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Audi A4 Quattro 2005 Service Manual

Suspension, wheels, steering

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00 - TECHNICAL DATA

TECHNICAL DATA

Suspension

Front axle

Rear axle

Vehicles up to VIN 400 000

Model:

Wheelbase:

Front track

Rear track

Maximum

Degree

steering angle at

inner wheel

1

*

These specified values correspond to a wheel offset of ET 39 mm and a load condition "empty without

driver".

2

*

These specified values correspond to a wheel offset of ET 42 mm and a load condition "empty without

driver".

Vehicles from VIN 400 001

Model:

2005 Audi A4 Quattro

2005 Audi A4 Quattro

SUSPENSION Suspension, Wheels, Steering

SUSPENSION Suspension, Wheels, Steering

Front Wheel Drive (FWD)/All Wheel Drive (AWD)

Standard

suspension 1BA

mm

2645

mm

1

1524

* See

note

1

mm

1517

* See

note

38

Front Wheel Drive (FWD)/All Wheel Drive (AWD)

Standard

1:05:17 AM

1:05:21 AM

Four-link lightweight suspension with virtual

steering axis, transverse stabilizer, twin gas-filled

struts and coil springs, control arm with hydraulic

damping mounts

Trapezoidal control arm - rear axle, independent

suspension

Sedan/Wagon

Sport

Comfort heavy

suspension 1BE

duty suspension

Sport

suspension 1BV

(quattro

GmbH) Audi

S4 1BD

2651

1

1528

* See

1521

note

1

1523

* See

1513

note

38

Sedan/Wagon

Sport

Comfort

Page 1

Page 1

Convertible

Standard

suspension 1BA

1BR

Sport

suspension 1BE

2642

2650

1

2

* See

1522

* See

note

note

1

2

* See

1517

* See

note

note

38

38

Basic

Sport

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Page 1 2005 Audi A4 Quattro 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering SUSPENSION Suspension, Wheels, Steering 00 - TECHNICAL DATA TECHNICAL DATA Suspension Front axle Four-link lightweight suspension with virtual steering axis, transverse stabilizer, twin gas-filled struts and coil springs, control arm with hydraulic...
Page 2 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering suspension suspension heavy duty suspension suspension 1BE Sport suspension suspension (quattro (quattro 1BV (quattro GmbH RS4) GmbH RS4) GmbH) Audi S4 1BD Wheelbase: 2644 2649 2640 2649 2652 Front track 1522 1524...
Page 3 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Clamp gas-filled strut vertically in vise, with piston ends facing downward.  CAUTION: Wear protective eye wear while drilling. Drill a 3 mm diameter hole - arrow A - through outer strut tube.
Page 4 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Pull piston rod upward, hold inner tube in place with pliers and push it downward so that it remains in  outer tube when piston rod is slowly raised. Remove piston rod from inner tube.
Page 5 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering B - Open with pipe cutter Special tools, testers and auxiliary items required Pipe cutter, e.g. Stahlwille Express 150/3  CAUTION: Wear protective eye wear when drilling or sawing. Fig. 4: Cutting Through Outer Tube Using Pipe Cutter Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 6 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 5: Turning Steering Pinion Courtesy of VOLKSWAGEN UNITED STATES, INC. Turn steering pinion in direction of - arrow - to stop.  Fig. 6: Identifying Steering Gear Saw Dimensions Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 7 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 7: Identifying Fluid Seepage Courtesy of VOLKSWAGEN UNITED STATES, INC. Oil leak (shown screened in illustration) is visible, but dull, matte and possibly dry from dust  Oil leak reaches at most, from upper shock absorber seal (piston rod seal) to lower spring plate - arrow -.
Page 8 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Struts are maintenance-free, shock absorber oil cannot be topped off.  A removed strut can be checked by hand as follows: Press strut together by hand.  Piston rods must move smoothly and with uniform difficulty over the entire range ...
Page 9 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Insufficient damping effect  NOTE: Intermediate values for reduced damping performance cannot be read out.  A prognosis on service life is not permitted.  Measured values that come about from involvement of suspension travel ...
Page 10 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Vehicle type Front axle Rear axle Comment A4 standard VA Up to and including sedan/wagon support spring OJJ (up to VA weight 918 Kg) A4 standard VA from support spring OJK sedan/wagon...
Page 11 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Vehicle type Front axle Rear axle Comment A4 standard VA Up to and including sedan/avant support spring OJJ (up to VA weight 918 Kg) A4 standard VA from support spring OJK sedan/wagon...
Page 12 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering CAUTION: When drilling, it is essential that eye protection be worn! Have thread repair checked by the responsible foreman or next person in charge.  Thread insert must be same length as thread in body.
Page 13: Front Suspension
2005 Audi A4 Quattro 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering SUSPENSION Suspension, Wheels, Steering 40 - FRONT SUSPENSION FRONT SUSPENSION, SERVICING General Information: When installing waxed components, contact surfaces must be cleaned. Contact surfaces must be free of wax and grease.
Page 14 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 9: Identifying Special Tools - Axle And Wheel Bearing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Engine/transmission jack V.A.G 1383 A  Tensioning Strap T10038 ...
Page 15 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering mode before being tightened (curb weight position) Otherwise, bonded rubber bushing will be stressed resulting in a shortened service life. By raising appropriate suspension using engine/transmission jack V.A.G 1383 A and Wheel Hub Support T10149 , this position can be simulated on the hoist.
Page 16 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 11: Measuring Wheel Bearing Courtesy of VOLKSWAGEN UNITED STATES, INC. Using engine/transmission jack V.A.G 1383 A , lift wheel bearing housing until dimension - a - is  reached. Tightening of the respective bolts/nuts must then only occur after dimension - a - , which was measured...
Page 17 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 12: Front Suspension Component, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Hex bolt, 75 Nm 2 - Washer 3 - Hex bolt Always replace if removed  4 - Upper rear link Removing and installing -->...
Page 18 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 5 - Hex bolt, 7 Nm For adjusting track constants "S"  6 - Bolt 7 - Hex nut, self-locking, 45 Nm Always replace if removed  8 - Hex bolt, 40 Nm...
Page 19 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 15 - Wheel bearing housing On vehicles with headlight range control module, note sensor removal and installation --> Vehicles with  automatic headlight vertical aim control, vehicle level sensor. Removing and installing --> Wheel bearing housing ...
Page 20 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 26 - Hex bolt 40 Nm plus an additional 90°( turn)  Always replace if removed  27 - Lower link On vehicles with headlight range control module, note sensor removal and installation --> Vehicles with ...
Page 21 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Bolt M 8: 40 Nm Bolt M10: 70 Nm 34 - Backing plate 35 - Drive axle Removing and installing --> Front drive axle, servicing  36 - Hex bolt Always replace if removed ...
Page 22 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Torque wrench V.A.G 1331  Torque wrench V.A.G 1332  Removing On vehicles with Dynamic Ride Control (DRC II), empty and fill system --> Dynamic Ride Control (DRC II), emptying and filling Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
Page 23 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 15: Removing Clip, Nut, Hex Bolt And Control Arms Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove clip - 1 - with a pair of pliers.  This clip does not need to be inserted again.
Page 24 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 16: Identifying Protective Sleeve Courtesy of VOLKSWAGEN UNITED STATES, INC. A 20 to 25 mm strip, dimension - A - , must be cut out of protective sleeve - 1 -.
Page 25 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 19: Removing/Installing Hex Bolts In Plenum Chamber Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove hex bolts - 1 - in plenum chamber.  Take out suspension strut with mounting bracket. ...
Page 26 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 21: Identifying Guide Link/Subframe Connection Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Insert suspension strut forked head into control arm and tighten threaded connection - 1 -  NOTE: Bolt must be inserted opposite direction of travel.
Page 27 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 23: Inserting Suspension Strut Forked Head Into Link Courtesy of VOLKSWAGEN UNITED STATES, INC. Insert new bolt - 2 - and self-locking nut and tighten  Insert ABS wiring into retainer on brake caliper.
Page 28 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 24: Spring Compressor Kit V.A.G 1752 Courtesy of VOLKSWAGEN UNITED STATES, INC. Spring compressor V.A.G 1752/1  Spring mounting tool V.A.G 1752/2  Spring holder V.A.G 1752/4  Spring holder V.A.G 1752/6 ...
Page 29 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 26: Suspension Strut Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Collar nut, 50 Nm Always replace  2 - Strut mounting 3 - Washer 4 - Mounting bracket Installed location Mounting bracket location ...
Page 30 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Removing Coil spring, removing and Coil spring, removing  Installing Coil spring, installing  Note different vehicle versions, see vehicle data plate. Clarification of Production Control numbers  (PR No.) 6 - Additional spring...
Page 31 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 27: Example Of Vehicle Data Sticker Courtesy of VOLKSWAGEN UNITED STATES, INC. Example of a vehicle data sticker Front axle PR no. is item - A -.  Rear axle PR no. is item - B -.
Page 32 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. You can find the suspension version PR no. in illustration see - arrow -. 1BA = Standard suspension 1BE = Sport suspension (20 mm lower than 1BA)
Page 33 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 30: Ensuring Correct Seating Of Coil Spring In Spring Holder V.A.G 1752/4 Courtesy of VOLKSWAGEN UNITED STATES, INC. Coil spring, removing When doing so, ensure correct seating of coil spring in spring holder V.A.G 1752/4 - arrow -.
Page 34 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 32: Strut, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove protective cap - 1 - and lower spring support - 2 -.  Mark installation position of lower suspension strut to strut.
Page 35 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Drive suspension strut downward using plastic hammer according to self-provided marking.  With a new damper, transfer marking from old damper. Note different installation locations on left and right sides. Suspension strut trimming - arrow - must result in clearance to body.
Page 36 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Position mounting bracket with spring support on pre-tension spring so that spring supports rests against end of coil spring - arrow -. Permissible deviation: ± 2°. Coil spring, installing Fig. 36: Coil Spring, Removing/Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 37 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 37: Tensioning Suspension Strut With Spring Compressor Vertically In Spring Mounting Tool V.A.G 1752/2 Courtesy of VOLKSWAGEN UNITED STATES, INC. Tension suspension strut with spring compressor vertically in spring mounting tool V.A.G 1752/2.
Page 38 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 39: Identifying Strut/Control Arm Direction Of Travel Courtesy of VOLKSWAGEN UNITED STATES, INC. Seen in direction of travel I = left II = right A - strut/control arm bolt axis Adjust angle B.
Page 39 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 40: Tensioning Suspension Strut With Spring Compressor Vertically In Spring Mounting Tool V.A.G 1752/2 Courtesy of VOLKSWAGEN UNITED STATES, INC. Spring mounting tool V.A.G 1752/2 arm - arrow - must be aligned with center of mounting bracket.
Page 40 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. Ball joint puller T40010  Torque wrench V.A.G 1331  Torque wrench V.A.G 1332  Removing Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
Page 41 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 43: Identifying Guide Link/Subframe Connection Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove ABS speed sensor bolt - 5 -.  Disengage ABS cable at wheel bearing housing  Remove disc brake.
Page 42 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 45: Identifying Nut, Control Links & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove combi-bolt - 3 - and bolt - 4 -.  NOTE: Align vehicle after repair --> Wheel alignment.
Page 43 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Separate guide link joint pin from tapered seat using ball joint puller T40010.  NOTE: Do not damage protective joint boot when doing this!  Ensure both puller lever arms are parallel to each other when using ...
Page 44 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Remove nut - 1 - , remove hex bolt and lift out both links - 2 - upward.  The slits in the wheel bearing housing must not be widened using a chisel or similar tool! Swing wheel bearing housing in direction of arrow away to side, when doing this remove drive axle pin ...
Page 45 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 51: Identifying Nut, Control Links & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Insert new bolt - 1 - and self-locking nut and tighten  Fig. 52: Identifying Steering Arm & Tie Rod Ball Joint Sealing Washer Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 46 Tighten drive axle hex bolt (only with vehicle resting on wheels -risk of accident-) Install drive axle  Perform vehicle alignment --> Wheel alignment.  Check front axle, alignment must take place on a VW/Audi recommended alignment stand. 1:06:01 AM Page 34...
Page 47 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Wheel bearing housing with bolted wheel bearing, servicing Fig. 55: Identifying Special Tools - Wheel Bearing Housing With Bolted Wheel Bearing, Servicing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Thrust plate VW 401 ...
Page 48 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 56: Sleeve VW 416 B Courtesy of VOLKSWAGEN UNITED STATES, INC. Sleeve VW 416 B  Fig. 57: Sleeve VW 519 Courtesy of VOLKSWAGEN UNITED STATES, INC. Sleeve VW 519 ...
Page 49 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 58: Wheel Bearing Housing With Bolted Wheel Bearing Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Wheel bearing housing 2 - Cap bolts 80 Nm plus an additional 90°( turn) ...
Page 50 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Bearing inner ring, pressing off --> Press bearing inner race from hub  Removing and installing Removing  Installed location:  The larger diameter of the wheel bearing faces the hub ...
Page 51 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Reinstall brake line bracket. Install hex bolt - 2 - and tighten.  Secure brake caliper to body so that caliper weight does not bend or damage brake line.  Continued for all vehicles Remove brake caliper and secure to body so that weight of caliper does not stress or damage brake hose ...
Page 52 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 62: Identifying Nut, Control Links & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen nut - 1 - , remove hex bolt and lift out both control arms - 2 - upward.
