is ...
Page 611 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Charge air pressure below specification Wastegate bypass regulator valve N75 faulty -  -> Wastegate bypass regulator valve N75 , checking , checking Hoses to Wastegate bypass regulator valve ...
Page 612 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB misfiring at high engine speeds. Effects of leakage at intake and exhaust end Leakage downstream of Mass Air Flow sensor Effect: Loss of power ...
Page 613 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 295: Checking Charge Air Pressure System Using Vag1687 Charge Air System Tester Courtesy of VOLKSWAGEN UNITED STATES, INC. Check the charge air pressure system using the VAG1687 Charge air system tester.
Page 614 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Special tool VAG 1687/1 pressure adapter, installing (1.8L Turbo) Separate intake hose from Mass Air Flow (MAF) sensor assembly.  Fig. 297: Special Tool VAG 1687/1 Pressure Adapter, Installing (1.8L Turbo) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 615 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Turbo). Special tool LKI9210 (Evaporative system leak detector), preliminary set-up Connect smoke generator leads to vehicle battery.  Fig. 299: Special Tool LKI9210 (Evaporative System Leak Detector), Preliminary Set-Up Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 616 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 300: Special Tool VAG1687 , Connecting To Pressure Adapter VAG1687/1 (1.8L Turbo) Courtesy of VOLKSWAGEN UNITED STATES, INC. VAG1687 is shown connected to VAG1687/1 - black arrow - Shop air supply will be connected to VAG1687 at - white arrow - Perform pressure test.
Page 617 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB CAUTION: DO NOT pressurize the system above 0.5 bar! Doing so may force oil into the intake system which can damage the engine. Slowly open outlet valve - 4 - (after gauge) to test hose connections.
Page 618 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB With VAS5051 diagnostic tool connected: Erase DTC memory.  Effects of leakage at exhaust end Effect: Charge air pressure too low, possible exhaust smell, soot traces in engine compartment ...
Page 619 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Vacuum hand pump VAG1390  Work sequence Fig. 304: Connecting Hand Vacuum Pump V.A.G 1390 To Vacuum Connection Of Charge Pressure Bypass Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 620 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 305: Identifying Special Tools - Recirculating Valve For Turbocharger N249 , Checking Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Multimeter VAG1526A or equivalent ...
Page 621 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Requirement Vehicle Diagnostic, Testing and Information System VAS5051 or Scan Tool VAG1551 must be  connected. Work sequence NOTE: The Recirculating valve for turbocharger N249 and its wiring are monitored ...
Page 622 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 307: Connect Test Hose To Valve Connection Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect test hose to valve connection marked with - arrow -.
Page 623 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 308: Identifying Secondary Air Injection (AIR) Solenoid Valve -N112- Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect connector from Recirculating valve for turbocharger N249- - 1 -.
Page 624 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Requirements Fuse for recirculating valve OK --> Electrical Wiring Diagrams, Troubleshooting and Component  Locations Fuel pump relay OK --> 24 - MULTIPORT FUEL INJECTION (MFI) ...
Page 625 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 311: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect voltage tester VAG1527B to contact 1 (positive) and 2 of connector.
Page 626 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB If wiring is OK: Replace engine control module.  Wastegate bypass regulator valve N75 , checking Fig. 313: Identifying Special Tools - Wastegate Bypass Regulator Valve N75 , Checking Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 627 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Vehicle Diagnostic, Testing and Information System VAS5051 VAS5051 with VAS5051/1  Scan Tool VAG1551 with VAG1551/3A  Requirement Vehicle Diagnostic, Testing and Information System VAS5051 or Scan Tool VAG1551 must be ...
Page 628 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB ..and must open and close (can be checked by blowing into test hose).  If valve does not click: Check internal resistance of valve. ...
Page 629 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fuel pump relay OK --> 24 - MULTIPORT FUEL INJECTION (MFI)  Fig. 316: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 630 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 317: Identifying 2-Pin Electrical Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect voltage tester VAG1527B to contact 1 (positive) and 2 of connector.
Page 631 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Connector contact Test box VAG1598/31 socket If necessary, eliminate open circuit/short circuit.  If wiring is OK: Replace engine control module.  Charge air pressure sensor G31 , checking Fig.
Page 632 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Multimeter VAG1526A or equivalent  Connector test set VAG1594A  Adapter VAG1598/31  Vehicle Diagnostic, Testing and Information System VAS5051 VAS5051 with VAS5051/1  Scan Tool VAG1551 with VAG1551/3A ...
Page 633 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 321: Identifying Connector Terminals 1 And 4 Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect multimeter and measure voltage between contacts 1 and 3 of connector.
Page 634 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 323: Identifying Connector Terminals 1 And 4 Courtesy of VOLKSWAGEN UNITED STATES, INC. Check for open circuit and short to Ground/positive in following wiring: ...
Page 635 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 324: Identifying Connector Terminals 1 And 4 Courtesy of VOLKSWAGEN UNITED STATES, INC. Check for open circuit and short to Ground/positive in following wiring connection: ...
Page 636 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 325: Turbocharger, Removing And Installing - Overview (Part I) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - 30 Nm Only use genuine bolt ...
Page 637 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 5 - 30 Nm 6 - 35 Nm 7 - Oil supply line Tighten union nut to 23 Nm  8 - 3.5 Nm 9 - Heat shield...
Page 638 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB 20 - Coolant supply line 21 - Banjo bolt, 35 Nm Apply D 000 600 when installing  22 - 10 Nm Apply D 000 600 when installing ...
Page 639 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 326: Turbocharger, Removing And Installing - Overview (Part II) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Vacuum hose To Recirculating valve for turbocharger N249 ...
Page 640 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB To turbocharger connection  5 - Hose To EVAP valve  6 - Line To crankcase breather  7 - 10 Nm 8 - Hose To crankcase breather line ...
Page 641 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 327: Identifying Hose Clamps 3094 Courtesy of VOLKSWAGEN UNITED STATES, INC. Hose clamps 3094  Removing Fig. 328: Noise Insulation Tray Retainers Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 642 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 329: Locating Securing Bolts For Ribbed Belt Tensioner For A/C Compressor Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen securing bolts of tensioning roller for ribbed belt of air conditioning compressor - arrows - , ...
Page 643 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 331: Removing Engine Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove engine cover - arrows -.  Fig. 332: Air Cleaner Cover Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 644 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Remove bolts - arrows -.  Remove air duct - 1 - and - 2 -.  Fig. 334: Disconnecting Wiring Connectors From Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 645 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 335: Removing Secondary Air Line Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove secondary air line. To do so, pull off hoses - arrows - and remove bolts - 1 -.
Page 646 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 337: Using Hose Clamp 3094 To Clamp Off Coolant Return Hose To Turbocharger Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - 1 - and - 3 - of oil supply line.
Page 647 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Top off cooling system --> Cooling system, draining and filling.  Check oil level --> Oil level, checking.  NOTE: After installing turbocharger, run engine for approx. 1 minute at idling ...
Page 648 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 338: Charge Air Cooling Components, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Air duct 2 - Rubber grommet 3 - Air hose Between charge air cooler and air duct in lock carrier ...
Page 649 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Replace if damaged  6 - Charge air pressure sensor G31 7 - 3 Nm 8 - Rubber grommet 9 - Bracket Riveted to body ...
Page 650 2005 Audi A4 Quattro ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AMB Fig. 340: Removing Air Duct In Front Of Charge Air Cooler Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove air duct in front of charge air cooler - arrows -.

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