2011 Audi A7 Sportback Electrical System Repair Manual
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Repair Manual
Audi A1 2011 ➤ , Audi A2 2001 ➤ ,
Audi A3 2004 ➤ , Audi A4 2001 ➤ ,
Audi A4 2008 ➤ ,
Audi A4 Cabriolet 2003 ➤ ,
Audi A5 Cabriolet 2009 ➤ ,
Audi A5 Coupé 2008 ➤ , Audi A6 1998 ➤ ,
Audi A6 2005 ➤ ,
Audi A7 Sportback 2011 ➤ ,
Audi A8 2003 ➤ , Audi A8 2010 ➤ ,
Audi Q5 2008 ➤ , Audi Q7 2007 ➤ ,
Audi R8 2007 ➤ , Audi TT 1999 ➤ ,
Audi TT 2007 ➤
Electrical Equipment General Information
Edition 10.2010
Service
Service Department. Technical Information
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List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
27 - Battery, Starter, Generator, Cruise Control
92 - Windshield Wiper/Washer System
94 - Exterior Lights, Switches
96 - Interior Lights, Switches
97 - Wiring
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2011 Audi AG, Ingolstadt D3E8007DE6D
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Contents
27 - Battery, Starter, Generator, Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Battery, Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Cruise Control, Vehicles With Electronic Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Safety Procedures And Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Lead-Acid Battery Warnings and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6 Non Maintenance-Free Batteries, Without Visual Indicator . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7 Maintenance-Free Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.1 Bosch Generator Overview, Through 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2 Bosch Generator Overview, From 2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3 Bosch Generator Overview, From 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4 Valeo Generator Overview, Through 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.5 Valeo Generator Overview, From 2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Battery, Checking - Vehicles Without A Battery Monitoring Control Module J367 or Energy
Management Control Module J644 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 Battery Checking - Vehicles With A Battery Monitoring Control Module J367 Or Energy
Management Control Module J644 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.3 Generator, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.4 Carbon Brush, Checking, Bosch Generators From 2001 . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.5 Carbon Brush Checking, Valeo Generator, From 2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.6 Carbon Brush Checking, Valeo Generator, From 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1 Voltage Regulator, Bosch Generator, From 2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.2 Voltage Regulator, Bosch Generator, From 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.3 Voltage Regulator, Valeo Generator, From 2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4 Voltage Regulator, Valeo Generator, From 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.5 Ribbed Belt Pulley Without Freewheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.6 Ribbed Belt Pulley With Freewheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
92 - Windshield Wiper/Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.1 Smooth Hose Washer Fluid Line, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.2 Corrugated Hose Washer Fluid Line, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.1 Washer Fluid Line Hose Connections, Disconnecting and Connecting . . . . . . . . . . . . . . . . 48
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
94 - Exterior Lights, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.1 HID Headlamps, Usage and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
96 - Interior Lights, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.1 Immobilizer, Vehicles Without an Access/Start Authorization Switch E415 (Mechanical
Ignition Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.2 Immobilizer, Vehicles With an Access/Start Authorization Switch E415 (Electronic Ignition
Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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Electrical Equipment General Information - Edition 10.2010
Contents i
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1.3 Heated Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Trailer Hitch Socket Connector Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.1 Trailer Hitch Socket - Version 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2 Trailer Hitch Socket - Version 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3 Trailer Hitch Socket - Version 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.1 Antenna Wires, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.2 Fiber Optic Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.3 Connector Housings and Connectors, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.4 Contact Housings, Releasing and Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.5 Cleaning contact surfaces with the contact surface cleaning set VAS 6410 . . . . . . . . . . . . 78
1.6 Vehicle Diagnosis, Testing and Information Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.7 Wiring Harnesses and Connectors, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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Electrical Equipment General Information - Edition 10.2010
ii Contents
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27 – Battery, Starter, Generator, Cruise Control
1 General Information
⇒ “1.1 Battery“, page 1
⇒ “1.2 Battery, Charging“, page 2
⇒ “1.3 Cruise Control, Vehicles With Electronic Power Control“,
page 7
⇒ “1.4 Safety Procedures And Precautions“, page 8
⇒ “1.5 Lead-Acid Battery Warnings and Safety Precautions“,
page 8
⇒ “1.6 Non Maintenance-Free Batteries, Without Visual Indica‐
tor“, page 11
⇒ “1.7 Maintenance-Free Battery“, page 16
1.1 Battery
WARNING
Risk of injury.
