1998-2004 Audi A6 C5 Service & Repair Manual

WARNING-Important Safety Notice ..... ...... ..... .. ... ... .. ... .... .... ....... ....... ....... ..... ... .... ii Foreword ... .......................... .... .... .. ... .. ... .. .... .. .. ..... .... ...... ... .......... ........... .............. iv Index ...... ....... .... .... ..... .... ............ .. ..... ..... .... ... ... ....... ..... .. ............... ..... .. rear of book 0 General Information, 00 Warnings and Cautions 02 Product Familiarization ~ Maintenance 01 Vehicle Identification 03 Maintenance and VIN Decoder 1 13 Timing Belt, Engine Pulley, Rear 17 Engine- Lubrication System ~ Engine Main Seal 19 Engine-Cooling System 15 Cylinder Head Cover 2 Engine Management, 20 Fuel Storage and Supply 26 Exhaust System ~ Exhaust and 21 Turbocharger and lntercooler 27 Battery, Alternator, Starter Engine Electrical 24 Fuel Injection 28 Ignition System 3 Clutch and 30 Clutch 37 Automatic Transmission ~ Transmission 32 Torque Converter 39 Final Drive, Driveshaft 34 Manual Transmission 4 Suspension, 40 Front Suspension 46 Brakes-Mechanical ~ Brakes and 42 Rear Suspension 47 Brakes- Hydraulic 44 Wheels, Tires, Alignment 48 Steering Steering 45 Antilock Brakes (ABS) 5 Body- 50 Body-Front 57 Doors and Locks ~ Assembly 55 Hood and Lids 6 Body- 60 Sunroof 66 Body-Exterior Equipment ~ Components and 63 Bumpers 69 Seat Belts, Airbags Accessories 64 Door Windows 7 Body- 70 Interior Trim ~ Interior Trim 72 Seats 8 Heating and 87 Heating and Air-conditioning ~ Air-conditioning 9 9 Electrical System-General 94 Exterior Lights ~ Electrical System 90 Instruments 96 Interior Lights, Switches, Anti-theft 91 Radio and Communication 97 Fuses, Relays, 92 Wipers and Washers Component Locations EWD Electrical Wiring Diagrams ~ OBD On Board Diagnostics

01 01-1 Vehicle Identification and VIN Decoder Vehicle identification number (VIN), decoding Some of the information in this manual applies only to cars of a particular model year or range of years. For example, 2003 refers to the 2003 model year but does not necessarily match the calendar year in which the car was manufactured or sold. To be sure of the model year of a particular car, check the vehicle identification number (VIN) on the car. The VIN is a unique sequence of 17 characters assigned by Audi to identify each individual car. When decoded, the VIN tells the country and year of manufacture; make, model and serial number; assembly plant and even some equipment specifications. The Audi VIN is on a plate mounted on the top of the dashboard, on the driver's side where the number can be seen through the windshield. The 10th character is the model year code. Examples: W for 1998, X for 1999, Y for 2000, 1 for 2001 , 2 for 2002, etc. The table below explains some of the codes in the VIN for 1998 - 2004 Audi A6 models covered by this manual. Sample VIN: WAUDA24BlXN001612 VIN Description position 1 Manufacturing country 2 Manufacturer 3 Vehicle Type 4 Series 5 Engine 6 Restraint system 7-8 Model 9 Check digit 10 Model year 11 Assembly plant 12-17 Serial number Decoding information T w A R u u 4A 4B w x y 1 2 3 4 A K N Hungary Germany Audi germany Audi Hungary quattro GmbH Passenger vehicle Varies with model year. See BentleyPublishers.com for more information A6 Avant A6, allroad quatt ro , S6, RS6 0 - 9 or X, calculated by NHTSA 1998 1999 2000 2001 2002 2003 2004 lngolstadt Karman-Rheine Neckarsulm Sequential production number for specific vehicle '---r-·~ I ' I

