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Repair Manual
Audi A1 2011 ➤,
Audi A1 Sportback 2018 ➤,
Audi A2 2001 ➤, Audi A3 2004 ➤,
Audi A3 2013 ➤, Audi A3 2021 ➤,
Audi A3 China 2021 ➤,
Audi A3 Limousine China 2014 ➤,
Audi A3 Sportback China 2014 ➤,
Audi A4 2001 ➤, Audi A4 2008 ➤,
Audi A4 2015 ➤,
Audi A4 Cabriolet 2003 ➤,
Audi A5 2016 ➤,
Audi A5 Cabriolet 2009 ➤,
Audi A5 Coupé 2008 ➤, Audi A6 1998 ➤,
Audi A6 2005 ➤, Audi A6 2011 ➤,
Audi A6 2019 ➤, Audi A6 China 2012 ➤,
Audi A6 China 2019 ➤,
Audi A7 Sportback 2011 ➤,
Audi A7 Sportback 2018 ➤,
Audi A8 2003 ➤, Audi A8 2010 ➤,
Audi A8 2018 ➤, Audi Q2 2016 ➤,
Audi Q3 2012 ➤, Audi Q3 2019 ➤,
Audi Q3 China 2013 ➤,
Audi Q3 China 2019 ➤,
Audi Q4 e-tron 2022 ➤, Audi Q5 2008 ➤,
Audi Q5 2017 ➤, Audi Q5 China 2010 ➤,
Audi Q7 2007 ➤, Audi Q7 2016 ➤,
Audi Q8 2018 ➤, Audi R8 2007 ➤,
Audi R8 2015 ➤, Audi TT 1999 ➤,
Audi TT 2007 ➤, Audi TT 2015 ➤,
Service
Service Department. Technical Information
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Audi e-tron 2019 ➤,
Audi e-tron GT 2022 ➤
Electrical Equipment General Information
Edition 01.2022
Service
Service Department. Technical Information
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List of Workshop Manual Repair Groups
Repair Group
27 - Starter, Generator and Cruise Control
92 - Windshield Washer System
94 - Exterior Lights, Lamps and Switches
96 - Interior Lights, Lamps and Switches
97 - Wires
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 © 2022 Audi AG, Ingolstadt D3E8007DE6D
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2022 Audi AG, Ingolstadt D3E8007DE6D
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Contents
27 - Starter, Generator and Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Battery Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Warnings and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Battery Post/Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Battery, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Visual Indicator Color Display, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Battery Test with Vehicle Diagnostic Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Battery Tester VAS6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6 Battery Tester with Printer VAS5097A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7 Current Draw Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.8 Battery, Checking Resting Voltage, Vehicles in Storage or Inventory . . . . . . . . . . . . . . . . 26
3 Battery, Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1 Battery Charger VAS5095A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Battery Charger VAS5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.3 Battery Charger VAS5903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4 Battery Charger VAS5906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.5 Battery Charger VAS5908 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.6 Solar Battery Maintainer VAS6102A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.7 Severely Discharged Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.1 Generator, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2 Overview - Generator, Bosch through MY 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3 Overview - Bosch Generator from 2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.4 Voltage Regulator, Bosch Generator from 2001, Removing and Installing . . . . . . . . . . . . 81
4.5 Overview - Bosch Generator from 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.6 Voltage Regulator, Removing and Installing, Bosch Generator from 2007 . . . . . . . . . . . . 83
4.7 Carbon Brushes, Checking, All Bosch Generators from 2001 . . . . . . . . . . . . . . . . . . . . . . 84
4.8 Overview - Generator, Valeo through MY 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.9 Overview - Valeo Generator from 2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.10 Voltage Regulator, Valeo Generator from 2001, Removing and Installing . . . . . . . . . . . . . . 86
4.11 Carbon Brushes, Valeo Generator from 2001, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.12 Voltage Regulator, Removing and Installing, Valeo Generator from 2007 . . . . . . . . . . . . . . 88
4.13 Carbon Brushes, Checking, Valeo Generator from 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.14 Ribbed Belt Pulley without Freewheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . 91
4.15 Ribbed Belt Pulley with Freewheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 92
4.16 Ribbed Belt Pulley with Freewheel, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.17 Overview - Hitachi Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.18 Voltage Regulator, Removing and Installing - Hitachi Generator . . . . . . . . . . . . . . . . . . . . 100
4.19 Carbon Brushes, Checking, Hitachi Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
92 - Windshield Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1 Washer Fluid Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.1 Washer Fluid Line Hose Connections, Disconnecting and Connecting . . . . . . . . . . . . . . . . 103
1.2 Smooth Hose Washer Fluid Line, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.3 Corrugated Hose Washer Fluid Line, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
94 - Exterior Lights, Lamps and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1 HID Headlamp Usage and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Audi A1 2011 ➤, Audi A1 Sportback 2018 ➤, Audi A2 2001 ➤, Audi A3 2004 ➤, Audi ...