♦ Follow all Warnings and Safety Precautions. Refer to
⇒ “1.5 Lead-Acid Battery Warnings and Safety Precau‐
tions“, page 8 .
Caution
Risk of damage to battery or vehicle.
♦ Vehicles with a battery that is not maintenance-free: Fol‐
low the instructions, refer to
⇒ “1.6.5 Visual Check“, page 12 .
♦ Vehicles with a battery that is not maintenance-free: Fol‐
low the instructions, refer to
⇒ “1.7.8 Visual Check“, page 19 .
♦ To guarantee a long service life, the battery must be checked,
serviced and maintained as described in this repair manual.
♦ In addition to its starting function, the battery acts as back-up
and supplies power for the entire electrical system.
Note
For additional information, refer to Self Study Program No. 234;
Vehicle Batteries.
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1. General Information 1
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1.2 Battery, Charging
⇒ “1.2.1 Charging The Battery Using VAS 5903 “, page 2
⇒ “1.2.2 Exhaustively Discharged Battery“, page 3
⇒ “1.2.3 Rapid Charging The Battery, Vehicles Without Battery
Monitoring Control Module J367 Or Energy Management Control
Module J644 “, page 5
⇒ “1.2.4 Battery Support Mode With VAS 5903 “, page 6
⇒ “1.2.5 Maintenance Charging With Solar Panel VAS 6102 A “,
page 7
1.2.1 Charging The Battery Using -VAS 5903-
Special tools and workshop equipment required
♦ Battery Charger VAS 5903 -VAS 5903-
Note
♦ Battery charger -VAS 5903- charges without current and volt‐
age peaks. Batteries can therefore also be charged when
installed. When doing this, heed the safety instructions. The
devices provide an assistance mode in which they provide
supply for the circuits.
♦ When working on the electrical system with the electrical con‐
sumers temporarily switched on and for “Guided Fault Find‐
ing“, the battery must be charged with a battery charger in
assistance mode to prevent damage to the battery. Refer to
⇒ “1.2.4 Battery Support Mode With VAS 5903 “, page 6 .
♦ For more information regarding the battery charger, refer to
the Operating Instructions that came with the charger.
Procedure
• The battery temperature must be at least +10 ℃.
WARNING
Risk of explosion due to open flame, fire and smoking.
♦ On non-maintenance-free batteries, the sealing plugs
must be installed tightly.
♦ Provide sufficient ventilation.
♦ A highly flammable gas forms when batteries are charged.
Never enter rooms where batteries are being charged car‐
rying an open flame or while smoking.
♦ Follow the battery charger and battery manufacturer safe‐
ty requirements.
♦ Rapid-charging batteries, refer to
⇒ “1.2.3 Rapid Charging The Battery, Vehicles Without
Battery Monitoring Control Module J367 Or Energy Man‐
agement Control Module J644 “, page 5 .
Risk of explosion on discharged battery with visual indicator.
♦ If the visual indicator has no color or is light yellow, the
battery may not be tested or charged. Jump starting must
not be used! There is a risk of explosion during testing,
charging or jump starting. The battery must be replaced.
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Electrical Equipment General Information - Edition 10.2010
2 Rep. Gr.27 - Battery, Starter, Generator, Cruise Control
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Caution
Risk of damaging AGM batteries.
♦ AGM batteries must be protected from over voltage.
– Switch off ignition and remove ignition key.
– Turn off all electrical consumers.
– Perform the battery charging prep work. Refer to⇒ Electrical
Equipment; Rep. Gr. 27 ; Description and Operation .