Page 53 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 64: Pressing Wheel Hub Out Of 82 Mm Diameter Wheel Bearing Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. Press bearing inner race from hub Fig. 65: Installing Separating Device In Notch Between Inner Bearing Ring, Hub And Pretension Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 54 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 66: Pressing Bearing Inner Race From Hub Courtesy of VOLKSWAGEN UNITED STATES, INC. Press bearing inner race off from wheel hub.  Light weight wheel hub --> Light weight wheel hub Pressing wheel hub into 82 mm diameter wheel bearing Fig.
Page 55 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 68: Removing/Installing Cap Bolts & Wheel Bearing Unit Courtesy of VOLKSWAGEN UNITED STATES, INC. Install cap bolts - 1 - and tighten  Install outer drive axle joint into hub and hand tighten with a new hex bolt.
Page 56 Wheels and Tire Guide Tighten drive shaft hex screw (only with vehicle resting on wheels -risk of accident-) Install drive axle.  Alignment must take place on a VW/Audi recommended alignment stand. LIGHT WEIGHT WHEEL HUB Characteristics Fig. 71: Identifying Conventional Wheel Hub & Slide Washer Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 57 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering The light weight wheel hub must only be used in conjunction with the corresponding wheel bearing. Slide washer - 1 - should be replaced if deformed or damage during wheel bearing removal.
Page 58 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 74: Identifying Conventional Wheel Hub & Slide Washer Courtesy of VOLKSWAGEN UNITED STATES, INC. Carefully pry off slide washer - 1 - , e.g. with a screwdriver.  Position slide washer on wheel hub.
Page 59 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Press slide washer off using assembly tool T40089/1 as shown in illustration up to wheel bearing hub  radius. NOTE: Slide washer must be pressed on up to wheel bearing hub radius.
Page 60 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering move in their positions. Upper front link Fig. 77: Adjusting Upper Front Link Height Courtesy of VOLKSWAGEN UNITED STATES, INC. Adjust height - A -.  A = 81 mm ± 2 mm Upper rear link Fig.
Page 61 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 79: Removing/Installing Nuts, Bolts & Links Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten nuts - 1 - ,  Check upper control arm positions  Repeat adjustment, if necessary  Reinstall mounting bracket --> Suspension strut, servicing.
Page 62 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 81: Identifying Front And Rear Bearing Tool 3348 Courtesy of VOLKSWAGEN UNITED STATES, INC. Assembly tool 3348/2  Assembly tool 3348/3  NOTE: Use protective covers when clamping aluminum links. ...
Page 63 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 83: Identifying Installation Location Of Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC. Installed location of bushing A = 90° ± 5° Fig. 84: Pulling In Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 64 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 85: Identifying Special Tools - Subframe, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Engine support bridge 10 - 222 A  Support 10 - 222 A/1 ...
Page 65 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Support engine entirely with engine support bridge.  Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).  Remove wheels.  Secure brake disc with a wheel bolt.
Page 66 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 87: Removing/Installing Bolts For Left/Right Transmission Mount Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove nuts - arrows - at transmission mounts if necessary.  Fig. 88: Identifying Nut & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 67 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 90: Removing Hex Bolt, Brake Line Bracket, Bolts From Brake Caliper And Brake Caliper Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove hex bolt - 2 - and remove brake line bracket.
Page 68 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Loosen guide link/subframe connection.  Remove tunnel crossmember if necessary --> Tunnel crossmember, removing and installing.  Place engine/transmission jack V.A.G 1383 A with wooden block under subframe and press lightly ...
Page 69 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 94: Identifying Nut & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolt - 3 -.  Loosen hex bolts - 2 - until subframe can be removed.  Installing Fig. 95: Inserting Subframe And Installing Hex Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 70 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 96: Identifying Hole, Sub-Frame Hole And Aluminum Console Hole Align On Both Sides Courtesy of VOLKSWAGEN UNITED STATES, INC. Holes - 1 - and - 2 - of subframe and hole - 3 - of aluminum bracket must line up on both sides.
Page 71 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 98: Identifying Nut & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Install nut - 1 -.  Fig. 99: Removing/Installing Bolts For Left/Right Transmission Mount Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 72 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Clip cable - arrow - into console.  Tightening sequence NOTE: Threads in body can be repaired according to DIN 8140 using wire thread  inserts (Heli-Coil). Thread insert must be same length as thread in body.
Page 73 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL  TRANSMISSION 01E ALL WHEEL DRIVE 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL  DRIVE 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL ...
Page 74 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 104: Identifying Guide Link/Subframe Connection Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten control arm hex head screws - 3 -  Tighten guide link hex bolts ,  Tighten connecting link to stabilizer bar - 4 - , ...
Page 75 If the subframe was not located, vehicle alignment must be done.  Perform vehicle alignment --> Wheel alignment.  Alignment must take place on a VW/Audi recommended alignment stand. Subframe bushings, replacing NOTE: Various subframe versions are installed. ...
Page 76 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 106: Sawing Off/Cut-Off Rubber Shoulder On Sub-Frame Mounting Courtesy of VOLKSWAGEN UNITED STATES, INC. Pulling out bonded rubber bushing Saw or cut rubber shoulder off subframe bushing up to outer bushing.
Page 77 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 108: Identifying All Bonded Rubber Bushings On Subframe Are Pulled Out Using Same Special Tool Courtesy of VOLKSWAGEN UNITED STATES, INC. Pulling out bonded rubber bushing All bonded rubber bushings on subframe are pulled out using same special tool.
Page 78 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 110: Aligning Bonded Rubber Mounting Courtesy of VOLKSWAGEN UNITED STATES, INC. Bonded rubber bushing, aligning The bonded rubber bushings must be aligned with a long rectangular tube or straightedge. A = 90° ± 5°...
Page 79 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 112: Pulling In Rear Bonded Rubber Mounting Courtesy of VOLKSWAGEN UNITED STATES, INC. Pulling in rear bonded rubber bushing Insert segments -3372/2- between bridge -3351/4- and subframe.  Pull mounting in onto stop.
Page 80 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 114: Push Mounting In Onto Stop Courtesy of VOLKSWAGEN UNITED STATES, INC. Pulling in front bonded rubber bushing Raise Installation Device 3372 and remove segments -3372/2-.  Replace bridge -3351/41 with thrust piece -3351/1 and then push mounting in onto stop.
Page 81 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 115: Pushing Stop Wedges Positioned In Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC. Push stop wedges - 1 - positioned in bonded rubber bushing as shown in illustration in to stop.
Page 82 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Engine/transmission jack V.A.G 1383 A  Torque wrench V.A.G 1331  Torque wrench V.A.G 1332  Removing Remove sound insulation. -->  50 BODY, FRONT  50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET ...
Page 83 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 118: Removing Bolts & Tunnel Crossmember Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - 1 - and - 2 -.  Remove tunnel crossmember  Installing Fig. 119: Removing/Installing Bolts & Tunnel Crossmember Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 84 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 120: Removing/Installing Combi-Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten combi-bolts - arrows - to 23 Nm.  Install sound insulation. -->  50 BODY, FRONT  50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET ...
Page 85 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Checking the headlight basic setting is necessary when: The track control link has been removed and reinstalled or replaced,  Assembly work was performed on level control system sensor,  The level control system sensor was replaced, ...
Page 86 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Hex bolt, 9 Nm 2 - Bracket 3 - Left Front Level Control System Sensor G78 Is checked electrically through On Board Diagnostics (OBD) ...
Page 87 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. Torque wrench V.A.G 1332  Fig. 123: Torque Wrench V.A.G 1410 Courtesy of VOLKSWAGEN UNITED STATES, INC. Torque wrench V.A.G 1410  When removing and installing control arm, it is necessary to loosen Left Front Level Control System Sensor G78 retaining clip.
Page 88 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Left Front Level Control System Sensor G78 connecting link retaining clip is secured at control arm  between stops with a clamp. When installing headlight range control, ensure correct position of crank and connecting link to each other.
Page 89 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Torque wrench V.A.G 1331  Torque wrench V.A.G 1332  Removing Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).  Remove wheel.  Remove sound insulation. -->...
Page 90 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 128: Identifying Guide Link/Subframe Connection Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove hex bolt - 1 -.  Remove bolts - 2 - and - 4 - , remove connecting link.
Page 91 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Tighten threaded connection - 1 -  Tighten bolt - 2 -  Tighten bolt - 4 -  On vehicles with headlight range control, install vehicle level sensor link at control link --> Vehicles with ...
Page 92 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 131: Ball Joint Puller T40010 Courtesy of VOLKSWAGEN UNITED STATES, INC. Ball joint puller T40010  Torque wrench V.A.G 1331  Torque wrench V.A.G 1332  Engine support bridge 10 - 222 A ...
Page 93 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Separate control link joint pin from tapered seat using ball joint puller T40010.  NOTE: Ensure both puller lever arms are parallel to each other when using  greatest force, adjust if necessary.
Page 94 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 135: Pulling Engine Mount And Stabilizer Bar Console Downward And Removing Bolts & Control Link Courtesy of VOLKSWAGEN UNITED STATES, INC. Pull engine mount and stabilizer bar console - 3 - downward and remove bolts - 2 -.
Page 95 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 136: Identifying Special Tools - Control Link Bushings, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Assembly tool 3301  Assembly tool 3301/3  Assembly tool 3301/4 ...
Page 96 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering NOTE: Use protective covers when clamping aluminum control links.  Fig. 137: Inner Bushing, Removing Courtesy of VOLKSWAGEN UNITED STATES, INC. Inner bushing, removing Mark location of old bushing.  Fig. 138: Bushing Installation Location Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 97 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 139: Inner Bushing, Pulling In Courtesy of VOLKSWAGEN UNITED STATES, INC. Inner bushing, pulling in Insert bearing - A - in thrust piece (3346/1) to a depth of 3.2 mm. ...
Page 98 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 141: Pull In Outer Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC. Pull in outer bushing To press in, use installation lubricant G 294 421 A1 thinned with water at a ratio of 1:100.
Page 99 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 143: Ball Joint Puller T40010 Courtesy of VOLKSWAGEN UNITED STATES, INC. Ball joint puller T40010  Torque wrench V.A.G 1332  Removing Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
Page 100 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. Separate guide link joint pin from tapered seat using ball joint puller T40010.  NOTE: Do not damage protective joint boot when doing this!  Ensure both puller lever arms are parallel to each other when using ...
Page 101 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 146: Tightening Nut On Joint Pin & Hex Head Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten nut on joint pin  Tighten hex head bolt - 2 - , ...
Page 102 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 147: Identifying Special Tools - Guide Link Mountings, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Assembly tool 3301  Assembly tool 3346/2  Assembly tool 3346/3 ...
Page 103 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 148: Remove Hydraulic Mount At Control Link Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove hydraulic mount at control link NOTE: Use protective covers when clamping aluminum control links.  Fig. 149: Installation Position Of Hydro-Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 104: Stabilizer Bar
2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 150: Pull In Hydro-Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC. Pull in hydro-bushing Insert hydro-bushing - A - into special tool (3347/2).  Tighten together with sleeve - 3348 - , spindle -3346/2- and hex nut.
Page 105 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 152: Identifying Guide Link/Subframe Connection Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolt -2-  Fig. 153: Identifying Front Stabilizer Bar Brackets Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove hex nut - 2 -.
Page 106 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 154: Identifying Front Stabilizer Bar Brackets Courtesy of VOLKSWAGEN UNITED STATES, INC. Install new nuts - 2 - but do not tighten.  Fig. 155: Identifying Guide Link/Subframe Connection Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 107: Cross Brace
2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Tighten nuts - 2 - to 25 Nm.  Install sound insulation. -->  50 BODY, FRONT  50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET  CROSS BRACE Cross brace, removing and installing NOTE: Cross brace is only installed on certain vehicle versions.
Page 108 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 158: Removing Combi-Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove combi-bolts - 2 - and - 4 -.  Remove cross brace - 1 - upward out of plenum chamber - 5 -.
Page 109 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 159: Identifying Torque Wrench V.A.G. 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC. Torque wrench V.A.G 1331  Fig. 160: Identifying Torque Wrench V.A.G. 1332 Courtesy of VOLKSWAGEN UNITED STATES, INC. Torque wrench V.A.G 1332 ...
Page 110 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 161: Identifying Nut, Control Links & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove nut - 1 - , remove hex bolt and lift out both control links - 2 - upward.
Page 111 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Install wheel and place vehicle on floor.  Turn drive axle bolt an additional 180°. (Only turn additional turn on vehicle resting on wheels -risk of  accident-). DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2000, SERVICING Tools Fig.