02-1 02 Product Familiarization GENERAL . ... . ... . ...... . .......... . ...... 02-1 Body dimensions ........... .. ............ 02-3 allroad quattro ... .. ....... ...... .... . .... 02-4 Audi RS6 .. ..... .. ... ................... 02-5 1 ENGINE ... . ......... ... ..... . .......... 02-5 V6 engines . . . ....... . .. .. . ......... .... 02-5 VB engines ....... . ... .... ...... . ....... 02-8 2 ENGINE MANAGEMENT . .... .... .. ... . .... 02-11 3 CLUTCH AND TRANSMISSION . ........... . .. 02-14 Self-adjusting clutch (SAC) ....... ... ..... . 02-14 Manual transmission .. .. ... . .. . ....... ... 02-14 Automatic transmission ...... . ... ... ...... 02-15 Multitronic® (CVT) transmission .. .... .. .... 02-16 RS6 transmission .... ... ....... . ........ 02-18 Torsen® differential ................ ... .. . 02-18 4 SUSPENSION, BRAKES AND STEERING . .... .. 02-19 Suspension ............................ 02-1 9 all road quattro air suspension ... . ....... ... 02-22 RS6 suspension . ... ... .. . ... ... ........ 02-24 Antilock brakes (ABS) ................. . . . 02-24 Brakes . .. .. . ........... . ..... . ....... . 02-26 Steering column ... .. ...... . ...... . ..... 02-27 5 BoDv-AssEMBLY 6 BODY-COMPONENTS AND ACCESSORIES 7 BoDv-INTERIOR TRIM .................... 02-28 8 HEATING AND AIR-CONDITIONING ...... ... .. 02-30 9 ELECTRICAL SYSTEM ................ ... . 02-31 Instrument cluster, dashboard and controls .. . 02-32 GENERAL The information included in this section, based on introductory material for 1998 through 2004 Audi A6 vehicles sold in the USA and Canada , is intended to serve as a product familiarization guide. CAUTION- • The information in this section is subject to change. Use it as a general reference only. Check Audi factory repair information or the publisher's website at www.bentleypublishers.com for information that may supersede material in this section . .;;;;;;(The fifth generation Audi A6, referred to as the C5 platform, was introduced in 1998 and continued through 2004 . The Audi A6 combines the latest engineering expertise with a future-oriented automobile design. The primary goals were to increase body rigidity, reduce body weight, and improve crash properties. Despite being lighter, the body is 50% more rigid than its predecessor. This results in better driving dynamics and increased ride comfort. The engine hood, window frame modules and side impact bars, for example, are manufactured using aluminum. ' ~--~-~ -, ~~ - ~.

02-2 Product Familiarization 229_06 __ 229_09 ~ T~e alumi~um engine hood i~ the first instance in which Audi used this material for a large exterior part on a high volume production vehicle. It is 36 percent lighter than a conventional engine hood, yet 20 percent more rigid. The use of magnesium and aluminum components in the running gear such as the transmission housing, suspension components, brake calipers and wheels is another weight-reducing measure. The four-link front suspension represents a breakthrough in handling and performance. Additionally, antilock brakes, electronic differential lock and traction control are combined to give the Audi A6 a standard of driving safety unrivalled in its class. All A6 models feature a host of standard equipment features aimed at improving active and passive safety. Included are: •ABS (antilock braking) • EDL (electronic differential lock) • EBD (electronic brake pressure distribution) • ASR (antislip regulation) •Ellipsoidal-principle headlights • Electrically adjustable and heated outside mirrors •Outside temperatun;) display •Driver and passenger airbags • Side impact airbags for front •Three-point automatic seat belts and head restraints for all seats • Pyrotechnic seat-belt tensioners for front and rear seats In addition, the A6 features extensive anti-theft measures: •Anti-theft alarm system with ultrasonic interior monitoring • Button on inside of driver's door for central locking •Break-in protection for door and luggage compartment locks (lock mechanism cannot be opened even if the car is broken into) • Remote (keyless) central locking The A6 was introduced with an all-new engine , the 2.8 liter, thirty- valve V6. This engine has variable intake manifold runners and variable camshaft timing. The engine delivers 200 hp and a peak torque of 207 lb-ft at 3200 rpm. An impressive feature of the 2.8 liter engine is that more than 188 lb-ft (91 %) of torque is available at engine speeds between 2500 and 5000 rpm. Additional engines were introduced throughout the production of the A6, including the 450 hp, 4.2 liter VB used in the limited edition Audi RS6. See 1 Engine for engine data.

Body dimensions A6 4.2 A6 Avant 56 Avant allroad quattro l 61 .9 " Level 1 Level4 Product Familiarization 02-3 4.r t----...... .,......._ ___________ _...;""-+...:;..----~ !loaded) t---- - - - 108.7" _ ____ _, t----- -- ------ 192.0 " -- ------ - - -..; 4.8" t----......,T"-------------_...;""-+...:;..----~lloadedl t------ - 108.6" _____ ___, ,___ _ _________ 193 .4 " - - --- --------! 7.5 " - ----- 109"----- - - - - -- - 189 " ___________ _..., Level3 A604020 17

02-4 Product Familiarization A60402002 allroad quattro The allroad quattro, introduced in 2000, shares its platform with the second generation C5 A6 Avant (station wagon), although an advanced air suspension, larger wheels with all-terrain tires and flared and unpainted bumpers give it a distinct appearance and more overall flexibility over varying terrain. Audi's quattro (all-wheel drive) system is standard equipment. The allroad quattro was not created by simply changing shock absorbers and springs to give an A6 more ground clearance. There are more than 1,100 new parts that make the all road a true all-terrain vehicle. The 4-level suspension system has two operating modes: • Automatic mode adjusts vehicle height according to vehicle speed and needs no driver input. • Manual mode allows driver to select vehicle height, depending on speed and terrain. Other functional and visual modifications to the allroad quattro include: • Larger exterior mirrors • Front and rear underbody protection •Matte paint finish on the bumpers, roof and door sills • Redesigned headlights

