Audi A4 (B5 Platform) Service and Repair Manual: 1996-2001

Introduction

This manual provides detailed service and repair procedures for Audi A4 models built on the Audi "B5" platform, covering model years 1996 through 2001. It does not include information specific to the Audi S4 sports model. The content is derived from factory service information, supplemented with practical tips and clarifications to assist technicians and owners in understanding and performing various vehicle procedures.

The manual aims to offer clear and comprehensive instructions for a wide range of tasks, from routine maintenance to complex engine and drivetrain repairs.

Cover of the Audi A4 Service Manual 1996-2001

Image Description: The front cover of the Audi A4 Service Manual, displaying the title "Audi A4 Service Manual 1996, 1997, 1998, 1999, 2000, 2001" along with "1.8L turbo, 2.8L including Avant and quattro". It features illustrations of a silver Audi A4 sedan and an Avant (wagon) model. The Bentley Publishers logo is visible at the bottom right.

Safety Information

Always prioritize safety when performing any service or repair on your vehicle. Failure to follow proper safety precautions can result in serious injury or damage to the vehicle. This manual assumes the user has a basic understanding of automotive repair practices and safety procedures.

Wear appropriate personal protective equipment (PPE), such as safety glasses, gloves, and sturdy footwear.
Ensure the vehicle is securely supported on jack stands before working underneath it. Never rely solely on a jack.
Disconnect the battery's negative terminal before working on electrical components to prevent accidental short circuits.
Allow the engine and exhaust system to cool down before working on them to avoid burns.
Be aware of hazardous fluids (e.g., engine oil, coolant, brake fluid) and dispose of them responsibly.
Work in a well-ventilated area, especially when dealing with fuel or exhaust fumes.

Maintenance Procedures

Routine maintenance is crucial for the longevity and optimal performance of your Audi A4. This section covers standard service intervals and procedures.

Oil changes and filter replacement.
Ribbed belt replacement.
Fluid level checks and top-ups (coolant, brake fluid, power steering fluid).
Tire rotation and pressure checks.
Brake system inspection.
Lighting and electrical system checks.

Engine Mechanical

This section details procedures for the engine and its associated components, including:

Engine and cylinder head service, including timing belt and camshaft replacement.
Component testing, removal, and installation for engine lubrication, cooling, and exhaust systems.
Turbocharger service, removal, installation, and intercooler components (for 1.8L turbo models).

Diagram of Audi A4 engine cylinder block and crankshaft assembly

Image Description: An open page from the service manual showing detailed diagrams and instructions for "Cylinder block, crankshaft and flywheel, servicing" on the left page, and "Vibration damper, removing and installing" and "Toothed belt, removing and installing" on the right page. The left page includes an exploded view diagram of engine components with numbered parts. The right page shows diagrams for removing the vibration damper and toothed belt, along with torque specifications.

Fuel Supply System

Information regarding the fuel delivery and management system:

Fuel pump delivery volume test.
Electrical checks for fuel system components.
EVAP (Evaporative Emission Control) system diagnostics.
Mechanical and electronic throttle control (E-gas) procedures.

Fuel Injection and Ignition System

This section covers the identification, testing, and adaptation of fuel injection and ignition components:

Component identification and electrical testing.
Technical data for various sensors and actuators.
Throttle valve control module adaptation using a factory scan tool.

Drivetrain and Transmission

Procedures for the vehicle's power transmission system:

Drivetrain maintenance, troubleshooting, adjustment, and repair.
Hydraulic clutch system service.
Gearshift linkage adjustments.
Drive axles and driveshaft (quattro models) removal and installation.

Brake System

Repair information for both ABS (Anti-lock Braking System) and mechanical/hydraulic brake components:

Brake pad and rotor replacement.
Brake fluid flushing and bleeding.
ABS sensor testing and replacement.
Master cylinder and brake line service.

Suspension, Wheels, and Steering

Details on the vehicle's suspension and steering systems for both front-wheel drive and all-wheel drive models:

Struts, wheel bearings, and CV joints.
Stabilizer bar and multi-link components.
Wheel alignment specifications.
Steering system components and service.

Diagrams for Audi A4 suspension and steering components

Image Description: An open page from the service manual showing diagrams and instructions related to "Suspension, Wheels, Steering". The left page illustrates "Connecting link, running change (m.y. 1999 v)" with detailed steps and torque specifications for different types of connecting links. The right page shows an exploded view diagram for "headlight range adjuster, removing and installing" with numbered components and notes on adjustment and removal.

Body Equipment and Interior

Information for interior and exterior body components:

Trim panels, airbags, bumpers, doors, hood, and lids.
Lights, instrument panel/dashboard, and sunroof.
Seatbelts and seats, including Recaro seat information.

Heating and Air Conditioning

Repair procedures for the climate control system:

A/C electrical component replacement.
Compressor, fresh air blower, and sensor service.
Vacuum hose layout and troubleshooting.

Electrical System and Wiring Diagrams

This section provides comprehensive details on the vehicle's electrical systems:

Wiring schematics for A4 and S4 models.
Component locations.
General explanation of electrical circuitry.

Image Description: An open page from the service manual displaying multiple detailed wiring diagrams for the Audi A4. Each diagram is labeled with "Wiring diagram" and a page number (e.g., "No. 1/4", "No. 1/5"). These diagrams illustrate the electrical connections and components within the vehicle's systems.

Troubleshooting and Diagnostics

This section assists in diagnosing issues using diagnostic trouble codes and provides guidance on common problems.

Audi OBD II diagnostic trouble codes section, including SAE and manufacturer-defined P-codes.
Guidance on interpreting diagnostic results.

Specifications

Key technical specifications and data for the Audi A4 (B5 platform) models covered by this manual.

Engines Covered:

1.8L turbo gasoline: Engine codes AEB, ATW, AWM
2.8L gasoline: Engine codes AFC, AHA, ATQ

Transmissions Covered:

5-speed Manual: Types 012, 01W, 01A
5-speed Automatic: Type 01V

General Specifications:

Comprehensive Audi factory tolerances.
Wear limits and adjustments.
Tightening torques for various fasteners.

Support and Publisher Information

This service manual is published by Bentley Publishers, known for their detailed and comprehensive automotive repair manuals. For further inquiries or to explore other publications, please refer to the publisher's official resources.

Publisher: Bentley Publishers

Publication Date: March 16, 2002

ISBN-10: 0837603714

ISBN-13: 978-0837603711

Inside page of Audi A4 Service Manual showing table of contents and Bentley Publishers contact information

Image Description: An open page from the service manual showing a partial table of contents on the left, listing sections like Maintenance, Engine Mechanical, Fuel Supply System, etc. The right page displays the manual's title "Audi A4 Service Manual 1996, 1997, 1998, 1999, 2000, 2001" and specifies "Audi platform code: B5". A business reply mail card from Bentley Publishers is partially visible, showing their address: 1734 Massachusetts Avenue, Cambridge, MA 02138-5940 USA.

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