Page 112 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Thrust plate VW 402  Assembly tool T10065  Punch VW 408 A  Fig. 163: Identifying Special Tools - Drive Axle With Triple Roller Joint Aar 2000, Servicing (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 113 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Component, overview Filling outer joint with grease G 000 603. Filling triple roller joint with grease G 000 605. Grease quantity and type Grease quantity Amount if: Outer joint Total quantity Joint...
Page 114 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 164: Drive Axle With Triple Roller Joint AAR 2000 Component, Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Bolt Always replace if removed  Loosen Remove drive axle  Fastening Install drive axle ...
Page 115 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 11 - Clamp For triple roller joint  Replace  12 - CV boot for triple roller joint Check for tears and chafing  Before clamping hose clamp, raise protective joint boot briefly to balance pressure. Joint must be in ...
Page 116 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 165: Bending Open Metal Tabs With Flat-Head Screwdriver And Prying Off Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. Bend open metal tabs with flat-head screwdriver and pry off housing.  Fig. 166: Identifying Joint Piece, Triple Roller Star, Driveshaft And Marking Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 117 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 2 - Triple roller star 3 - Axle shaft Take O-ring - arrow - out of groove.  Hold joint and take drive axle out of vise.  Fig. 167: Removing Circlip From Triple Roller Joint/Drive Axle Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 118 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 168: Pressing Triple Roller Star Off Drive Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC. Hold drive axle, then press triple roller star off drive axle.  Ensure roller bodies are free when pressing off.
Page 119 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 170: Installing Triple Roller Star Onto Shaft As Per Markings Courtesy of VOLKSWAGEN UNITED STATES, INC. Install triple roller star onto shaft as per markings and drive in to stop. ...
Page 120 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 171: Identifying Joint Piece, Triple Roller Star, Driveshaft And Marking Courtesy of VOLKSWAGEN UNITED STATES, INC. Insert new sealing ring - arrow - from repair kit into groove.  Fig. 172: Installing New Cover On Joint Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 121 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Screw Pressure Spindle 3207 with M 16/M14 thread version into joint pins until constant velocity joint is  press off of drive axle. Remove circlip  Outer CV joint, installing Slide joint protective boot onto drive axle.
Page 122 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Screw old drive axle bolt into joint as shown in illustration.  Drive joint onto drive axle with plastic hammer until circlip engages.  Apply 40 g joint grease in boot side of joint.
Page 123 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 177: Two Rectangular Windows Aligned With Joint Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. Turn cage, until two rectangular windows - arrow - contact joint body.  Lift out cage together with hub.
Page 124 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Tools Fig. 179: Identifying Special Tools - Peened Triple Roller Joint AAR 2600 i Or 3300 i, Disassembling And Assembling (1 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Thrust plate VW 401 ...
Page 125 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 180: Identifying Special Tools - Peened Triple Roller Joint AAR 2600 i Or 3300 i, Disassembling And Assembling (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Hose clamp pliers V.A.G 1275...
Page 126 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 181: Slide Hammer-Multi-Purpose Tool Set VW 771 Courtesy of VOLKSWAGEN UNITED STATES, INC. Slide hammer - complete set VW 771  Fig. 182: Assembly Device T40018 For Triple Roller Joint AAR 3300 i Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 127 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Grease joint again when replacing protective joint boot. Fig. 183: Peened Triple Roller Joint AAR 2600 i Or 3300 i Component Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Clamp Always replace ...
Page 128 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Always replace  4 - Circlip Only present on certain versions  5 - Spring washer Only present on certain versions  Installed location Location of spacer and spring washer (wheel side) ...
Page 129 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 11 - Outer constant velocity protective joint boot Check for tears and chafing  Before clamping hose clamps, raise protective joint boot briefly to balance pressure Protective joint  boot, ventilating Different version in rubber or Hytrel ...
Page 130 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 184: Tightening Clamp On Inner Joint Courtesy of VOLKSWAGEN UNITED STATES, INC. Driving outer constant velocity joint down Fig. 185: Striking Copper Or Brass Drift On CV Joint Inner Race With Hammer Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 131 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 186: Protective Joint Boot, Ventilating Courtesy of VOLKSWAGEN UNITED STATES, INC. Only for joint protective boot of rubber A vacuum can form in joint when installing protective joint boot. This pressure pulls a fold in while driving, see - arrow -.
Page 132 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 3 - Spacer ring (plastic) Instructions only apply to stainless steel clamps. Fig. 188: Tightening Hose Clamp On Outer Joint Courtesy of VOLKSWAGEN UNITED STATES, INC. Tightening hose clamp on outer joint Position CV Joint Boot Clamp Tool VAG 1682 as shown in illustration.
Page 133 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering A waterproof felt tipped pen is suitable for marking. Fig. 189: Identifying Clamps & Protective Boot Courtesy of VOLKSWAGEN UNITED STATES, INC. Open clamps - arrows -.  Slide back protective boot.
Page 134 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering device T40084 behind joint. Fig. 191: Bringing Installation Device Into Contact With Joint By Turning Knurled Thumb Screws Courtesy of VOLKSWAGEN UNITED STATES, INC. Guide pins - 1 - must contact joint.
Page 135 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Leave joint in assembly device T40018 or T40084. Fig. 193: Identifying Drive Axle & Triple Roller Star & Mark Courtesy of VOLKSWAGEN UNITED STATES, INC. Mark installation position of parts 1 and 2 with lines.
Page 136 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 195: Pressing Triple Roller Star Off Drive Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC. Press triple roller star off of drive axle  Assembly tool T10065/4 must not be applied to roller body.
Page 137 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 196: Pressing On Circlip To Center Of Splines Courtesy of VOLKSWAGEN UNITED STATES, INC. Press on circlip - 1 - to center of splines  Fig. 197: Assembling Special Tools Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 138 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 198: Identifying Joint/Triple Roller Star Splines Courtesy of VOLKSWAGEN UNITED STATES, INC. Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.
Page 139 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 200: Pressing Triple Roller Star Axle Shaft With Cylindrical Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC. This illustration only applies to cylindrical drive axle - arrow - ! Use special tool shown in illustration.
Page 140 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 1 - Pliers (commercially available) Press 70 grams of joint grease, from repair kit, into reverse side of triple roller joint.  Lightly lubricate roller body  Make sure roller body does not tilt! Fig.
Page 141 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering NOTE: While positioning joint in center position, it is necessary to bleed  protective boot, e.g. with a screwdriver. - Arrow - Fig. 204: Identifying Clamping Sleeve Connecting Tube & Flanges Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 142 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 206: Identifying Special Tools - Drive Axle With Constant Velocity Inner Joint (Diameter 100 mm), Servicing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Thrust plate VW 401 ...
Page 143 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 207: Identifying Thrust Piece VW 434 Courtesy of VOLKSWAGEN UNITED STATES, INC. Press piece VW 434  Fig. 208: Pressing Appliance VW 459 Courtesy of VOLKSWAGEN UNITED STATES, INC. Pressing appliance VW 459 ...
Page 144 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 209: Drive Axle With Constant Velocity Inner Joint (Diameter 100 mm) Individual Component Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Bolt Always replace if removed  Loosen Remove drive axle ...
Page 145 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Installing Outer CV joint, installing  Greasing Grease quantity and type  Checking --> Outer constant velocity (CV) joint, checking  When installing joint on profile shaft, profile shaft splines must be lightly coated with grease used in ...
Page 146 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Greasing Grease quantity and type  Adhesive surface must be free of oil and grease  Checking --> Inner constant velocity (CV) joint, checking  When installing joint on profile shaft, profile shaft splines must be lightly coated with grease used in ...
Page 147 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 211: Identifying Seal Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove seal - arrow -  Fig. 212: Driving Protective Joint Boot Cap Under With Brass Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 148 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 213: Removing/Installing Circlip Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove circlip  Fig. 214: Pressing Inner CV Joint Off Of Drive Axle With Special Tool Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 149 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 216: Identifying Joint/Triple Roller Star Splines Courtesy of VOLKSWAGEN UNITED STATES, INC. Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.
Page 150 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 218: Removing/Installing Circlip Courtesy of VOLKSWAGEN UNITED STATES, INC. Install circlip  Check circlip for correct seating.  Circlip must be replaced Apply 50 g joint grease in boot.  Make sure you do not damage sealant bead.
Page 151 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 220: Identifying Seal Courtesy of VOLKSWAGEN UNITED STATES, INC. Grease seal contact surface - arrow -.  Remove adhesive foil from seal and adhere to CV joint.  Align new cover with screw holes.
Page 152 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 222: Positioning Protective Joint Boot Courtesy of VOLKSWAGEN UNITED STATES, INC. Position protective joint boot between - arrows -.  Outer constant velocity joint, servicing Outer CV joint, removing Drive axle, clamping in vise ...
Page 153 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Slide joint protective boot onto drive axle.  Insert new circlip  Circlip (snap ring) must be replaced Apply 50 g joint grease in inside of joint.  Fig. 224: Identifying Joint/Triple Roller Star Splines Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 154 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Outer constant velocity (CV) joint, checking In order to replace grease in case of strong soiling, joint must be disassembled or if journal surface of balls must be checked for wear and damage.
Page 155 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 228: Tilting Hub Out Of Cage Courtesy of VOLKSWAGEN UNITED STATES, INC. Swing segment of hub into rectangular window of cage.  Tilt hub out of cage.  Checking 6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small indentations (pitting) and signs of seizure.
Page 156 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 229: Pressing Out Ball Joint Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. Swivel ball hub and ball cage.  Press out ball joint housing in direction of - arrow -. ...
Page 157 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 231: Inserting Ball Hub Over Both Chamfers Into Ball Cage Courtesy of VOLKSWAGEN UNITED STATES, INC. Insert ball hub into ball cage via two chamfers. The hub can be installed in any position. Press balls into ...
Page 158 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 233: Ball Hub Installed With Hub Able To Be Swivelled Out Of Cage Courtesy of VOLKSWAGEN UNITED STATES, INC. Install ball hub, whereby hub must be swiveled out of cage - arrows - far enough to allow balls to fit into ...
Page 159 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Tools Fig. 235: Identifying Special Tools - Drive Axle With Constant Velocity Inner Joint (Diameter 108 mm), Servicing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Thrust plate VW 401 ...
Page 160 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Component overview Constant velocity joints are packed with grease G 000 603: Grease quantity and type Grease quantity Amount in: Outer joint Total quantity Joint Boot [mm] Inner joint Apply grease through ball paths Grease joint again when replacing protective joint boot.
Page 161 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Cover Always replace  2 - Circlip Remove and install with commercially-available circlip pliers  3 - Inner constant velocity joint Exterior diameter: 108 mm ...
Page 162 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering In case of damage, check outer constant velocity joint --> Outer constant velocity (CV) joint, checking  Sealing surfaces must be free of grease when installing.  10 - Clamp Always replace ...
Page 163 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Inner CV joint, servicing Inner CV joint, removing Drive axle, clamping in vise  Use protective vise covers for this. Fig. 237: Driving Cover Down With Copper Or Brass Drift Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 164 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 239: Clamping Drive Axle In Vise At CV Joint Courtesy of VOLKSWAGEN UNITED STATES, INC. Clamp drive axle in vise at CV joint, as shown in illustration.  A 2nd technician must hold drive axle horizontally so that CV joint is not damaged.
Page 165 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 241: Identifying Sealing Surface To Be Covered With D 454 300 A2 Courtesy of VOLKSWAGEN UNITED STATES, INC. Apply sealant D 454 300 A2 - hatched surface - to clean surface on inner side of protective boot cover or ...
Page 166 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 243: Securing CV Joint From Coming Apart With Adhesive Tape Courtesy of VOLKSWAGEN UNITED STATES, INC. Secure CV joint from coming apart, e.g. with adhesive tape - arrow -.  Press off CV joint.
Page 167 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Drive off protective boot with cap using plastic hammer.  Clear away leaking sealant immediately.  Fig. 245: Aligning New Cover With Bolts To Screw Holes Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 168 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 246: Striking Copper Or Brass Drift On CV Joint Inner Race With Hammer Courtesy of VOLKSWAGEN UNITED STATES, INC. Strike a copper or brass drift on CV joint inner race with a hammer.
Page 169 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 248: Installing Outer Constant Velocity (CV) Joint With Flange Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC. Drive joint onto drive axle with plastic hammer until circlip engages.  Apply 40 g joint grease in boot side of joint.
