Audi A4 2008-2016 Petrol Diesel Workshop Repair Manual PDF MY2008 - MAUDIA4MY08MY16.zip
A full workshop repair manual featuring Electrical Wiring Diagrams for the Audi A4 petrol and diesel ranges, packed with everything needed to service, troubleshoot, fix, and rebuild the car to a professional mechanic's standard.
Covering every 2008-2016 Audi A4 variant, the workshop service and repair manual contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 11,085 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Audi A4 2008 ➤, Audi A5 Coupé 2008 ➤.pdf
6-cylinder direct petrol injection engine (3.2 ltr. 4-valve), mechanics - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
6-cylinder TDI engine (2.7 ltr.; 3.0 ltr. 4-valve common rail), mechanics - A4 2008 ➤, A5 Cabriolet 2009 ➤, A5 Coupé 2008 ➤, A5 Sportback 2010 ➤.pdf
6-speed manual gearbox 0B1, front-wheel drive - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
6-speed manual gearbox 0B2, four-wheel drive - Audi A4 2008 ➤, Audi A5 Coupé 2008 ➤.pdf
6-speed manual gearbox 0B3, front-wheel drive - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
6-speed manual gearbox 0B4, four-wheel drive - Audi A4 2008 ➤, Audi A5 Coupé 2008 ➤.pdf
Air conditioners with refrigerant R1234yf - General information - Audi models.pdf
Air conditioner with refrigerant R134a - Audi Models.pdf
Automatic gearbox 0B6, four-wheel drive - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
Auxiliary heater - Audi A4 2008 ➤ Audi A5 Coupé 2008 ➤ Audi A5 Sportback 2010 ➤.pdf
Body Repairs - Audi A4 2008 ➤.pdf
Brake system - Audi A4 2008 ➤.pdf
Direct petrol injection and ignition system (4- cylinder 1.8 ltr.4-valve turbo with timing chain) - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
Direct petrol injection and ignition system (4- cylinder 2.0 ltr. 4-valve turbo with timing chain) - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
Electrical Equipment General Information - Audi Models.pdf
Electrical system (Audi A4 2008 ➤).pdf
Electrical Wiring Diagrams.pdf
Fitting instructions- radio communication systems.pdf
Fitting instructions, retrofitting key-operated switch to deactivate airbag on front passenger side - Audi Models.pdf
Fuel supply system, diesel engines - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤, Audi A5 Sportback 2010 ➤.pdf
Fuel supply system, petrol engines - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
General body Protected repairs, exterior (Audi A4 2008 ➤, Audi A4 Avant 2008 ➤).pdf
General body repairs, interior - Audi A4 2008 ➤.pdf
General InformationBody Repairs, General Body Repairs - Audi Models.pdf
Maintenance - Audi A4 2008 ➤.pdf
multitronic 0AW, front-wheel drive - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
Radio Installation Instructions - Audi Models.pdf
Rear final drive 0BC, 0BD, 0BE, 0BF - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤ , Audi A8 2010 ➤ , Audi Q5 2008 ➤ , Audi Q5 China 2010 ➤.pdf
Rear final drive 0BC - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤ , Audi A8 2010 ➤ , Audi Q5 2008 ➤.pdf
Rear final drive 0BD - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤, Audi Q5 2008 ➤.pdf
Rear final drive 0BF and 0BE - sport differential - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤ , Audi A8 2010 ➤.pdf
Rear final drive 0BF and 0BE – sport differential - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤ , Audi A8 2010 ➤.pdf
Refrigerant R134a Servicing - Audi Models.pdf
Running gear, front-wheel drive and four-wheel drive - Audi A4 2008 ➤.pdf
Servicing 4-cyl. engine, 2.0 ltr. 4-valve TFSI (EA 888, Gen. III).pdf
Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI (EA 888, Gen. II) - A4 2008 ➤, A5 Cabriolet 2009 ➤, A5 Coupé 2008 ➤, A6 2011 ➤, A6 China 2012 ➤, A8 2010 ➤, Q5 2008 ➤, Q5 China 2010 ➤.pdf
Servicing 6-speed manual gearbox 0B1, front-wheel drive - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi Q5 2008 ➤.pdf
Servicing 6-speed manual gearbox 0B1, front-wheel drive - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi Q5 2008 ➤.pdf
Servicing 6-speed manual gearbox 0B2, four-wheel drive - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤, Audi Q5 2008 ➤.pdf
Servicing 6-speed manual gearbox 0B3, front-wheel drive - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
Servicing 6-speed manual gearbox 0B4, four-wheel drive - Audi A4 2008 ➤, Audi A5 Coupé 2008 ➤.pdf
Servicing 7-speed dual clutch gearbox 0B5 (S tronic) - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤ , Audi Q5 2008 ➤ , Audi Q5 China 2010 ➤.pdf
