1. Introduction
This manual provides detailed instructions and procedures for the maintenance, service, and repair of Audi A4 (B5 chassis) models manufactured between 1995 and 2000. It covers both petrol and diesel engine variants. The information is structured to assist owners and technicians in performing various tasks, from routine checks to complex overhauls, ensuring the vehicle's optimal performance and longevity.
For specific details regarding your vehicle's configuration, always refer to the vehicle's identification plate and any supplementary documentation provided by Audi.
Figure 1.1: Front cover of the Audi A4 1995-2000 Service and Repair Manual, illustrating the vehicle with an exposed engine bay.
2. Roadside Repairs
This section outlines essential procedures for common issues that may arise during vehicle operation, requiring immediate attention. Familiarity with these steps can help resolve minor problems safely and efficiently.
2.1. Jump Starting
If the vehicle's battery is discharged, it can be jump-started using booster cables and another vehicle with a 12-volt battery. Ensure both vehicles are turned off before connecting cables. Connect the positive (+) terminal of the discharged battery to the positive (+) terminal of the donor battery. Then, connect the negative (-) terminal of the donor battery to a good ground point on the engine block of the vehicle with the discharged battery, away from the battery itself. Start the donor vehicle, then attempt to start the Audi A4. Once started, disconnect cables in reverse order.
2.2. Wheel Changing
In the event of a flat tire, follow these steps to safely replace it with the spare wheel. Park the vehicle on a level, firm surface and engage the parking brake. Place wheel chocks if available. Loosen the wheel nuts slightly before jacking up the vehicle. Use the vehicle's jack at the designated jacking points. Once the wheel is clear of the ground, remove the nuts completely and replace the wheel. Tighten nuts by hand, lower the vehicle, and then fully tighten the nuts in a diagonal pattern. Have the tire pressure checked and the wheel nuts torqued to specification at the earliest opportunity.
2.3. Towing
If the vehicle needs to be towed, ensure proper procedures are followed to prevent damage. For short distances and low speeds, the vehicle can be towed with all four wheels on the ground, provided the transmission is in neutral (manual) or the selector lever is in 'N' (automatic) and the steering is unlocked. For longer distances or higher speeds, or if the transmission is damaged, the vehicle should be transported on a flatbed truck or with the drive wheels lifted off the ground.
3. Weekly Checks
Regular weekly checks are crucial for maintaining your Audi A4's reliability and safety. These simple inspections can help identify potential issues before they become serious problems.
- Engine Oil Level: Check the engine oil level using the dipstick when the engine is cold and the vehicle is on level ground. Add oil if necessary, ensuring it meets Audi specifications.
- Coolant Level: Verify the coolant level in the expansion tank. It should be between the 'MIN' and 'MAX' marks. Top up with the correct coolant mixture if low.
- Brake Fluid Level: Inspect the brake fluid level in the reservoir. A low level could indicate worn brake pads or a leak in the system.
- Power Steering Fluid Level: Check the power steering fluid level. Low fluid can lead to difficult steering and potential pump damage.
- Battery Condition: Visually inspect the battery terminals for corrosion and ensure the battery is securely mounted.
- Tire Condition and Pressure: Check tire pressures, including the spare, against the manufacturer's recommendations. Inspect tires for wear, damage, and embedded objects.
- Washer Fluid Level: Ensure the windshield washer fluid reservoir is adequately filled.
- Wiper Blades: Check wiper blades for signs of wear or damage. Replace if they leave streaks or do not clear the windshield effectively.
- Lights: Verify the operation of all exterior lights, including headlights, tail lights, brake lights, turn signals, and hazard lights.
4. Maintenance
This section details routine maintenance and servicing procedures to keep your Audi A4 in optimal condition. Adhering to the recommended service schedule is vital for vehicle longevity and performance.
4.1. Routine Maintenance and Servicing - Petrol Models
Regular servicing includes various checks and replacements based on mileage or time intervals. Key tasks include:
- Engine Oil and Filter Change: Typically recommended every 10,000 miles or annually, whichever comes first.
- Air Filter Replacement: Inspect and replace as needed, usually every 20,000-30,000 miles.
- Spark Plug Replacement: Replace according to the manufacturer's schedule, often every 40,000-60,000 miles.
- Fuel Filter Renewal: Replace the fuel filter at specified intervals to ensure clean fuel delivery.
- Pollen Filter Renewal: Replace the cabin air (pollen) filter to maintain air quality inside the vehicle.
- Brake System Inspection: Check brake pads, discs, and fluid levels.
- Suspension and Steering Component Check: Inspect for wear and damage.
Figure 4.1: Excerpt from the manual detailing routine maintenance tasks such as fuel filter and pollen filter renewal, and underbody sealant checks.
4.2. Halogen Headlamp Adjustment
Proper headlamp alignment is essential for safe driving and to avoid dazzling oncoming traffic. Adjustment typically involves using specific tools and following a precise procedure to set the beam pattern correctly. Refer to the detailed instructions in the manual for specific adjustment points and methods.