Page 170 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 250: Turning Cage Until Two Cage Windows Rest On Joint Body Courtesy of VOLKSWAGEN UNITED STATES, INC. Turn cage until two cage windows - arrow - rest on joint body. ...
Page 171 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Cage must be installed laterally correct.  Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint  body must be re-established. Pack grease into joint body, grease quantity and type Grease quantity and type.
Page 172 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 253: Tilting Ball Hub Out Of Ball Cage Over Ball Track Courtesy of VOLKSWAGEN UNITED STATES, INC. Flip out ball hub from ball cage via running path of ball - arrows -.
Page 173 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. NOTE: When inserting make sure that the wide space - a - on joint housing is  aligned with the narrow space - b - on the hub after swiveling in.
Page 174 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Constant velocity joint is properly assembled, if ball hub can be slid back and forth by hand over whole compensation length. 1:06:13 AM Page 162...
Page 175: Rear Suspension
2005 Audi A4 Quattro 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering SUSPENSION Suspension, Wheels, Steering 42 - REAR SUSPENSION REAR AXLE COMPONENT ALLOCATION General information When installing waxed components, contact surfaces must be cleaned. Contact surfaces must be free of wax and grease.
Page 176 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 258: Identifying Special Tools - Axle And Wheel Bearing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Engine/transmission jack V.A.G 1383 A  Tensioning strap T10038 ...
Page 177 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering mode before being tightened (curb weight position) Otherwise, bonded rubber bushing will be stressed resulting in a shortened service life. By raising appropriate suspension using engine/transmission jack V.A.G 1383 A and Wheel Hub Support T10149 , this position can be simulated on hoist.
Page 178 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 260: Measuring Wheel Bearing Courtesy of VOLKSWAGEN UNITED STATES, INC. Using engine/transmission jack V.A.G 1383 A , lift wheel bearing housing until dimension - a - is  reached. Tightening of the respective bolts/nuts must then only occur after dimension - a - , which was measured...
Page 179 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 261: Rear Axle Component Groups Courtesy of VOLKSWAGEN UNITED STATES, INC. I - Subframe - front wheel drive --> Part I, Subframe - front wheel drive II - Subframe - all wheel drive --> Part II, Subframe - all wheel drive III - Trapezoidal control arm, transverse link, tie rod -->...
Page 180 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 262: Wheel Bearing Housing (Aluminum) - All Wheel Drive Courtesy of VOLKSWAGEN UNITED STATES, INC. Wheel bearing housing (aluminum) - all wheel drive VII - Wheel bearing housing aluminum - all wheel drive --> Part VII, Wheel bearing housing (aluminum) -...
Page 181 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 263: Rear Axle Part I, Subframe - Front Wheel Drive Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Subframe Removing and installing --> Subframe, removing and installing  Subframe bushings, replacing --> Subframe bushings, replacing ...
Page 182 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 4 - Combi-bolt Always replace  Tighten to 110 Nm plus an additional 90° turn  Threads in body can be repaired according to DIN 8140 using wire thread inserts (Heli-Coil). Thread ...
Page 183 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 264: Rear Axle Part II, Subframe - All Wheel Drive Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Subframe Removing and installing --> Subframe, removing and installing  Subframe bushings, replacing --> Subframe bushings, replacing ...
Page 184 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Part of purchased bushing assembly  6 - Washer Always replace  7 - Combi-bolt Always replace  Tighten to 110 Nm plus an additional 90° turn  Threads in body can be repaired according to DIN 8140 using wire thread inserts (Heli-Coil). Thread ...
Page 185 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 265: Rear Axle Part III, Trapezoidal Control Arm, Transverse Link, Tie Rod Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Trapezoidal control arm Various versions --> Trapezoidal control arm  Mixed installation not permissible ...
Page 186 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 3 - Eccentric washer Inner bore with tab  4 - Hex nut, self-locking, 95 Nm Always replace  Tighten bolts only in curb weight position  5 - Combi-bolt Always replace ...
Page 187 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 14 - Nut, self-locking Always replace  Tighten to 85 Nm plus an additional 90° turn  Tighten bolts only in curb weight position  15 - Tie rod Various versions ...
Page 188 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 266: Rear Axle Part IV, Stub Axle Carrier - Front Wheel Drive Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Stub axle carrier Vehicles with front wheel drive  Removing and installing --> Stub axle carrier/wheel bearing housing and wheel bearing unit ...
Page 189 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering If wheel bearing unit can be removed from stub axle carrier by hand, wheel bearing unit is OK and can be  reinstalled. If it cannot be removed by hand, wheel bearing unit must be replaced.
Page 190 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 11 - Combi-bolt Always replace  Tighten to 150 Nm plus an additional 90° turn  Tighten bolts only in curb weight position  Speed sensor wire routing on trapezoidal control arm Fig.
Page 191 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 268: Identifying Longer Collar On Strut Must Sit In Centering Seat On Stub Axle Carrier/Wheel Bearing Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. Longer collar on strut - arrow A - must sit in centering seat on stub axle carrier/wheel bearing housing - arrow B -.
Page 192 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 269: Rear Axle Part V, Wheel Bearing Housing (Steel) - All Wheel Drive Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Wheel bearing housing Vehicles with all-wheel drive  Removing and installing --> Stub axle carrier/wheel bearing housing and wheel bearing unit ...
Page 193 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 3 - Wheel hub Removing and installing with wheel bearing housing removed --> Wheel bearing housing (steel) - all  wheel drive, servicing Removing and installing in vehicle --> Wheel bearing (with wheel bearing housing (steel) installed - ...
Page 194 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 11 - Combi-bolt, 36 Nm 12 - Combi-bolt Always replace  Tighten to 150 Nm plus an additional 90° turn  Tighten bolts only in curb weight position  Part VI, Stabilizer bar Fig.
Page 195 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Vehicle data plate. Removing and installing --> Stabilizer bar, removing and installing  Replace bearing --> Stabilizer bushings, replacing  Always replace mounts on both sides of vehicle  2 - Clamp...
Page 196 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 271: Rear Axle Part VII, Wheel Bearing Housing (Aluminum) - All Wheel Drive Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Wheel bearing housing Vehicles with all-wheel drive  Removing and installing --> Stub axle carrier/wheel bearing housing and wheel bearing unit ...
Page 197 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 4 - Collar bolt Always replace  Tighten to 200 Nm plus an additional 180° turn  Tighten to 200 Nm, if vehicle is raised, only tighten with additional turn when vehicle is on floor ...
Page 198 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Always replace  Tighten to 150 Nm plus additional 90° turn  Tighten bolts only in curb weight position  VEHICLE LEVEL SENSOR IN VEHICLES WITH AUTOMATIC HEADLIGHT VERTICAL AIM CONTROL Vehicle level sensor in vehicles with automatic headlight vertical aim control NOTE: General information -->...
Page 199 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 272: Identifying Combi-Bolt, Left Rear Level Control System Sensor G76 Or G77 Right Rear Level Control System Sensor G77, Collar Bolt & Trapezoidal Control Arm Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 200 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 94 LIGHTS, SWITCHES - EXTERIOR  94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET  3 - Collar bolt, 10 Nm 4 - Trapezoidal control arm Vehicle level sensor in vehicle, replacing Special tools, testers and auxiliary items required Torque wrench V.A.G 1331...
Page 201: Rear Coil Spring
2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 94 LIGHTS, SWITCHES - EXTERIOR  94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET  Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information;  Wheels and Tire Guide...
Page 202 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 275: Identifying Spring Compressor V.A.G 1752/1 With Adapter V.A.G 1752/9 And Spring Holder A4, Rear Axle V.A.G 1752/16 In Coil Spring Courtesy of VOLKSWAGEN UNITED STATES, INC. Insert spring compressor V.A.G 1752/1 with adapter V.A.G 1752/9 and spring holder A4, rear axle ...
Page 203 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 276: Identifying Trapezoidal Control Arm Hole, Spring Seat, Colored Markings & Spring Seat Stop Courtesy of VOLKSWAGEN UNITED STATES, INC. - Arrow B - : Colored markings must be at bottom.
Page 204: Table Of Contents
2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 277: Spring Compressor Kit V.A.G 1752 Courtesy of VOLKSWAGEN UNITED STATES, INC. Spring compressor V.A.G 1752/1  Adapter V.A.G 1752/9  Spring holder A4, rear axle V.A.G 1752/16  Torque wrench V.A.G 1331 ...
Page 205: Courtesy Of Volkswagen United States, Inc
2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 278: Removing/Installing Strut Nut & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove nut - 1 - and remove bolt (Illustration without cover plate).  Remove bolts - 2 -. ...
Page 206 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 279: Removing/Installing Strut Nut & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten bolts - 2 -.  Note location of lower mounting Strut location Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms ...
Page 207: Torque Wrench V.a.g 1331
2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 280: Identifying Torque Wrench V.A.G. 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC. Torque wrench V.A.G 1331  Fig. 281: Special Wrench 3017 A Courtesy of VOLKSWAGEN UNITED STATES, INC. Special wrench 3017 A ...
Page 208 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 282: Exploded View Of Strut Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Hex nut, self-locking, 25 Nm Always replace  Loosening and tightening Loosening and tightening bolted connection for strut mount ...
Page 209 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Removing and installing --> Strut  Note different vehicle versions, see vehicle data plate. Clarification of Production Control numbers  (PR No.) Faulty struts must be vented and emptied before disposal --> Strut, checking ...
Page 210: Torque Wrench V.a.g 1332
2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 284: Identifying Special Tools - Stub Axle Carrier/Wheel Bearing Housing (Steel), Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Grease cap puller VW 637/2 ...
Page 211 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Vehicles with front wheel drive NOTE: If wheel bearing unit is not replaced, do not remove collar bolt and dust  cap. Remove wheel.  Fig. 285: Tapping Lightly On The Claws Of The Grease Cap Puller VW 637/2 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 212: Remove Tire
2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Continued for all vehicles Fig. 287: Wheel Hex Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC. Only loosen collar bolt - arrow - 90°, otherwise wheel bearing is damaged.  CAUTION: When loosening and tightening collar bolt, vehicle must stand on wheels.
Page 213: Remove Coil Spring --> Rear Coil Spring
2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Remove disc brake.  Remove coil spring --> Rear coil spring.  Fig. 289: Identifying Collar Bolt, Cover Plate & Wheel Bearing Unit Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove collar bolt - 1 -.
Page 214 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 291: Identifying Speed Sensor, Eccentric Screw Position & Connections Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove speed sensor - 2 -.  Mark eccentric screw position - 1 - at top of stub axle carrier/wheel bearing housing, e.g. with a felt-tip ...
Page 215 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 292: Identifying Speed Sensor, Eccentric Screw Position & Connections Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten connections - 1 - , - 3 - , - 4 - and - 5 -.
Page 216 Continued for all vehicles Perform vehicle alignment --> Wheel alignment.  Alignment must take place on a VW/Audi recommended alignment stand. Stub axle carrier - front wheel drive, servicing Special tools, testers and auxiliary items required Thrust plate VW 402 ...
Page 217 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Sleeve VW 415 A  Press piece VW 434  Assembly tool VW 792  Assembly tool 3301/4  Fig. 295: Exploded View Of Stub Axle Carrier - Front Wheel Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 218 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 2 - Shield plate 3 - Wheel bearing unit Does not need to be replaced  If wheel bearing unit can be removed from stub axle carrier by hand, wheel bearing unit is OK and can be ...
Page 219 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 297: Rubber Bushing, Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. Clean bearing seat in stub axle carrier/wheel bearing housing.  Completely coat rubber bushing and stub axle carrier/wheel bearing housing bearing set using installation ...
Page 220 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Special tools, testers and auxiliary items required Thrust plate VW 401  Punch VW 408 A  Punch VW 412  Sleeve VW 415 A  Press piece 2050  Thrust pad 3005 ...
Page 221 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Wheel bearing housing Removing and installing --> Stub axle carrier/wheel bearing housing and wheel bearing unit  2 - Wheel bearing Interior diameter in tiered version ...
Page 222 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. NOTE: Wheel bearing housing must rest on machined screw hole surface.  Pressing wheel bearing out of wheel bearing housing Fig. 301: Pressing Wheel Bearing Out Of Wheel Bearing Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 223 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Pressing wheel hub into wheel bearing Fig. 303: Pressing Wheel Hub Into Wheel Bearing Courtesy of VOLKSWAGEN UNITED STATES, INC. Install wheel hub - B - and press on over wheel bearing inner race to stop.
Page 224 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 305: Identifying Foot Pump With High Pressure Hose V.A.G 1389 A/1 Courtesy of VOLKSWAGEN UNITED STATES, INC. Foot pump with high pressure hose V.A.G 1389 A/1  If available in shop, hand pump V.A.G 1389/1 can also be modified for use as a foot pump.
Page 225 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 307: Identifying Supplementary Set V.A.G 1459 B/2 Courtesy of VOLKSWAGEN UNITED STATES, INC. Supplementary set V.A.G 1459 B/2  Bell E-40  Press piece E-43  Thrust sleeve E-44-1  Remove brake caliper, brake disc and brake disc cover. --> 46 - BRAKES - MECHANICAL ...
Page 226 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 1 - Bell E-40 2 - Hollow piston cylinder HKZ-15 3 - Special nut E-8-214 and tie bolt Wheel bearing, pulling out Fig. 309: Attaching Pressure Piece With Collar To Bearing, Pressure Sleeve With Four Tiered Interior Diameters To Wheel Bearing Housing, Hollow Piston Cylinder With Tie Bolt &...