Electrical Equipment General Information - Edition 01.2022
Contents i
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96 - Interior Lights, Lamps and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1 Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.2 Faulty Transponder or Lost Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.3 Induction Coil, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.4 Lock Set, Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2 Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.1 Trailer Hitch Socket, Removing and Installing - Version 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.2 Trailer Hitch Socket, Removing and Installing - Version 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.3 Trailer Hitch Socket, Removing and Installing - Version 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.4 Trailer Hitch Socket, Removing and Installing - Version 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 120
97 - Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1 Vehicle Diagnosis, Testing and Information Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.1 Vehicle Diagnostic Tester, Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2 Wiring Harness and Connector Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.1 Vehicle Electrical System, General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.2 Wiring Harness Repair Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.3 Tool Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.4 Wiring Harnesses, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.5 Fiber-Optic Cables, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.6 Antenna Wires, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.7 Connector Housings and Connectors, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.8 Connector Housings, Releasing and Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3 Contact Surface Cleaning Set VAS6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.1 Contact Surface Cleaning Set VAS6410, Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
4 ESD Work Surface VAS6613 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.1 ESD Work Surface VAS6613, Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Audi A1 2011 ➤, Audi A1 Sportback 2018 ➤, Audi A2 2001 ➤, Audi A3 2004 ➤, Audi ...
Electrical Equipment General Information - Edition 01.2022
ii Contents
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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27 – Starter, Generator and Cruise Control
1 Battery
(Edition 01.2022)
A005AA00421 - 02.01.2022
⇒ I1.1 nformation”, page 1
⇒ T1.2 ypes”, page 1
⇒ a1.3 nd Safety Precautions”, page 3
⇒ P1.4 ost/Terminal”, page 5
1.1 General Information
To guarantee a long service life, the Battery -A- must be
checked, serviced and maintained as described in this manual.
The Battery -A- supplies the power to start the engine. The
Battery -A- also acts as a power reserve for the entire vehicle
electrical system.
Note
Refer to Self Study Program.
WARNING
Risk of injury. Follow all warning messages and Safety Pre‐
cautions. ⇒ a1.3 nd Safety Precautions”, page 3
Caution
In order to prevent damage to the Battery -A- or vehicle,
observe the battery type information. Refer to ⇒ T1.2 ypes”,
page 1 .
1.2 Battery Types
General Information
⇒ B1.2.1 atteryA with Visual Indicator”, page 1
⇒ 1.2.2 , page 2
⇒ 1.2.3 , page 3
1.2.1 Battery -A- with Visual Indicator
Caution
The following described Batteries -A- are maintenance-free
Batteries -A-. Do not remove any of the labels on the bat‐
tery and do not add distilled water. Perform only a visual
inspection. Note the chapter on battery testing. Refer to ⇒
C2 hecking”, page 6 .
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Electrical Equipment General Information - Edition 01.2022
1. Battery 1
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Maintenance-free Battery -A- with fluid electrolyte (wet battery).
Caution
Do not remove any of the labels on the battery and do not
add distilled water. Perform only a visual inspection. Note
the chapter on battery testing. Refer to ⇒ C2 hecking”, page
6 .
WARNING
Do not check or charge a Battery -A- when the visual indica‐
tor has »no color or is bright yellow«. Jump starting must not
be used!
There is a risk of explosion during testing, charging or jump
starting.
These Batteries -A- must be replaced.
This Battery -A- has a visual indicator. The colors in the visual
indicator show the Battery -A- charge and electrolyte level.
Visual indicator color display, checking. Refer to ⇒ I2.3 ndicator
Color Display, Checking”, page 9 .
1.2.2 EFB-Battery
Caution
The following described Batteries -A- are maintenance-free
Batteries -A-. Do not remove any of the labels on the bat‐
tery and do not add distilled water. Perform only a visual
inspection. Note the chapter on battery testing. Refer to ⇒
C2 hecking”, page 6 .
Maintenance-free Battery -A- with fluid electrolyte (wet battery).
Caution
Do not remove any of the labels on the battery and do not
add distilled water. Perform only a visual inspection. Note the
chapter on battery testing.
WARNING
Do not check or charge a Battery -A- when the visual indica‐
tor has »no color or is bright yellow«. Jump starting must not
be used!
There is a risk of explosion during testing, charging or jump
starting.
These Batteries -A- must be replaced.
The Battery -A- is installed in certain Stop/Start vehicles due to
special requirements. “EFB” is written on the battery cover to
identify this battery.
Audi A1 2011 ➤, Audi A1 Sportback 2018 ➤, Audi A2 2001 ➤, Audi A3 2004 ➤, Audi ...
Electrical Equipment General Information - Edition 01.2022
2 Rep. Gr.27 - Starter, Generator and Cruise Control
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
“EFB” stands for »Enhanced Flooded Battery« (enhanced wet
battery).
An EFB battery may only be replaced with another EFB battery.
This Battery -A- has a visual indicator. The colors in the visual
indicator show the Battery -A- charge and electrolyte level.