Servicing 7-speed dual clutch gearbox 0CJ,0CL,0CK,0DN,0DP,0HL - A4,A4 Avant,A4 China,A4 allroad quattro 2015➤,A5 2016➤,A6,A6 Avant,A6 China 2012 2011-2019➤,A7 Sportback,Sportback USA 2011-2018➤,Q5 2008-2017➤,Q5 China 2019 ➤.pdf
Servicing 8-speed automatic gearbox - A4 2008-2015-2016➤ ,A5 Cabriolet 2009➤ ,A5 Coupé 2008➤,A6,A6 China 2011-2019➤ ,A7 Sportback 2011-2018➤ ,A8 2010➤,A8,A8 China 2018➤,Q5 2008-2017➤,Q5 China 2010➤ ,Q7 2016➤.pdf
Servicing multitronic 0AW - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤.pdf
Servicing multitronic 0AW - Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤.pdf
Simos direct petrol injection and ignition system (6- cylinder 3.0 ltr. TFSI 4-valve) - Audi A4 2008 ➤, Audi S5 Cabriolet 2010 ➤, Audi S5 Coupé 2008 ➤.pdf
Simos direct petrol injection and ignition system (6- cylinder 3.2 ltr. 4-valve) - Audi A4 2008 ➤.pdf
Specifications for testing the braking force (accordingto German legislation) - Audi models.pdf
System description - adaptive cruise control - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
System description - dynamic steering - Audi A4 2008 ➤.pdf
System description - entry and start authorisation - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤, Audi Q5 2008 ➤.pdf
System description - exterior lights - Audi A4 2008 ➤, Audi Q5 2008 ➤.pdf
System description - infotainment and audio output (MOST) - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
System description - infotainment and navigation system - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
System description - interior lights - Audi A4 2008 ➤, Audi Q5 2008 ➤.pdf
System description - lane change assist (Audi side assist) - Audi A4 2008 ➤, Audi A5 Coupé 2008 ➤.pdf
System description - lane departure warning (Audi lane assist) - Audi A4 2008 ➤, Audi A5 Coupé 2008 ➤.pdf
System description - steering wheel - Audi A4 2008 ➤.pdf
System description - Windows and doors - Audi A4 2008 ➤.pdf
System description - wiper and washer systems - Audi A4 2008 ➤, Audi Q5 2008 ➤.pdf
TDI injection and glow plug system (4- cylinder 2.0 ltr. 4-valve common rail) - Audi A4 2008 ➤, Audi A5 Cabriolet 2009 ➤, Audi A5 Coupé 2008 ➤.pdf
Towing Guide - Audi models.pdf
Trailer Operation Guide - Audi models.pdf
Wheels and tyres - Audi Models.pdf
Wheel & Tire General Information - Audi Models.pdf
Wheel_Tyre Guide - Audi A4 2008 ➤, Audi A4 2015 ➤.pdf
MAIN SECTIONS
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Audi A4 2008 >, Audi A5 Coup> 2008 >.......7
00 > Technical data.......13
1 Engine number.......13
2 Engine data.......14
3 Safety precautions.......15
3.1 Working on the fuel system.......15
3.2 Working on the cooling system.......16
3.3 Working on vehicles with start/stop system.......16
3.4 Using testers and measuring instruments during a road test.......17
3.5 Working on the exhaust system.......17
3.6 Working on the subframe.......17
4 General repair instructions.......18
4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger.......18
4.2 Checking for leaks in the fuel system.......18
4.3 Foreign particles in engine.......19
4.4 Contact corrosion!.......19
4.5 Routing and attachment of pipes, hoses and wiring.......19
4.6 Installing radiators, condensers and charge air coolers.......19
4.7 Checking vacuum system.......19
10 > Removing and installing engine.......21
1 Removing engine.......21
2 Securing engine to engine and gearbox support.......38
3 Installing engine.......39
4 Assembly mountings.......45
4.1 Assembly mountings - exploded view.......45
4.2 Removing and installing engine mountings.......46
4.3 Removing and installing torque reaction support and cross member.......49
13 > Crankshaft group.......50
1 Cylinder block (pulley end).......50
1.1 Poly V-belt drive - exploded view.......50
1.2 Removing and installing poly V-belt.......52
1.3 Removing and installing tensioner for poly V-belt.......54
1.4 Removing and installing vibration damper.......54
1.5 Removing and installing bracket for ancillaries.......55
1.6 Sealing flange (pulley end) - exploded view.......58
1.7 Renewing crankshaft oil seal (pulley end).......58
1.8 Removing and installing sealing flange (pulley end).......60
2 Cylinder block (gearbox end).......64
2.1 Sealing flange (gearbox end) and drive plate - exploded view.......64
2.2 Removing and installing drive plate.......65
2.3 Removing and installing needle bearing in drive plate.......66
2.4 Renewing sealing flange (gearbox end).......67