Page 227 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 310: Putting Wheel Bearing , Pressure Piece (Put Collar Into Bearing) And Hollow Piston Cylinder With Tie Bolt On Wheel Bearing Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. Put wheel bearing - 1 - , pressure piece - 2 - (put collar into bearing), and hollow piston cylinder - 3 - with ...
Page 228 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Put wheel hub - 1 - and hollow piston cylinder - 2 - with tie bolt onto wheel bearing.  Attach pressure piece - 3 - with collar to special nut - 4 - from inside.
Page 229 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 312: Identifying Special Tools - Bolted Wheel Bearing Unit, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Thrust plate VW 401  Thrust plate VW 402 ...
Page 230 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 313: Rear Axle Part VII, Wheel Bearing Housing (Aluminum) - All Wheel Drive Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Wheel bearing housing Wheel bearing housing, removing and installing --> Wheel bearing housing (aluminum) - all wheel ...
Page 231 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Always replace  Tighten to 200 Nm plus an additional 180° turn  Tighten to 200 Nm, if vehicle is raised, only tighten with additional turn when vehicle is on floor ...
Page 232 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Always replace  Tighten to 150 Nm plus an additional 90° turn  Tighten bolt only in curb weight position  Fig. 314: Kukko 21/2 Internal puller, Kukko 21/4 Internal puller, Kukko 22/2 Counter support Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 233 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 316: Removing Securing Bolts From Brake Caliper Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove mounting bolts - 1 - from brake caliper.  Remove brake caliper and hang up on body.
Page 234 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 318: Pulling Wheel Bearing Unit Outward Courtesy of VOLKSWAGEN UNITED STATES, INC. Pull wheel bearing unit outward.  Fig. 319: Pressing Wheel Hub Out Of 82 Mm Diameter Wheel Bearing Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 235 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Press bearing inner race from hub. Insert separator into of bearing inner race ring groove - arrow - , and pre-tension with spindle.  NOTE: Use commercially available separating device e.g. Kukko 15-17.
Page 236 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering When pressing on, thrust piece VW 511 must bear only against inner race.  Installing Installation is in reverse order of removal. Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms if vehicle is in curb weight position -->...
Page 237 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Remove disc brake.  Fig. 324: Identifying Socket Head Bolt & ABS Vehicle Speed Sensor Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove hex socket head bolt - 1 -.  Remove ABS wheel speed sensor - 2 - from wheel bearing housing.
Page 238 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 326: Removing Bolts For Tie Rod Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolt - A - for tie rod.  Mark installation position of eccentric washer for bolt - B -.
Page 239 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Perform vehicle alignment --> Wheel alignment.  Alignment must take place on a VW/Audi recommended alignment stand. LIGHT WEIGHT WHEEL HUB Characteristics Fig. 328: Identifying Conventional Wheel Hub & Slide Washer Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 240 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 329: Press Piece VW 473 Courtesy of VOLKSWAGEN UNITED STATES, INC. Press piece VW 473  Fig. 330: Thrust Plate VW 401 Courtesy of VOLKSWAGEN UNITED STATES, INC. Thrust plate VW 401 ...
Page 241: Transverse Link
2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 332: Installing Special Tools Courtesy of VOLKSWAGEN UNITED STATES, INC. Install special tools as shown in illustration.  1. Press piece VW 473 2. Assembly tool T40089/1 3. Slide washer 4. Wheel hub 5.
Page 242 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 333: Identifying Inner Bolt & Eccentric Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC. NOTE: Because of poor accessibility to inner bolt - 1 - when vehicle is resting on  wheels, transverse link can only be removed when subframe is removed.
Page 243 Loosen connection - 2 - and retighten.  Perform vehicle alignment --> Wheel alignment.  Alignment must take place on a VW/Audi recommended alignment stand. Transverse link bracket, replacing Special tools, testers and auxiliary items required Thrust plate VW 401 ...
Page 244 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 336: Removing Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC. Removing bonded rubber bushing Fig. 337: Installing Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC. Installing bonded rubber bushing Press bracket on until ends project evenly on both sides.
Page 245 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 338: Identifying Inner Bolt & Eccentric Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC. Because of poor accessibility to inner bolt - 1 - when vehicle is resting on  wheels, transverse link can only be removed when subframe is removed.
Page 246 Alignment must take place on a VW/Audi recommended alignment stand. TRAPEZOIDAL CONTROL ARM General information Modified trapezoidal links are installed in Audi A4 with front or all wheel drive.  A mixed installation between old and new trapezoidal control arms in a vehicle is not permitted.
Page 247 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 8E0 505 311 S/8E0 505 312 S Also identified with yellow dot (dia. approx. 15 8E0 505 311 T 8E0 505 312 T NOTE: Measure vehicle after repair --> Wheel alignment. ...
Page 248 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Disengage parking brake cable from bracket under trapezoidal control arm. Loosen bolts to do this.  Fig. 342: Removing/Installing Bolts With Angled Wrench Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolt - 1 - on vehicles with headlight range control.
Page 249 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering vehicles with front wheel drive, subframe should be lowered slightly before removing bolts. Vehicles with all-wheel drive Remove drive shaft from rear final drive. --> 39 - FINAL DRIVE, DIFFERENTIAL  Secure drive shaft to body with wire.
Page 250 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove trapezoidal control arm (items 3 to 6).  NOTE: When doing so, ensure subframe is held securely.  Installing Replace bolts and self-locking nuts --> Notes in exploded view diagrams at --> Part I, Subframe - front wheel drive.
Page 251 Tighten bolt - 1 - on vehicles with headlight range control :  Perform vehicle alignment --> Wheel alignment.  Alignment must take place on a VW/Audi recommended alignment stand. Vehicles with heavy duty suspension Install stone protection and tighten bolts. ...
Page 252: Rear Subframe
2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Install diagonal braces - 1 - and - 2 - --> Diagonal braces.  Continued for all vehicles Install underbody trim.  REAR SUBFRAME Subframe, removing and installing NOTE: The procedure steps show you how you can remove the subframe as a ...
Page 253 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 349: Identifying Engine/Transmission Jack V.A.G. 1383 A Courtesy of VOLKSWAGEN UNITED STATES, INC. Engine/transmission jack V.A.G 1383 A  Fig. 350: Spring Compressor Kit V.A.G 1752 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 254 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 351: Identifying Diagonal Braces Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove diagonal braces - 1 - and - 2 - --> Diagonal braces.  Continued for all vehicles Remove rear and side underbody trim in front of subframe.
Page 255 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 352: Identifying Spring Compressor V.A.G 1752/1 With Adapter V.A.G 1752/9 And Spring Holder A4, Rear Axle V.A.G 1752/16 In Coil Spring Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove coil spring --> Rear coil spring.
Page 256 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Vehicles with heavy duty suspension Remove stone protection from trapezoidal control arm.  Continued for all vehicles Disengage parking brake cable from bracket under trapezoidal control arm. To do this, loosen bolts.
Page 257 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 355: Removing/Installing Strut Nut & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - 2 - and remove strut.  Remove brake disc and brake disc cover.  Continued for all vehicles Fig.
Page 258 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering (e.g. load luggage compartment with approx. 50 kg). Remove subframe bolts - arrows -.  Vehicles with front wheel drive Lay parking brake cable with brake caliper over transverse link.  Carefully lower subframe. Guide subframe so it does not shift.
Page 259 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering ENGINE MECHANICAL, ENGINE CODE(S): AMB 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO  ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE ...
Page 260 -risk of accident- Install rear and side underbody trim.  Perform vehicle alignment --> Wheel alignment.  Alignment must take place on a VW/Audi recommended alignment stand. Vehicles with heavy duty suspension Install stone protection and tighten bolts ,  Convertible only Fig.
Page 261 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Special tools, testers and auxiliary items required Fig. 359: Identifying Engine/Transmission Jack V.A.G. 1383 A Courtesy of VOLKSWAGEN UNITED STATES, INC. Engine/transmission jack V.A.G 1383 A with universal transmission mount V.A.G 1359/2 ...
Page 262 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 361: Identifying wheel bearing V.A.G 1459 B Courtesy of VOLKSWAGEN UNITED STATES, INC. Wheel bearing tool V.A.G 1459 B  Hollow piston cylinder HKZ-15 mit Druckstuck E-0-204-T hydraulisch  Tie bolt E-0-217+218 ...
Page 263 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Remove wheels.  Remove left and right coil spring --> Rear coil spring.  Fig. 362: Identifying Left/Right Underbody Trim Courtesy of VOLKSWAGEN UNITED STATES, INC. Only remove rear left/right underbody trim if front hydraulic mounting will be replaced.
Page 264 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 364: Positioning Engine And Transmission Jack V.A.G 1383 A With Universal Transmission Support V.A.G 1359/2 And Corresponding Wooden Block At Subframe Or Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC. Position engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 and a ...
Page 265 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Mark location of hydraulic mounting - 1 - to subframe - 2 - , e.g. with a felt-tip pen (Fig. shows subframe  on front wheel drive vehicle). Arrow A: Driving direction Arrows B and C: Marking Fig.
Page 266 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering NOTE: When removing hydraulic bushing with special tool wheel bearing tool  V.A.G 1459 B , you must cut back. Pull in front or rear hydraulic bushing Front and hydraulic bushings are different. Ensure correct allocation when installing.
Page 267 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Pre-tension special tool with hydraulic bushing.  Completely coat hydraulic bushing with installation lubricant G 294 421 A1 -thin with water at a ratio of  1:100-. Fig. 368: Ensuring Ends Of Rubber Beads On Hydraulic Bushing Align With Markings On Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 268 Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information;  Wheels and Tire Guide Perform vehicle alignment if more than 2 hydraulic bushing bolts were loosened --> Wheel alignment.  Alignment must take place on a VW/Audi recommended alignment stand. Subframe bushing, component overview 1:07:12 AM Page 94...
Page 269 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 370: Subframe Bushing, Component Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Combi-bolt 2 - Rear differential mount 3 - Hex nut 4 - Subframe 5 - Hex nut 6 - Combi-bolt...
Page 270 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 8 - Washer 9 - Rear crossmember 10 - Combi-bolt 11 - Combi-bolt 12 - Rear differential bushing web alignment 13 - Washer Rear differential bushing, replacing Special tools, testers and auxiliary items required Fig.
Page 271 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Engine/transmission jack V.A.G 1383 A  Torque wrench V.A.G 1331  Torque wrench V.A.G 1332  Removing Place engine/transmission jack V.A.G 1383 A with universal transmission support 1359/2 under rear final ...
Page 272 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 374: Using Removal And Assembly Tool T40032 To Differential Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC. Use Removal And Assembly Tool T40032 as shown in illustration and remove differential bushing. ...
Page 273 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fasten front transmission support to rear final drive ,  Install drive shaft to rear final drive. -->39 - FINAL DRIVE, DIFFERENTIAL  Remove engine/transmission jack V.A.G 1383 A.  TIE ROD...
Page 274 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove threaded connections - 1 - and - 2 - and remove tie rod.  Installing NOTE: Replace bolts and self-locking nuts --> Notes in exploded view diagrams at ...
Page 275 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Alignment must take place on a VW/Audi recommended alignment stand. Tie rod (three-piece version) stone protection 8E0 501 561 (old version), removing and installing Special tools, testers and auxiliary items required Fig. 379: Torque Wrench V.A.G 1410 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 276 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Unclip stone protection from tie rod.  Installation is in reverse order of removal. Torque specification item 2: 5 Nm Stone protection, replacing with tie rod installed Removing Cut stone protection with a knife in threaded connection area at trapezoidal control arm. Do not damage ...
Page 277 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. Cut in new stone protection at top - A -.  Slide clamping parts - 1 - inward.  Clip stone protection onto tie rod. ...
Page 278 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 384: Pressing Clip Forward In Direction Of Travel Out Of Stone Protection Courtesy of VOLKSWAGEN UNITED STATES, INC. Press clip - 3 - forward in direction of travel out of stone protection - 2 -.
Page 279 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 386: Cutting New Stone Protection For Right Side At Markings And For Left Side At Markings Courtesy of VOLKSWAGEN UNITED STATES, INC. Cut new stone protection for right side at markings - A - and for left side at markings - B -.
Page 280 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering impact protection Courtesy of VOLKSWAGEN UNITED STATES, INC. Press filed clip from behind in direction of - arrow - on vehicle interior side through tie rod and stone  impact protection. Clip stone impact protection onto tie rod. Ensure stone protection engages correctly.
Page 281 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE  MECHANICAL, ENGINE CODE(S): AVK, BGN 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL,  ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE...
Page 282 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 391: Identifying Bolt, Clamp & Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC. Rubber bushing must rest on stabilizer bar collar - arrow -.  Fig. 392: Identifying Stabilizer & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 283 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering ENGINE MECHANICAL, ENGINE CODE(S): AMB 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO  ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE ...