Note
♦ In vehicles without a Battery monitoring control module -J367-
or Energy management control module -J644- , the battery
charger clamps can be connected to the battery terminals or
the positive and ground terminals in the engine compartment.
♦ In vehicles with a Battery monitoring control module -J367- or
Energy management control module -J644- , the black charg‐
er clamp “–“ must not be connected to the battery negative
terminal but to the ground terminal in the engine compartment
or the ground pin of the energy management control module
-J644- .
– After connecting the charging clamps, connect the battery
charger electrical system connector.
– Switch the charger on.
– If necessary, adjust the charge current according to the battery
capacity.
• Current should be 10% of the battery capacity (with a 60 Ah
battery, about 6 Ah).
– When the battery is fully charged, refer to Battery charger op‐
erating instructions, disconnect the battery charger clamps “+“
and “–-“ from the battery.
– Disconnect the battery charger electrical system connector.
1.2.2 Exhaustively Discharged Battery
♦ Batteries that have not been used in driving operation for a
long time, for example in stored vehicles, discharge them‐
selves.
♦ Batteries are considered to be exhaustively discharged if the
no-load voltage drops below 11.6 V. In the case of extended
downtime under 12.2 volts, the battery is prematurely dam‐
aged.
♦ Measure the no-load voltage in vehicles without a Battery
monitoring control module -J367- or Energy management con‐
trol module -J644- . Refer to
⇒ “4.1.2 Measuring No Load Voltage“, page 32 .
♦ Perform a battery test with a Vehicle Diagnosis Tester if the
vehicle has a Battery monitoring control module -J367- or En‐
ergy management control module -J644- . Refer to
⇒ “4.2.2 Battery Test with Vehicle Diagnosis Tester -“,
page 34 .
♦ With exhaustively discharged batteries, the battery acid (mix‐
ture of sulfuric acid and water) is mostly water, with a greatly
reduced sulfuric acid content.
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Electrical Equipment General Information - Edition 10.2010
1. General Information 3
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♦ Exhaustively discharged batteries become sulfated, i.e. all the
plate surfaces of such batteries become hardened. Instead of
being transparent, the electrolyte has a slightly milky appear‐
ance.
♦ The sulfating process may be reversed if an exhaustively dis‐
charged battery is recharged immediately.
♦ If battery is not recharged, plates will continue to harden, and
ability to accept a charge will diminish. This results in reduction
of battery performance.
Procedure
• The battery temperature must be at least +10 ℃.
WARNING
Risk of explosion on discharged battery with visual indicator.
♦ If the visual indicator has no color or is light yellow, the
battery may not be tested or charged. Jump starting must
not be used! There is a risk of explosion during testing,
charging or jump starting. The battery must be replaced.
Caution
Risk of exhaustively discharged batteries freezing.
♦ Exhaustively discharged batteries freeze at low tempera‐
tures, the housing can crack.
♦ Batteries that have frozen must no longer be used.
Discharged sulfated batteries must be charged as follows using
a low charging current:
– Adjust the charge current to approximately 5% of the battery
capacity, i.e., the charging current for a 60 Ah battery is then
approximately 3 ampere.
Note
♦ The battery voltage must be at least 0.6 V!
♦ The -VAS 5903- battery charger automatically detects ex‐
haustively discharged batteries and carefully starts the charg‐
ing procedure with a low charging current. The charge current
is automatically adjusted to the battery charge state.
Caution
Risk of damaging exhaustively discharged batteries.
♦ Do not rapid-charge exhaustively discharged batteries.
– Charge the battery. Refer to
⇒ “1.2.1 Charging The Battery Using VAS 5903 “, page 2 .
• The charging voltage may be a maximum of 14.4 V.
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Electrical Equipment General Information - Edition 10.2010
4 Rep. Gr.27 - Battery, Starter, Generator, Cruise Control
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Note
If the battery must be replaced, follow the disposal regulations,
refer to ⇒ page 11 .
1.2.3 Rapid Charging The Battery, Vehicles
Without Battery Monitoring Control Mod‐
ule -J367- Or Energy Management Con‐
trol Module -J644-
Procedure
• The battery temperature must be at least +10 ℃.