3 Crankshaft.......76
3.1 Crankshaft - exploded view.......76
3.2 Crankshaft dimensions.......77
3.3 Measuring axial clearance of crankshaft.......77
3.4 Measuring radial clearance of crankshaft.......78
3.5 Pulling spur gear off crankshaft and shrink-fitting new spur gear.......78
4 Pistons and conrods.......81
4.1 Pistons and conrods - exploded view.......81
4.2 Measuring piston projection at >TDC>.......85
4.3 Piston and cylinder dimensions.......86
4.4 Measuring radial clearance of conrods.......86
15 > Cylinder head, valve gear.......88
1 Toothed belt drive.......88
1.1 Toothed belt drive - exploded view.......88
1.2 Removing and installing toothed belt.......90
2 Cylinder head.......99
2.1 Cylinder head cover - exploded view.......99
2.2 Removing and installing cylinder head cover.......100
2.3 Renewing injector seals.......103
2.4 Cylinder head - exploded view.......105
2.5 Removing and installing cylinder head.......107
2.6 Checking compression.......116
3 Valve gear.......119
3.1 Valve gear - exploded view.......120
3.2 Measuring axial clearance of camshafts.......121
3.3 Measuring radial clearance of camshafts.......122
3.4 Renewing camshaft oil seal.......122
3.5 Removing and installing camshafts.......125
3.6 Checking hydraulic valve compensation elements.......130
3.7 Renewing valve stem oil seals with cylinder head installed.......131
3.8 Renewing valve stem oil seals with cylinder head removed.......135
3.9 Valve dimensions.......138
3.10 Machining valve seats.......138
3.11 Checking valve guides.......138
3.12 Checking valves.......139
17 > Lubrication.......140
1 Sump, oil pump, balance shaft assembly.......140
1.1 Sump, oil pump, balance shaft assembly - exploded view.......141
1.2 Removing and installing oil level and oil temperature sender -G266-.......143
1.3 Removing and installing sump.......143
1.4 Removing and installing oil pump.......146
1.5 Removing balance shaft assembly.......147
1.6 Installing a new balance shaft assembly.......148
1.7 Re-installing a used balance shaft assembly.......151
2 Oil filter bracket, engine oil cooler and oil supply line.......153
2.1 Oil filter bracket and engine oil cooler - exploded view.......153
2.2 Removing and installing oil filter bracket with engine oil cooler.......154
2.3 Removing and installing engine oil cooler.......156
2.4 Removing and installing oil pressure switch -F1-.......157
2.5 Checking oil pressure switch -F1-.......158
2.6 Checking oil pressure.......159
2.7 Engine oil.......160
2.8 Checking oil level.......160
19 > Cooling.......161
1 Cooling system.......161
1.1 Diagram of coolant hose connections.......161
1.2 Draining and filling cooling system.......164
1.3 Checking cooling system for leaks.......170
2 Coolant pump and 4/2-way valve with thermostat.......172
2.1 Coolant pump and 4/2-way valve with thermostat - exploded view.......172
2.2 Removing and installing coolant pump.......173
2.3 Removing and installing 4/2-way valve with thermostat.......173
2.4 Checking thermostat.......176
3 Coolant pipes, coolant temperature senders, coolant circulation pump.......177
3.1 Coolant pipes, coolant temperature senders, coolant circulation pump - exploded view.......178
3.2 Removing and installing coolant temperature sender -G62-.......179
3.3 Removing and installing radiator outlet coolant temperature sender -G83-.......180
3.4 Removing and installing coolant pipe (top left).......181
3.5 Removing and installing coolant pipe (bottom left).......182
3.6 Removing and installing coolant pipe (rear right).......184
3.7 Removing and installing coolant pipe (rear).......186
3.8 Pump for exhaust gas recirculation cooler -V400- - exploded view.......189
3.9 Removing and installing pump for exhaust gas recirculation cooler -V400-.......189
3.10 Continued coolant circulation pump -V50- - exploded view.......192
3.11 Removing and installing coolant circulation pump -V50-.......192
4 Radiator and radiator fan.......194
4.1 Radiator and radiator fan - exploded view.......195
4.2 Removing and installing radiator with radiator cowl - Audi A4.......196
4.3 Removing and installing radiator - Audi A5.......200
4.4 Removing and installing radiator cowl - Audi A5.......203
4.5 Removing and installing radiator fan control unit -J293-.......208
4.6 Removing and installing radiator fan -V7-.......208
21 > Turbocharging/supercharging.......210
1 Turbocharger.......210
1.1 Diagram of vacuum connections.......210
1.2 Turbocharger - exploded view.......212