Page 284 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Installing Fig. 394: Identifying Bolt, Clamp & Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC. Rubber bushing must rest on stabilizer bar collar - arrow -.  Only hand-tighten bolts - 1 - for the time being.
Page 285 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Installing Installation is in reverse order of removal. Torque specifications --> Part VI, Stabilizer bar DIAGONAL BRACES Front or rear diagonal braces, removing and installing Special tools, testers and auxiliary items required Torque wrench V.A.G 1332...
Page 286 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 397: Removing/Installing Diagonal Brace & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. If the same diagonal braces - 1 - , - 5 - or - 6 - are to be reinstalled, identify location of braces to body, ...
Page 287 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 398: Removing/Installing Diagonal Brace & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Align diagonal brace - 1 - , - 5 - or - 6 - according to threaded holes or markings on body.
Page 288 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 399: Spring Compressor Kit V.A.G 1752 Courtesy of VOLKSWAGEN UNITED STATES, INC. Torque wrench V.A.G 1332  Removing Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
Page 289 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Remove coil spring --> Rear coil spring.  Fig. 401: Removing/Installing Combi-Bolts & Trapezoidal Control Arm Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove combi-bolts - 2 - and cover.  Remove bolts - 1 -.
Page 290 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Press exhaust pipe down again slightly and guide drive axle outward over cover plate.  Fig. 403: Removing Drive Axle Downward & Ensuring Cover Plate And Body Are Not Damaged Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 291 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 404: Removing/Installing Combi-Bolts & Trapezoidal Control Arm Courtesy of VOLKSWAGEN UNITED STATES, INC. Align drive axle holes and flange shaft/transmission holes with each other, install bolts - 1 - and tighten , ...
Page 292 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 405: Identifying Special Tools - Drive Axle With Constant Velocity Inner Joint (Diameter 100 mm), Servicing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Thrust plate VW 401 ...
Page 293 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 406: Identifying Hose Clamp Pliers V.A.G 1275 Courtesy of VOLKSWAGEN UNITED STATES, INC. Hose clamp pliers V.A.G 1275  Constant velocity joints are packed with grease G 000 603: Grease quantity and type...
Page 294 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 407: Exploded View Of Drive Axle With Constant Velocity Inner Joint Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Cover Carefully drive off using a drift Drive off cover for inner joint ...
Page 295 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 3 - Inner constant velocity joint Exterior diameter: 100 mm  Replace only as a unit  Pressing off Pressing off inner constant velocity joint  Pressing on Pressing on inner constant velocity joint ...
Page 296 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Always replace  Tensioning Tighten clamp  10 - Circlip Always replace  Insert in shaft groove  11 - Outer constant velocity joint Exterior diameter: 88 mm  Replace only as a unit ...
Page 297 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Drift must be placed precisely on star of CV joint. Driving joint on Drive onto shaft with plastic hammer until securing ring engages.  Tighten clamp Fig. 409: Tightening Clamp Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 298 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 411: Pressing Off Inner Constant Velocity Joint Courtesy of VOLKSWAGEN UNITED STATES, INC. Rebound circlip  Drive off protective boot with drift.  NOTE: Support ball hub with Thrust Plate VW402.
Page 299 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 413: Pressing On Inner Constant Velocity Joint Courtesy of VOLKSWAGEN UNITED STATES, INC. Press on joint until stop.  Use support sleeve VW 522 Insert circlip.  NOTE: Position ball hub with chamfer on inner diameter (splines) on drive axle.
Page 300 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Special tools, testers and auxiliary items required Thrust plate VW 401  Thrust plate VW 402  Punch VW 409  Punch VW 412  Support sleeve VW 522  Clamp 40-204 A ...
Page 301 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 415: Exploded View Of Driveshaft With Constant Velocity Inner Joint Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Cover Carefully drive off using a drift Drive off cover for inner joint ...
Page 302 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 3 - Inner CV joint with protective boot cap Exterior diameter: 108 mm  Replace only as a unit  Pressing off Pressing off inner constant velocity joint  Pressing on Pressing on inner constant velocity joint ...
Page 303 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 10 - Clamp Always replace  Tensioning Tighten clamp  11 - Circlip Always replace  Insert in shaft groove  12 - Outer constant velocity joint Replace only as a unit ...
Page 304 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering NOTE: Cap - A - must not be supported on thrust plate VW 401. Use segments  T10065/4 as spacers. Pressing on inner constant velocity joint Fig. 417: Identifying Joint/Triple Roller Star Splines Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 305 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Disassembling Fig. 419: Identifying Joint Body Marking Courtesy of VOLKSWAGEN UNITED STATES, INC. Before disassembling mark ball hub position in relation to the ball cage and housing with an electric  scriber or oil stone. (see arrow) Swivel ball hub and ball cage.
Page 306 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 421: Swinging Hub Segment In Cage Window Courtesy of VOLKSWAGEN UNITED STATES, INC. Swing a hub segment in a cage window.  Tilt hub out of cage.  Checking 6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small indentations (pitting) and signs of seizure.
Page 307 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 422: Pressing Out Ball Joint Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. Swing ball hub and ball cage and pull out of joint in direction of - arrow -.  Press balls out of cage.
Page 308 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 424: Inserting Ball Hub Over Both Chamfers Into Ball Cage Courtesy of VOLKSWAGEN UNITED STATES, INC. Insert ball hub into ball cage via two chamfers. The hub can be installed in any position. Press balls into ...
Page 309 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 426: Ball Hub Installed With Hub Able To Be Swivelled Out Of Cage Courtesy of VOLKSWAGEN UNITED STATES, INC. Install ball hub, whereby the hub must be swiveled out of cage - arrows - far enough to allow balls to fit ...
Page 310: Self-Leveling Suspension
2005 Audi A4 Quattro 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering SUSPENSION Suspension, Wheels, Steering 43 - SELF-LEVELING SUSPENSION DYNAMIC RIDE CONTROL (DRC II) General information Only approved oil should be used for filling or topping off. To attach or detach charging device V.A.S 6209/2 , system line to be checked must be locked at central valve to limit the quantity of oil leaked to a minimum and to prevent pressurized central valve from emptying.
Page 311 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 428: Dynamic Ride Control (DRC II) Installation Location Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Right front suspension strut 2 - Front right extraction/filling valve 3 - DRC line to front right suspension strut...
Page 312 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 7 - Left front and right rear central valve Central valve is installed in direction of travel at right --> Central valve and connections to suspension  struts 8 - Right front and left rear central valve Central valve is installed in direction of travel at left -->...
Page 313 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 429: Central Valve And Connections To Suspension Struts Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Right front and left rear central valve Central valve is installed in direction of travel at left ...
Page 314 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 7 - Left rear right wiring harness shut-off valve 8 - Left front and right rear central valve Central valve is installed in direction of travel at right  9 - DRC line to right rear strut...
Page 315 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering - 2 - torque specification: 19 Nm Rear strut Fig. 431: Rear Strut Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC. NOTE: When fastening item - 2 - , ensure lug is seated properly in bracket.
Page 316 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering harnesses. Replace  leaking dampers Complaint fixed? No ? Yes ? Check system pressure in both lines. (Central valve must be locked when connecting and disconnecting charging device.) System pressure greater than 12.0 bar?
Page 317 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 432: Bleeding Pressure Gauge And Line Section Courtesy of VOLKSWAGEN UNITED STATES, INC. To bleed pressure gauge - B - and line section - A - , install special tool as shown in illustration.
Page 318 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Remove plastic cover - 1 -.  Fig. 434: Loosening Lock Nut On Line To Be Checked & Screwing In Shut-Off Screw Until It Is Hand Tight Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 319 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 436: Loosening Lock Nut On Line To Be Checked & Screwing In Shut-Off Screw Until It Is Hand Tight Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen lock nut - 1 - on line to be checked, unscrew shut-off screw - 2 - until it is hand tight and lock nut ...
Page 320 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 438: Loosening Lock Nut On Line To Be Checked & Screwing In Shut-Off Screw Until It Is Hand Tight Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen lock nut - 1 - on line to be checked, screw in shut-off screw - 2 - until it is hand tight and lock nut ...
Page 321 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 440: Loosening Lock Nut On Line To Be Checked & Screwing In Shut-Off Screw Until It Is Hand Tight Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen lock nut - 1 - on line to be checked, unscrew shut-off screw - 2 - until it is hand tight and lock nut ...
Page 322 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Charging device V.A.S 6209  Vehicle connection adapter V.A.S 6209/1  Only approved oil should be used for filling or topping off. Filling must only be done at room temperature (approx. 20°Celsius).
Page 323 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 1 - Vehicle connection adapter with ventilation valve V.A.S 6209/1 2 - Connecting hose 3 - Venturi with exhaust hose 4 - Valve 5 - Pressure reducer 6 - Pressure gauge with valves and filler hose...
Page 324 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Connect venturi - 3 - to valve - 4 -.  Connect compressed air hose to venturi - 3 -.  Slowly open valve - 4 - and draw oil out of storage container into new oil container.
Page 325 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 445: Empty Used Oil Container Courtesy of VOLKSWAGEN UNITED STATES, INC. Slowly open valve - 4 - and press oil out of used oil container - 8 - as completely as possible.
Page 326 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 446: Removing/Installing Plastic Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove plastic cover - 1 -.  NOTE: To attach or detach adapter V.A.S 6209/1 , system line must be locked at ...
Page 327 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 448: Connecting Adapter V.A.S 6209/1 To Line To Be Suctioned Courtesy of VOLKSWAGEN UNITED STATES, INC. Connect adapter V.A.S 6209/1 to line to be suctioned.  Fig. 449: Performing Suction Procedure Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 328 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 450: Performing Suction Procedure Courtesy of VOLKSWAGEN UNITED STATES, INC. Adjust valve as follows:  - A - = Open (lever longitudinal to direction of flow) - B - = Closed (lever perpendicular to direction of flow)
Page 329 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 452: Performing Suction Procedure Courtesy of VOLKSWAGEN UNITED STATES, INC. To shorten suction process, valve - D - should be quickly and regularly opened lightly and closed again  immediately during the suction process.
Page 330 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. Close line connection - 1 - to strut again.  Evacuating: "Suctioning" step must be performed. Fig. 455: Performing Evacuating Procedure Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 331 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Close valve - C -.  Close valve - 4 -.  Disconnect compressed air line.  Perform leak test.  NOTE: Vacuum must remain stable at -0.9 bar for at least 2 minutes.
Page 332 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 458: Performing Evacuating Procedure Courtesy of VOLKSWAGEN UNITED STATES, INC. Valve - B - open.  Oil flows out of new oil container - 9 - into connected component. Recognizable with decreasing oil level in new oil container.
Page 333 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen lock nut - 1 - on filled line, unscrew shut-off screw - 2 - until it is hand tight and lock nut - 1 - ...
Page 334 2005 Audi A4 Quattro 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering SUSPENSION Suspension, Wheels, Steering 48 - STEERING STEERING WHEEL WITH AIRBAG Steering wheel with airbag, assembly overview Fig. 485: Steering Wheel With Airbag, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 335 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Removing and installing --> Airbag steering wheel, removing and installing  Various versions  3 - Spiral spring connector 4 - Airbag unit connector 5 - Signal horn connector 6 - Airbag unit Observe safety precautions -->...
Page 336: Steering Column
2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering When installing, observe the following: Before positioning steering wheel, make sure wheels are in straight position. Position steering wheel and tighten to 50 Nm.  Always replace screws.  STEERING COLUMN Steering column, assembly overview: The steering column is delivered only as a complete replacement part.
Page 337 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 486: Steering Column, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Retainer plate 2 - Shear head screw, 15 Nm 3 - Steering column 4 - Steering lock with ignition switch without lock cylinder...
Page 338 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 487: Checking Gap Dimension Between Slits And Mounting Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC. Check gap dimension - A - between slits and mounting bracket.  - Dimension - A - ; Maximum 0.5 mm or smaller If dimension - A - is greater than 0.5 mm, steering column is damaged and must be replaced.
Page 339 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove steering column adjustment lever.  Remove airbag steering wheel --> Airbag steering wheel, removing and installing.  Remove steering column switch trim. -->  70 - INTERIOR TRIM ...
Page 340 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Remove connectors from ignition switch and coil.  Locking cable must be disengaged on vehicles with automatic transmission: Bring selector lever into park position.  Fig. 490: Raising Locking Bracket Slightly And Removing Locking Cable From Ignition Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 341 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 492: Removing/Installing Steering Column Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - 1 -  Remove steering column.  Installing Installation is in reverse order of removal. Observe the following when installing: New replacement steering columns are secured with transportation protection.