Visual indicator color display, checking. Refer to ⇒ I2.3 ndicator
Color Display, Checking”, page 9 .
Note
“EFB” batteries are being used in certain Audi A1 and Audi A3
models from August 2011.
1.2.3 AGM-Battery
Caution
The following described Batteries -A- are maintenance-free
Batteries -A-. Do not remove any of the labels on the bat‐
tery and do not add distilled water. Perform only a visual
inspection. Note the chapter on battery testing. Refer to ⇒
C2 hecking”, page 6 .
Maintenance-Free Battery -A- with Fixed Electrolyte (AGM bat‐
tery).
Lead-acid battery, where the electrolyte is fixed in an absorbent
glass mat (AGM). The Battery -A- is closed and equipped with
breather valves.
“AGM” is the English abbreviation for Absorbent Glass Mat.
These Batteries -A- cannot have a visual indicator due to the
fixed electrolyte. AGM is on the Battery -A- to identify it.
When replacing an AGM battery, another AGM battery must be
installed.
1.3 Warnings and Safety Precautions
⇒ W1.3.1 hen Working with Batteries”, page 3
⇒ S1.3.2 afety Label”, page 4
1.3.1 Dangers When Working with Batteries
Recognizing and Preventing Risks
Batteries -A- present risks. Read the warnings on the Battery
-A- label, in the Owner's Manual and in ELSA to prevent these
risks.
Audi A1 2011 ➤, Audi A1 Sportback 2018 ➤, Audi A2 2001 ➤, Audi A3 2004 ➤, Audi ...
Electrical Equipment General Information - Edition 01.2022
1. Battery 3
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
WARNING
♦ Personnel instructed in protection, such as a trainee or
an apprentice, may only perform work on vehicle Bat‐
teries -A- under supervision of technical personnel, for
example, a master automotive technician or a master
automotive electrician.
♦ Acid has strong corrosive properties. If Batteries -A- are
handled inappropriately, there is a risk that personal in‐
jury may result from exposure to harmful electrolyte in‐
fluences. Therefore, suitable remedies for acid damage
must be kept readily available. Soapy water would be a
suitable remedy.
♦ If electrolyte drips out from the Battery -A-, skin can be
burned by acid and the vehicle may be affected by acid
erosion and corrosion. It is a possibility that safety-rela‐
ted vehicle components can be damaged.
♦ When charging and when resting after charging, explo‐
sive gas is present. In extreme cases, if the Battery -A-
is handled inappropriately, the emitted gases may cause
the battery to explode.
♦ Replace a Battery -A- if the visual indicator has »no col‐
or or is bright yellow«. They may not be tested or charg‐
ed and jump starting may not be used. There is a risk of
explosion during testing, charging or jump starting.
♦ Producing sparks by sanding, welding, cutting and open
flames, (also from smoking near the battery) is forbid‐
den. Producing sparks through electrostatic discharge
must also be avoided. Always touch the vehicle body
before touching the Battery -A-.
♦ Only perform Battery -A- procedures in suitable and
well-ventilated locations.
WARNING
Pollution risk.
♦ Old batteries require special disposal. They contain poi‐
sonous lead (Pb) and sulfuric acid.
♦ Follow disposal requirements, only dispose of used bat‐
teries in suitable containers at an authorized collection
site.
1.3.2 Battery Safety Label
Safety Label on the Battery -A-
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Electrical Equipment General Information - Edition 01.2022
4 Rep. Gr.27 - Starter, Generator and Cruise Control
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Models covered:
- Audi e-tron 50 Quattro 230 Kw (313 HP)
- Audi e-tron 55 Quattro 261 Kw (335 HP)
This 2022 Audi e-tron Service & Repair Manual is a comprehensive guide for repairing and servicing your specific Audi model and its variants. Whether you're a professional mechanic or a DIY enthusiast, this manual provides detailed troubleshooting and replacement procedures, complete with step-by-step instructions, clear images, and exploded-view illustrations.
Regular maintenance is essential for the durability of your vehicle. This manual equips you with the manufacturer's recommended troubleshooting charts and replacement procedures, ensuring that you can address any issues and replace worn-out parts effectively.
With this repair manual, you can save on repairs, enhance your vehicle's reliability, and minimize visits to the repair shop. It's the ultimate solution for both weekend DIY’ers and professional mechanics working on Audi vehicles!
The 2022 Audi e-tron Service & Repair Manual includes everything you need to rebuild the engine and replace components, such as wiring diagrams, torque specs, and exploded-view illustrations. Additionally, the manufacturer's troubleshooting charts enable you to quickly diagnose specific symptoms like hard starts, rough idling, vibrations, leaks, and more, making it user-friendly even for beginners!
In summary, this manual empowers you to save significantly on repairs and maintenance, making it a worthwhile investment that pays for itself after the first oil change.
Compatible with various electronic devices, including PC & Mac computers, Android and Apple smartphones & tablets, this manual is easily accessible and printable. It requires Adobe Reader, which is available for free.