lbs-ft Nm 370 500 333 450 296 400 259 350 I .,. v- ,V I ~ t"--... kW hp 200 268 1 80 24 1 '1 60 214 140 188 Product Familiarization 02-5 AudiRS6 ~ The Audi RS6, a limit.ed production po~er~ouse , is t~e perfect synthesis of extraordinary power, pract1cal1ty and poise. The company's most powerful model to date, the RS6 features an engine producing an amazing 450 horsepower at 6,500 revolutions per minute, making it a world-class luxury sedan with the heart of a sports car. Tuned by quattro GmbH, the high-performance arm of Audi AG and well known for the remarkable RS4 model sold exclusively in Europe, the RS6 is the first vehicle quattro GmbH has produced for the North American market. 1 ENGINE Both V6 and V8 engines were available for the A6. V6 power plants included a 2.7 liter biturbo engine and 2.8 liter and 3.0 liter normally- aspirated engines. The three variants of the V8 engine all displace 4.2 liters, with power output ranging from 299 hp to 450 hp. V6 engines 2.7 liter VG biturbo, engine codes APB, BEL ~The 2.7 liter V6 biturbo engine, introduced in model year 2000 , uses two small turbochargers, one fitted at each bank of cylinders. Due to their lower inertia, the dual turbochargers respond more quickly than a single larger unit. Each turbocharger has its own intercooler for more efficient cooling of the intake air. 2.7 liter engine, general s_p_e_ ci _ fic_a_ ti_o_n_s __ _ I Engine codes APB (2000 - 2003) Engine type Engine size Horsepower APB BEL Torque (lb-ft) BEL (2003 - 2004) J dual overhead belt and chain-driven -_ camshafts, 30-valve V6 2.7 liters I 163 cu . in . I ~~ ; 5 - ~ - ~ - ~ ;~: = = --_ 258 @ 1800 ::___ 450~p~ 222 300 (1) ::J I y "'~ I I ' 120 161 ::; ~ 2.7 liter engine horsepower and torque graph. er ._ 185 250 ~ v 0. 100 134 ::; 0 148 200 111 150 74 100 ' I I v 80 107 0 80 40 54 37 50 20 27 0 0 0 1 000 2000 3000 4000 5000 6000 7000 Speed (rpm) 198 02

02-6 Product Familiarization 2.7 liter turbochargers Air filter \ Turbochargers Air distributor I Charge air intercoolers 2.8 liter VG engine, engine codes AHA, ATQ A60402001 <Oil( The initial V6 offering was the 2.8 liter naturally-aspirated engine with the cylinder banks positioned 90° apart. Other features include 5 valves per cylinder, distributorless ignition and variable valve timing. Two variants of this engine were available. A redesigned combustion chamber and centrally-located spark plug are responsible for improving combustion efficiency, reducing fuel consumption and lowering exhaust emissions. 2.8 liter engine, general specifications - - Engine codes AHA (1998 - 2000) ATQ (2000 - 2001) Engine type dual overhead belt and chain-driven camshafts, 30-valve V6 Engine size 2.8 liters I 169 cu . in . Horsepower -- - - I 1 I ~AHA __ =l 200 @ 6000 'E'.11 ____ -- -- - ATQ 193 @ 6000 rpm ---- Torque (lb-ft) -----i --- ---- AHA 207 @ 3200 rpm ATQ 207 @ 3200 rpm

Crankshaft Balance shaft ~ Cyl.6 255_035 Product Familiarization 02-7 3.0 liter VG engine, engine code AVK ~The 3.0 liter V6, which replaced the 2.8 liter base engine in 2002, features : • Aluminum cylinder block manufactured using patented Cosworth rollover casting process-a technique used for race car engines. • Plastic two-position variable intake manifold reduces engine mass and provides torque over a broad range with maximum power available at high rpm. •Dual overhead camshafts with continuously variable intake camshaft adjustment and two-position exhaust camshaft adjustment boost power output and torque and ensure compliance with exhaust emissions standards. • Five-valve-per-cylinder technology ensures optimum flow of fuel-air mixture and exhaust gases to keep fuel consumption and exhaust emissions low. ~ • Balance shaft integrated with oil pump into single module located underneath engine block in sump provides for exceptional running smoothness. • Motronic ME 7.1.1 engine management system with "drive by wire" electronic throttle control for immediate response to driver input: Accelerator pedal movement is transmitted to the engine management system instantly and without loss. • Mapped-characteristic ignition and solid-state spark distribution are exceptionally reliable and improve fuel mixture combustion. ~ •Tubular air-gap-insulated exhaust manifolds lower weight, improve noise pattern, quickly heat catalytic converters to light-off temperature, and reduce heat transfer to engine compartment. •Cylinder-bank-selective oxygen sensing, with two pre-converters close to engine and two main catalytic converters farther back ensure long-term stability in exhaust emissions. • Ultra-low emissions vehicle (ULEV) certification. 3.0 liter engine , general specifications - ---- -- Engine code AVK (2002 - 2004) - - --------------- Engine type dual overhead belt-driven camshafts, 30-valve V6 Engine size 3.0 liters I 182 cu . in. -j --1 Horsepower 220 @ 6300 rpm - ---- ----------------- Torque (lb-ft) 221 @ 3200 rpm ___J

1998-2004 Audi A6 C5 Service & Repair Manual

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