Page 342 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 494: Removing/Installing Lower Part Of Steering Column From Power Steering Gear Courtesy of VOLKSWAGEN UNITED STATES, INC. Position steering column joint on power steering gear and install bolt - arrow -.
Page 343 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 496: Raising Locking Bracket Slightly And Removing Locking Cable From Ignition Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. Ignition key in position "B" , ignition on. Selector lever must be able to be shifted out of park position without catching.
Page 344 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Torque wrench V.A.G 1331  Removing Steering column, removing --> Steering column, removing and installing  Fig. 497: Drilling Out Shear Head Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Drill out shear head bolts ...
Page 345 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Power steering gear is completely removed and installed with tie rods. Fig. 498: Power-Assist Steering Gear, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Power assist steering gear with tie rods Removing and installing -->...
Page 346 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 4 - Steering column 5 - Bulkhead boot Check for tears and chafing  Note installation location --> Power steering gear, removing and installing  6 - Combi-bolt, 40 Nm plus an additional 90° turn Always replace ...
Page 347 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Always replace  20 - Banjo bolt with check valve, 35 Nm 21 - Extension hose For 4-cylinder engines  22 - Extension hose For 6-cylinder engines  23 - Tie rod Removing and installing -->...
Page 348 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 3 - Steering rack 4 - Steering gear housing Move steering wheel slightly around center position.  A second technician turns steering centering screw VAS 6224 in steering gear until it noticeably engages ...
Page 349 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Open socket insert SW 19 (commercially available)  Removing Remove plenum chamber cover -->  27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL  27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL  EQUIPMENT, CABRIOLET Disconnect battery and remove if necessary.
Page 350 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 503: Identifying Hose Clamps 3094 Courtesy of VOLKSWAGEN UNITED STATES, INC. Clamp off suction and return line using hose clamps Hose Clamps Up to 25 mm dia. 3094.  Remove front wheels.
Page 351 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 505: Identifying Nut, Control Links & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen nut - 1 - , remove hex head bolt and remove both links - 2 - upward (only on left side of vehicle).
Page 352 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 508: Removing Panel Nut Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove panel nut - arrow -.  Pry out clips.  Disengage electrical line  Remove plastic cover  On 6- and 8-cylinder engines, shield on driver side must be removed --> Shield, removing and ...
Page 353 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 510: Removing Return Line Banjo Bolt (22 mm AF) From Steering Gear Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove return line banjo bolt (22 mm AF) from steering gear.  With certain engine-transmission versions, banjo bolt can only be loosened from wheel housing.
Page 354 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 512: Identifying Bolts & Steering Lock Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolt - 1 -.  Take out steering gear through left-hand wheel housing (second technician required).  NOTE: Ensure bulkhead boot is not damaged by steering gear pinion.
Page 355 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Move steering rack until centering position on rack - arrow - aligns with thread - 2 -.  Install steering centering screw VAS 6224 hand tight.  Steering gear in area of bulkhead boot seat is lubricated with lubricant G 052 745 A3.
Page 356 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Pressure and return hose must not touch or come in contact with other  parts! With certain engine-transmission versions, banjo bolts can only be tightened from wheel housing. To do this, use an open socket insert SW 19 (commercially available) Reinsert bulkhead boot while noting installation location.
Page 357 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 517: Removing/Installing Lower Part Of Steering Column From Power Steering Gear Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten bolt - arrow -  Remove mounting device from steering column.  Install drivers side stowage compartment. -->...
Page 358 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 519: Inserting Suspension Strut Forked Head Into Link Courtesy of VOLKSWAGEN UNITED STATES, INC. Insert new bolt - 2 - and self-locking nut and tighten  Insert fork-head suspension strut in link and hand tighten threaded connection - 1 -.
Page 359 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 521: Identifying Steering Arm & Tie Rod Ball Joint Sealing Washer Courtesy of VOLKSWAGEN UNITED STATES, INC. NOTE: Install tie rod in steering arm - 1 - when doing so, only by hand and do not ...
Page 360 Bleed steering system --> Steering system, bleeding after reconstructing  Check steering system for leaks --> Steering system, checking for leaks.  Perform vehicle alignment --> Wheel alignment.  Alignment must take place on a VW/Audi recommended alignment stand. 1:09:18 AM Page 27...
Page 361 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Power steering gear, servicing Special tools, testers and auxiliary items required Fig. 524: Identifying Hose Clamp Pliers V.A.G 1275 Courtesy of VOLKSWAGEN UNITED STATES, INC. Hose clamp pliers V.A.G 1275  Torque wrench V.A.G 1331 ...
Page 362 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 525: Exploded View Of Power Steering Gear Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Tie rod end Removing and installing --> Tie rod ball joint and tie rod  Check dust caps for damage and correct seating ...
Page 363 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Check for damage  Must not be twisted after toe is adjusted  Can be replaced with steering gear installed  Remove to replace tie rods --> Tie rod, removing and installing.
Page 364 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 526: Shield Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Plenum chamber 2 - Power-assist steering gear 3 - Spreader nut 4 - Shield With 6 and 8-cylinder gasoline engines, remove front exhaust pipe -->...
Page 365 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE  MECHANICAL, ENGINE CODE(S): AVK, BGN 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL,  ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE...
Page 366 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Carry out a road test.  Ensure that when maneuvering or negotiating corners the steering self-centers without sticking, re-adjust  if necessary. SERVOTRONIC STEERING GEAR Servotronic steering gear, assembly overview Fig. 528: Servotronic Steering Gear, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 367 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Location: in left front wheel housing  3 - Relay carrier, 9-pin Located under trim in driver footwell --> Electrical Wiring Diagrams, Troubleshooting and Component  Locations Servotronic Control Module J236 item 2 ...
Page 368 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering On vehicles with Servotronic steering gear, power steering is controlled electronically and is dependent  on vehicle speed. If electronics malfunction, steering works like the normal power steering.  Servotronic Control Module J236 does not have On Board Diagnostic (OBD) capabilities.
Page 369 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Remove Servotronic Control Module J236 , item 2.  Switch on ignition  Set digital multimeter V.A.G 1526 on voltage measurement area up to 20 Volt.  Measure control module connector between contacts 6 and 8.
Page 370 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 68 - INTERIOR EQUIPMENT for BODY INTERIOR - CABRIOLET  Fig. 531: Identifying Servotronic Control Module J236 Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove Servotronic Control Module J236 , item 2. ...
Page 371 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 532: Socket V.A.G 1332/12 Courtesy of VOLKSWAGEN UNITED STATES, INC. Socket V.A.G 1332/12  Torque wrench V.A.G 1332  Removing Remove wheel.  Fig. 533: Removing/Installing Hex Head Nut And Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 372 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 534: Identifying Steering Arm & Tie Rod Ball Joint Sealing Washer Courtesy of VOLKSWAGEN UNITED STATES, INC. Do not use a chisel or similar tool between steering arm - 1 - and tie rod ...
Page 373 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 536: Removing/Installing Hex Head Nut And Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten combi-nut - 3 - , to do this, use socket V.A.G 1332/12. When tightening, counterhold at tie rod ...
Page 374 Wheels and Tire Guide Perform vehicle alignment --> Wheel alignment.  Alignment must take place on a VW/Audi recommended alignment stand. Tie rod, removing and installing Special tools, testers and auxiliary items required Fig. 539: Identifying Box End Wrench Insert V.A.G 1923 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 375 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering They can be removed and installed with the steering gear in vehicle. Removing Remove front wheel.  Fig. 540: Identifying Nut, Control Links & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove hex head bolt - 3 - and remove threaded connection - 4 -.
Page 376 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Tie rod may only be pressed off steering arm over tie rod ball joint pin  ends or driven with a wooden or rubber hammer. Remove cover for tie rod.  Fig. 542: Opening Clips On Boot Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 377 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering - Boot does not twist. Replace spring hose clamp and ear hose clamp.  Install tie rod cover.  Align tie rod so that tie rod ball joint pints are in installation location.
Page 378 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Alignment must take place on a VW/Audi recommended alignment stand. CHECKING OIL LEVEL, BLEEDING STEERING SYSTEM, CHECKING FOR LEAKS Power steering fluid level, checking Do not run engine and turn front wheels to straight ahead position.
Page 379 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering After exchanging entire steering system or exchanging steering gear: Check hydraulic fluid level and top off if necessary.  Raise vehicle until front wheels are off the ground.  Briefly start engine (max. 2 sec.) ...
Page 380 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering pressure. To avoid damage to pump, steering wheel must not be held at stop longer than 10 seconds during this test. In this position, the following components must be checked for leaks.
Page 381 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 547: Vehicles With 4-Cylinder Engines, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Power-assist steering gear 2 - Return hose 3 - Extension hose 4 - Cap with dip stick Check fluid level -->...
Page 382 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Refilling with hydraulic oil  7 - Rubber bushing 8 - Clamp Tension using V.A.G 1275  Always replace  9 - Return hose Between reservoir and cooling line  10 - Clamp Tension using V.A.G 1275...
Page 383 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 19 - Sealing ring Always replace  20 - Banjo bolt, 50 Nm 21 - Power steering pump For 4-cylinder engines  Fill with oil before installing --> Note --> Power steering pump, reservoir and hydraulic lines, ...
Page 384 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 548: 6-Cylinder Gasoline Engine, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Power-assist steering gear 2 - Extension hose 3 - Return hose 4 - Cap with dip stick Check fluid level -->...
Page 385 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Refilling with hydraulic oil  7 - Rubber bushing 8 - Clamp Tension using V.A.G 1275  Always replace  9 - Return hose Between reservoir and cooling line  10 - Clamp Tension using V.A.G 1275...
Page 386 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Always replace  19 - Power steering pump Fill with oil before installing --> Note --> Power steering pump, reservoir and hydraulic lines,  assembly overview 20 - Sealing ring Always replace ...
Page 387 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 549: Identifying Special Tools - Power Steering Pump Delivery Pressure Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Hose clamps up to 25 mm dia. 3094 ...
Page 388 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 550: Identifying Hose Clamps 3094 Courtesy of VOLKSWAGEN UNITED STATES, INC. Clamp off suction and return line using hose clamps Hose Clamps Up to 25 mm dia. 3094.  Remove pressure hose from power steering pump.
Page 389 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering If pressure is not to specification, replace pump --> Power steering pump, removing and installing. Switch off engine.  Remove pressure gauge.  Connect pressure line to power steering pump with banjo bolt.
Page 390 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Disconnect extension hose - arrow - while counterholding extension hose hex head.  NOTE: Place a cloth under separation point to absorb escaping hydraulic oil.  Remove hydraulic line bracket if necessary to make work easier.
Page 391 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Switch off engine.  Remove pressure gauge.  Connect extension hose while counterholding hose hex head.  Check power steering fluid level --> Power steering fluid level, checking.  Check steering system for leaks --> Steering system, checking for leaks.
Page 392 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Hose clamp 3094  Power steering test unit V.A.G 1402  Adapter V.A.G 1402/2  Hose from adapter kit V.A.G 1402/6 (qty. 2)  Special tools, testers and auxiliary items required Fig. 555: Identifying Drip Tray V.A.G 1306 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 393 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Clamp off suction and return line with hose clamps up to 25 mm dia. 3094.  Remove noise insulation -->  50 BODY, FRONT  50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET ...
Page 394 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Install Power steering test unit V.A.G 1402 as shown in illustration.  1 - Pressure hose 2 - Adapter V.A.G 1402/4 3 - Pressure hose 4 - Hose from adapter set V.A.G 1402/6 5 - Pressure gauge V.A.G 1402...
Page 395 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Start engine without giving gas and run at idle.  Read pump pressure immediately after starting at idle speed (have it read  by second technician, if necessary). Because pressure falls over the course of the test, the highest pressure ...
Page 396: Power Steering Pump, Removing And Installing
2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Install noise insulation -->  50 BODY, FRONT  50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET  POWER STEERING PUMP, REMOVING AND INSTALLING General information There is no provision for servicing the power steering pump. If there are customer complaints, the cause must be determined using a pressure and leak test.
Page 397 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 561: Identifying Special Tools - Power Steering Pump (Vehicles With 4-Cylinder Engine), Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required Hose clamps up to 25 mm dia. 3094 ...