1.3 Removing and installing turbocharger.......213
2 Charge air cooling.......219
2.1 Charge air cooler - exploded view.......220
2.2 Removing and installing charge air cooler.......221
2.3 Removing and installing charge pressure sender -G31- / intake air temperature sender -G42-.......223
2.4 Checking charge air system for leaks.......223
26 > Exhaust system.......227
1 Silencers.......227
1.1 Silencers - exploded view.......228
1.2 Removing and installing front exhaust pipe.......230
1.3 Removing and installing particulate filter.......231
1.4 Separating centre and rear silencers.......232
1.5 Renewing tailpipes.......233
1.6 Stress-free alignment of exhaust system.......234
1.7 Checking exhaust system for leaks.......235
2 Exhaust manifold.......237
2.1 Exhaust manifold - exploded view.......237
2.2 Removing and installing exhaust manifold.......238
3 Exhaust gas temperature control.......240
3.1 Exhaust gas temperature senders - exploded view.......240
3.2 Removing and installing exhaust gas temperature sender>1 -G235-.......241
3.3 Removing and installing exhaust gas temperature sender>3 -G495-.......243
3.4 Removing and installing exhaust gas temperature sender>4 -G648-.......244
4 Exhaust gas recirculation.......247
4.1 Diagram of vacuum connections.......247
4.2 Exhaust gas recirculation system - exploded view.......247
4.3 Checking exhaust gas recirculation cooler change-over.......248
4.4 Removing and installing exhaust gas recirculation cooler.......248
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Audi A4 2008 >, Audi A5 Cabriolet 2009 >, Audi A5 Coup> 2008 >.......252
00 > Technical data.......258
1 Engine number.......258
2 Engine data.......259
3 Safety precautions.......261
3.1 Working on the fuel system.......261
3.2 Procedure before opening high-pressure section of injection system.......261
3.3 Working on the cooling system.......262
3.4 Working on vehicles with start/stop system.......262
3.5 Using testers and measuring instruments during a road test.......263
3.6 Working on the exhaust system.......263
3.7 Working on the subframe.......263
4 General repair instructions.......264
4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger.......264
4.2 Checking fuel system for leaks.......264
4.3 Foreign particles in engine.......264
4.4 Contact corrosion!.......264
4.5 Routing and attachment of pipes, hoses and wiring.......265
4.6 Checking vacuum system.......265
4.7 Installing radiators, condensers and charge air coolers.......265
10 > Removing and installing engine.......267
1 Removing engine.......267
2 Securing engine to assembly stand.......281
3 Installing engine.......283
4 Supporting engine with support bracket.......289
5 Assembly mountings.......290
5.1 Assembly mountings - exploded view.......290
5.2 Removing and installing engine mountings.......290
13 > Crankshaft group.......293
1 Cylinder block (pulley end).......293
1.1 Poly V-belt drive, bracket for ancillaries - exploded view.......293
1.2 Removing and installing poly V-belt.......295
1.3 Removing and installing tensioner for poly V-belt.......296
1.4 Removing and installing bracket for ancillaries.......297
1.5 Removing and installing vibration damper.......300
2 Cylinder block (gearbox end).......303
2.1 Sealing flange and drive plate - exploded view.......303
2.2 Removing and installing drive plate.......304
2.3 Removing and installing drive plate in needle bearing - vehicles with manual gearbox.......305
2.4 Removing and installing sealing flange (gearbox end).......306
3 Crankshaft.......309
3.1 Crankshaft - exploded view.......309
3.2 Removing and installing sender wheel.......310
3.3 Allocation of crankshaft bearing shells (classification).......311
3.4 Crankshaft dimensions.......312
3.5 Measuring axial clearance of crankshaft.......312
3.6 Measuring radial clearance of crankshaft.......313
4 Pistons and conrods - exploded view.......315
4.1 Separating parts of new conrod.......318
4.2 Piston and cylinder dimensions.......318
15 > Cylinder head, valve gear.......319
1 Chain drive.......319
1.1 Timing chain cover - exploded view.......319
1.2 Removing and installing camshaft control valve 1 -N205-.......320
1.3 Removing and installing timing chain cover (top).......321
1.4 Removing and installing timing chain cover (bottom).......321
1.5 Renewing oil seal for vibration damper.......326
1.6 Camshaft timing chain - exploded view.......329
1.7 Removing and installing camshaft timing chain.......330