4.3. Auxiliary Drivebelt Removal and Refitting
The auxiliary drivebelt powers various components like the alternator, power steering pump, and air conditioning compressor. Its removal and refitting require specific steps to ensure correct tension and alignment. This process often involves releasing tension from a tensioner pulley, carefully removing the old belt, and installing the new one, ensuring it is correctly routed over all pulleys.
Figure 4.2: Detailed diagram of the auxiliary drivebelt system, showing components and routing for removal and refitting procedures.
5. Repairs and Overhaul
This section covers more extensive repair procedures for major vehicle systems, including engine, transmission, brakes, and suspension components.
5.1. Suspension Strut Removal and Overhaul
The suspension struts are critical for vehicle handling and ride comfort. Removal and overhaul procedures involve safely compressing the coil spring, detaching the strut from the vehicle, and disassembling its components. This task requires specialized tools, such as a spring compressor, and should only be attempted by individuals with appropriate mechanical experience due to safety risks associated with compressed springs.
Figure 5.1: Visual guide for suspension strut removal, showing the coil spring compression and component separation.
6. Specifications
This section provides technical data, capacities, and torque settings essential for proper maintenance and repair of your Audi A4.
6.1. Servicing Specifications - Petrol Models
| Category | Item | Specification |
|---|---|---|
| Capacities | Engine oil (including filter) 1595 cc engines (ADP, AHL) | 3.3 litres |
| Engine oil (including filter) All other engines | 3.9 litres | |
| Cooling system | 6.0 litres approx. | |
| Transmission | Manual transmission | 2.25 litres |
| Automatic transmission fluid: Initial filling | 5.5 litres | |
| Automatic transmission fluid: Oil change | 3.0 litres | |
| Fuel Tank | All models (approximate) | 62 litres |
| Cooling System | Antifreeze mixture: 50% antifreeze | Protection down to -25°C |
| Antifreeze mixture: 50% antifreeze | Protection down to -35°C | |
| Brakes | Front brake pad minimum thickness (including backing) | 7.0 mm |
| Rear brake pad minimum thickness (including backing) | 7.0 mm |
Figure 6.1: Excerpt showing detailed servicing specifications for petrol models, including fluid capacities and brake pad minimum thicknesses.
6.2. Torque Wrench Settings
| Component | Nm | lbf ft |
|---|---|---|
| Automatic transmission final drive oil filler/level plug | 25 | 18 |
| Automatic transmission inspection plug (N/N) | 15 | 11 |
| Automatic transmission overflow pipe (N/N) | 7 | 5 |
| Coolant pump drain plug | 30 | 22 |
| Manual transmission filler/level plug | 25 | 18 |
| Power steering pump mounting | 30 | 22 |
| Subframe bolts | 120 | 89 |
| Sump plug | 30 | 22 |
| Engine codes ADP, AHL | 50 | 37 |
| All other engines | 50 | 37 |
6.3. Wiring Diagrams
Detailed wiring diagrams are provided to assist in diagnosing electrical issues and understanding the vehicle's electrical system. These diagrams include color codes for wires, component identification, and circuit layouts for various systems such as interior lighting, alarm, central locking, and the injection system.
Figure 6.2: Example of a wiring diagram, illustrating connections for interior lighting, alarm, and central locking systems.
7. Troubleshooting
This section offers guidance on diagnosing and resolving common problems that may occur with your Audi A4. It provides a systematic approach to identify the root cause of issues and suggests appropriate corrective actions.
7.1. Electrical System Faults
For electrical issues, refer to the wiring diagrams in Section 6.3. Common electrical problems include:
- Non-functional lights: Check bulbs, fuses, and wiring connections.
- Starting problems: Inspect battery charge, starter motor, and ignition system components.
- Warning lights illuminated: Consult the vehicle's owner's manual for specific warning light meanings and recommended actions.
7.2. Engine Performance Issues
If the engine experiences rough running, loss of power, or unusual noises:
- Check fluid levels: Ensure engine oil and coolant levels are correct.
- Inspect air and fuel filters: Clogged filters can restrict flow and affect performance.
- Examine spark plugs and ignition coils: Faulty components can lead to misfires.
- Listen for unusual sounds: Identify the source of any knocking, hissing, or grinding noises.
8. Support
For further assistance or if you encounter issues not covered in this manual, it is recommended to contact an authorized Audi service center or a qualified automotive technician. They have access to specialized diagnostic tools and up-to-date technical information specific to your vehicle model.
You may also find additional resources and support on the official Audi website or through reputable automotive forums dedicated to the Audi A4 (B5) model.
9. Warranty Information
This instruction manual does not provide specific warranty details for your Audi A4 vehicle. Warranty coverage is typically provided by the vehicle manufacturer at the time of purchase and may vary based on region, model year, and specific terms and conditions. For information regarding your vehicle's warranty, please refer to your original vehicle documentation, contact your authorized Audi dealer, or visit the official Audi website.
Performing maintenance and repairs according to manufacturer specifications, as outlined in this manual, is generally required to maintain warranty validity.