Page 398 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 562: Support Tool 3369 Courtesy of VOLKSWAGEN UNITED STATES, INC. Support tool 3369 Removing For all vehicles. Remove noise insulation. -->  50 BODY, FRONT  50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET ...
Page 399 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering MECHANICAL, ENGINE CODE(S): BKH 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 4V ENGINE  MECHANICAL, ENGINE CODE(S): BNS 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 5V ENGINE ...
Page 400 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering counterhold. For all vehicles with TFSI Fig. 565: Removing/Installing Power Steering Pump Connections Through Holes In Ribbed Belt Pulley Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove power steering pump connections - 1 - through holes in ribbed belt pulley.
Page 401 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering pressure side. Secure all hose connections with new hose clamps.  Turn hub by hand until oil runs out of pressure side.  Fig. 567: Removing/Installing Power Steering Pump Connections Through Holes In Ribbed Belt Pulley Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 402 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 568: Removing/Installing Threaded Connection On Backside Of Power Steering Pump Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten screw - arrow - on back side of power steering pump. -->  13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 1.8 LITER 4-CYL. 5V TURBO ...
Page 403 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. Tighten power steering pump belt pulley. -->  13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 1.8 LITER 4-CYL. 5V TURBO  ENGINE MECHANICAL, ENGINE CODE(S): AMB 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 2.0 LITER 4-CYL.
Page 404 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Start engine and check belt running.  Check power steering fluid level --> Power steering fluid level, checking.  Bleed steering system --> Steering system, bleeding after reconstructing  Check steering system for leaks --> Steering system, checking for leaks.
Page 405 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 571: Unbolting Power Steering Pump Pulley & Counterholding Using Spanner Wrench 3212 Courtesy of VOLKSWAGEN UNITED STATES, INC. Unbolt power steering pump pulley - arrows - , counterholding using Spanner Wrench 3212.
Page 406 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 573: Removing Banjo Bolt, Suction Hose & Power Steering Pump With Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove banjo bolt - 1 -.  Remove suction hose - 2 -.
Page 407 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Power steering pump (vehicles with 8-cylinder gasoline engine with chain drive), removing and installing Special tools, testers and auxiliary items required Fig. 574: Identifying 10-222A Engine Support Bridge With 10-222A/8 Bracket For Engine Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 408 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 576: Positioning Support Bridge 10-222 A On Bolted Fender Edges Courtesy of VOLKSWAGEN UNITED STATES, INC. Position support bridge 10-222 A on bolted fender edges.  Engage support bridge hooks on engine lifting eyes.
Page 409 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 578: Removing Left Drive Axle Heat Shield Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove left drive axle heat shield - arrows -.  Fig. 579: Removing Left And Right Stabilizer Bar Bracket Nuts Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 410 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 580: Removing Nuts, Bolts & Left Engine Console Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove nuts - 2 -.  Remove bolts - 1 - and - 3 - and remove left engine console.
Page 411 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect electrical connector - 1 - at left engine mount.  Remove nut - 2 - and remove engine mount. (If nut - 2 - cannot be loosened due to poor accessibility, skip ...
Page 412 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 585: Removing Hydraulic Pressure Line At Power Steering Pump Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove hydraulic pressure line at power steering pump - arrow -.  Lay aside hydraulic pressure line.
Page 413 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Replace sealing rings.  On vehicles that did not have spring - 6 - installed, repair kit with spring cannot be installed. Fig. 587: Exploded View Of Power Steering Pump Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 414 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Component Power steering pump to engine Engine supports to cylinder block Coolant line bracket to Upper part of oil pan Bracket Hydraulic pressure line to power steering pump Return line Engine support...
Page 415 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 589: Intake Hose To Power Steering Oil Reservoir (Applies To All Engines), Location Courtesy of VOLKSWAGEN UNITED STATES, INC. Marking on intake hose - 1 - must align with formed seam on power steering oil reservoir - arrows -.
Page 416 2005 Audi A4 Quattro 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering SUSPENSION Suspension, Wheels, Steering 44 - WHEELS, TIRES, VEHICLE ALIGNMENT WHEELS, TIRES This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide TIRE PRESSURE MONITORING SYSTEM General information Observe notes about usage in your Owners Manual.
Page 417 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 460: Tire Pressure Monitoring System, Component Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 - Left Front Tire Pressure Monitoring Sensor G222 , Right Front G223 , Left Rear G224 and Right Rear G225 Spare Tire Pressure Monitoring Sensor G226 ...
Page 418 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 4 - Display in instrument cluster See Vehicle diagnostic, test and information system VAS 5051  Wheel electronics, assembly overview Fig. 461: Wheel Electronics, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 419 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering 3 - Sealing ring Removing and installing --> Metal valve body, removing and installing  4 - Rim Tires, mounting and dismounting Dismounting tire and Mounting tire  5 - Wheel electronics Must be completely replaced ...
Page 420 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Balance tires.  Dismounting tire Fig. 462: Dismounting Tire Courtesy of VOLKSWAGEN UNITED STATES, INC. Roll or press tires off. When using pressure paddles, first separate tires from side opposite of valve.
Page 421 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Position wheel electronics approx. 180° opposite of mounting head.  Press tire in bed approx. 90° in front of mounting head - arrow -.  Mount tire.  Metal valve body, removing and installing Special tools, testers and auxiliary items required Fig.
Page 422 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 465: Securing Against Turning With Counterhold Courtesy of VOLKSWAGEN UNITED STATES, INC. Secure against turning with counterhold - 1 - (e.g. drill bit 2 mm dia.).  Fig. 466: Pressing Wheel Electronics Into Bed And Fasten At Rear Of Valve With Microencapsulated Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 423 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Disconnect connector - 2 - and remove control module.  Installing Installation is in reverse order of removal. Rear Tire Pressure Monitoring System antenna, removing and installing Removing Reception antenna is found at bottom of rear bumper.
Page 424 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Recode Tire Pressure Monitoring Control Module J502. If Tire Pressure Monitoring Control Module J502 is replaced, new control module must be coded. To do this, proceed as follows. Connect vehicle diagnosis, testing, and information system VAS 5051 and select function test using ...
Page 425: Wheel Alignment
WHEEL ALIGNMENT General information Wheel alignment must only performed using VW/Audi-approved wheel alignment equipment! Each time wheels are aligned, both front and rear wheels must be aligned. Otherwise correct vehicle performance is not guaranteed and an off center steering wheel may exist.
Page 426 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 469: Example Of Vehicle Data Sticker Courtesy of VOLKSWAGEN UNITED STATES, INC. Example of a vehicle data sticker In this example the vehicle is equipped with the standard suspension - arrow -.
Page 427 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Vehicle empty weight * See note  * Empty weight means: Weight of the vehicle ready for the road (fuel tank and fluid reservoir for window/headlamp washer system completely filled, spare wheel, vehicle tools and vehicle jack) and without driver.
Page 428 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering gear Subframe Stabilizer Stabilizer bar Specifications for wheel alignment Sedan and wagon (front and all wheel drive) Specifications valid for all engine versions Front axle Standard Sport Sport Comfort heavy Sport suspension...
Page 429 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering * Data applies to Sedan from VIN 8E_2_025688 as well as to wagon. *Wheel stop on outer wheel is reduced by this amount. It can also be indicated negatively in alignment computer, depending on manufacturer.
Page 430 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering (unladen) Toe constant per wheel (setting + 14' ± 2' + 14' ± 2' value) Toe constant for each wheel + 14' ± 7' + 14' ± 7' (check value) Toe constant difference between max.
Page 431 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering A correct toe-in adjustment will not be possible without performing lateral run-out compensation! Carry out wheel run-out compensation. For this, observe notes by manufacturer of wheel alignment  equipment. Fig. 470: Inserting Brake Pedal Depressor V.A.G 1869/2 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Page 432 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Check which suspension is installed in the vehicle. This information can  be found on the vehicle data plate. Refer to Clarification of Production Control numbers (PR No.) Observe the following work sequence! 1 - Check rear axle camber and adjust if necessary -->...
Page 433 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 471: Identifying Front Axle Camber Hex Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen hex head bolt - 1 - , - 2 - , - 3 - , - 4 - , - 5 - , - 6 - , - 7 - and - 8 -.
Page 434 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Specifications for wheel alignment --> Specifications for wheel alignment. Fig. 473: Identifying Front Axle Camber Hex Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC. Install new hex head bolts - 7 - and - 8 - and tighten.
Page 435 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 474: Removing Wheel Bearing Housing/Transverse Link Connection Nut & Adjusting Camber Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove wheel bearing housing/transverse link connection nut - A -.  Adjust camber by turning eccentric bolt - B -.
Page 436 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 476: Identifying Diagonal Braces Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove diagonal brace - 1 - or - 2 - on side with toe to be adjusted --> Diagonal braces. ...
Page 437 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Install diagonal brace --> Diagonal braces.  Continued for all vehicles Install underbody trim.  Front axle toe-in curve, adjusting Explanation: When the wheel compresses or rebounds, the wheel s toe changes as a function of the compression and rebound travel.
Page 438 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 478: Installing Adapter V.A.G 1925/6 Onto Adapters V.A.G 1925/3 Or V.A.G 1925/4 Of Spacer Gauge Courtesy of VOLKSWAGEN UNITED STATES, INC. Position axle lift under front jacking points and raise vehicle.
Page 439 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering With all suspension versions Check of whether the present toe-in value of each wheel matches the specification is performed in this position by the alignment program on the alignment computer. If necessary, correct toe-in using tie rod length adjuster.
Page 440 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 481: Loosening Hex Head Nut & Unscrewing Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen hex head nut - A -.  Unscrew bolt - B - approx. 4 mm. ...
Page 441 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 483: Loosening Hex Head Nut & Unscrewing Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC. Screw in bolt - B - until specified value is reached exactly.  Tighten hex head nut - A - , and check value.
Page 442 2005 Audi A4 Quattro SUSPENSION Suspension, Wheels, Steering Fig. 484: Identifying Lock Nut & Hex Nut Courtesy of VOLKSWAGEN UNITED STATES, INC. Adjust toe on left and right-hand wheels at hex - A -.  Be sure that boot is not twisted after turning tie rods.
Page 443: Description And Operation
2005 Audi A4 Quattro 2005 Audi A4 Quattro TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 DESCRIPTION & OPERATION...
Page 444 2005 Audi A4 Quattro TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 Check and correct tire inflation pressures of wheels on vehicle (including spare tire). Tire pressure information is provided on the tire pressure label located on driver's side door pillar.
Page 445 2005 Audi A4 Quattro TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 saved, the system will measure the actual pressures once again, and then save these as the new pressures. Fig. 1: Identifying Tire Pressure Menu Courtesy of AUDI OF AMERICA, INC.
Page 446 2005 Audi A4 Quattro TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 Fig. 2: Identifying Starting Menu Courtesy of AUDI OF AMERICA, INC. 1:27:40 AM Page 4...
Page 447 2005 Audi A4 Quattro TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 Fig. 3: Storing Tire Pressure (1 Of 2) Courtesy of AUDI OF AMERICA, INC. 1:27:40 AM Page 5...
Page 448 2005 Audi A4 Quattro TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 Fig. 4: Storing Tire Pressure (2 Of 2) Courtesy of AUDI OF AMERICA, INC. WHEEL CHANGE INITIALIZATION NOTE: If tire was changed, the new tire must be initialized. Tire change is incomplete if initialization process is not performed.
Page 449 2005 Audi A4 Quattro TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 Fig. 5: Initializing New Wheels Courtesy of AUDI OF AMERICA, INC. DISMOUNTING/MOUNTING PROCEDURES CAUTION: The tire should be dismounted from the wheel using the tire changer manufacturer's instructions.
Page 450: Tire Pressure Sensor
2005 Audi A4 Quattro TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 NOTE: In order for the tire pressure monitoring system to work, the specified pressures (provided on tire pressure label located on driver's side door pillar) must be reprogrammed after every change in air pressure or after every wheel change.
Page 451 2005 Audi A4 Quattro TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 Fig. 6: Removing & Installing Tire Pressure Sensor Courtesy of VOLKSWAGEN UNITED STATES, INC. 1:27:40 AM Page 9...
Page 452 2005 Audi A4 Quattro TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 Fig. 7: Removing & Installing Tire Pressure Sensor Nut Courtesy of VOLKSWAGEN UNITED STATES, INC. 1:27:40 AM Page 10...
Page 453 2005 Audi A4 Quattro TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 Fig. 8: Exploded View Of Tire Pressure Sensor Courtesy of VOLKSWAGEN UNITED STATES, INC. Installation 1. To identify replacement tire pressure sensors, see TIRE PRESSURE SENSOR PART IDENTIFICATION table.
Page 454: Torque Specifications
2005 Audi A4 Quattro TIRE PRESSURE MONITOR SYSTEMS Audi - 2005 A4 & S4 system. See STORING TIRE INFLATION PRESSURES under RESET PROCEDURES. TIRE PRESSURE SENSOR PART IDENTIFICATION Application Part No. Left Front G222 Right Front G223 Left Rear G224...