WARNING
Risk of explosion due to open flame, fire and smoking.
♦ On non-maintenance-free batteries, the sealing plugs
must be installed tightly.
♦ Provide sufficient ventilation.
♦ A highly flammable gas forms when batteries are charged.
Never enter rooms where batteries are being charged car‐
rying an open flame or while smoking.
♦ Follow the battery charger and battery manufacturer safe‐
ty requirements.
Risk of explosion on discharged battery with visual indicator.
♦ If the visual indicator has no color or is light yellow, the
battery may not be tested or charged. Jump starting must
not be used! There is a risk of explosion during testing,
charging or jump starting. The battery must be replaced.
Caution
Risk of damaging the battery and vehicle electronic compo‐
nents.
♦ Do not rapid charge AGM batteries.
♦ Do not rapid charge batteries in vehicles with a battery
monitoring control module -J367- or energy management
control module -J644- .
♦ Do not rapid-charge exhaustively discharged batteries.
♦ Rapid-charging of batteries should only be performed in
exceptional circumstances (for example, jump starting)
since rapid charging may cause damage.
♦ Battery must not be connected to vehicle electrical system
when performing rapid charging. Disconnect the positive
and negative cables from the terminals. Refer to⇒ Elec‐
trical system; Rep. Gr. 27 ; Removal and Installation .
♦ The maximum charging voltage is 14.8 volt.
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1. General Information 5
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
If the battery must be replaced, follow the disposal regulations,
refer to ⇒ page 11 .
1.2.4 Battery Support Mode With -VAS 5903-
Special tools and workshop equipment required
♦ Battery Charger VAS 5903 -VAS 5903-
The battery support mode is needed, for example, when taking
breaks from fault finding in the workshop or when replacing the
battery.
Procedure
Note
♦ For more information regarding the battery charger, refer to
the Operating Instructions that came with the charger.
♦ In the following, the battery support mode is described as an
example of -VAS 5900- .
– Switch off ignition and remove ignition key.
– Turn off all electrical consumers.
– Connect the battery charger electrical system connector -VAS
5900- .
• The last selected operating mode appears on the display.
– Press the Start/Stop button for approximately 5 seconds.
• The menu selection “Charging severely discharged batteries/
Support mode“ is activated.
– Press the ↑ button or the ↓ button in order to adjust the vehicle
electrical system.
Note
If no button is pressed within 5 seconds, the -VAS 5900- switches
back to the main menu.
– Confirm selected battery voltage with Start/Stop button.
– Perform the battery support mode prep work. Refer to ⇒ Elec‐
trical Equipment; Rep. Gr. 27 ; Description and Operation .
• The charging clips are checked for connection to correct poles.
Caution
Risk of damaging the -VAS 5900- and vehicle electronic com‐
ponents.
♦ If the battery terminal clamps are connected incorrectly,
the Start/Stop button must not be pressed.
– Confirm charging clips are connected to correct poles via
Start/Stop .
Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A4 2001 ➤ , Au ...
Electrical Equipment General Information - Edition 10.2010
6 Rep. Gr.27 - Battery, Starter, Generator, Cruise Control
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Find the most complete service and repair manual for AUDI A7 SPORTBACK 2011 ELECTRICAL. This professional technical manual contains service, maintenance, and troubleshooting information for your AUDI A7 SPORTBACK 2011 ELECTRICAL. It is the manual used in the local service repair shop. AUDI A7 SPORTBACK 2011 ELECTRICAL manual is guaranteed to be fully useful to save your precious time.
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Repair Group
- 27 - Battery, Starter, Generator, Cruise Control
- 92 - Windshield Wiper/Washer System
- 94 - Exterior Lights, Switches
- 96 - Interior Lights, Switches
- 97 - Wiring
- ... and more
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Product Details:
- File Format: .PDF
- Language: English
- Specifications: Full Printable
- Zoom IN/OUT: YES
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- Requirements: Adobe Reader & Win
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