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Quick Reference
Specification Book
2006 2010 Audi A3
Quick Reference Specification Book
Table of Contents
General Information....................................................... 1
Decimal and Metric Equivalents............................................1
Tightening Torque..................................................................2
Warnings and Cautions.........................................................4
Maintenance.................................................................... 9
Vehicle Identification.................................................... 12
VIN on Lower Edge of Front Window.....................................12
VIN on Suspension Strut Mount.............................................12
VIN Decoder...........................................................................13
Vehicle Data Sticker...............................................................16
Sales Codes.................................................................. 17
Engine.................................................................................17
Engine Codes.........................................................................17
Transmission.......................................................................17
Transmission Codes...............................................................17
Vehicle Lifting............................................................... 17
Lifting Points for Lifting Platform and Trolley Jack..................17
General, Technical Data............................................... 19
Engine Number Location 2.0L BPY/CBFA/CCTA.............19
Engine Number Location 3.2L BUB/CBRA.......................20
Engine Number Location 2.0L TDI CBEA.........................20
Engine Data............................................................................21
Engine Mechanical, Fuel Injection & Ignition 2.0L
BPY/CBFA/CCTA........................................................... 23
Engine Removing and Installing
2.0L BPY/CBFA/CCTA.........................................................23
Engine Tightening Torques..................................................23
Assembly Mountings Tightening Torques............................23
Crankshaft/Cylinder Block 4-Cylinder 4V Turbo Engine
2.0L BPY/CBFA/CCTA . ...................................................24
Assembly Attachments Mounting Tightening Torques.........24
Accessory Assembly Bracket Tightening Sequence...............25
Sealing Flange Tightening Torques.....................................25
Flywheel/Drive Plate Tightening Torques............................25

Audi A3 Quick Reference Specification Book October 2010 i


Crankshaft/Cylinder Block 4-Cylinder 4V Turbo Engine
2.0L BPY/CBFA/CCTA (continued)..................................25
Crankshaft Assembly Tightening Torques...........................25
Crankshaft Dimensions..........................................................26
Identification on Crankshaft Bearing, Top...............................26
Piston and Connecting Rod Tightening Torques.................27
Piston Ring End Gaps............................................................27
Piston Ring Clearance............................................................27
Piston and Cylinder Dimensions.............................................27
Cylinder Head - 2.0L Engine - BPY/CBFA/CCTA...............27
Cylinder Head Tightening Torques......................................27
Cylinder Head Tightening Sequence...................................28
Cylinder Head (Valve) Cover Tightening Sequence............28
Cylinder Head (Valve) Cover Tightening Torques................28
Compression Pressures.........................................................29
Valvetrain 2.0L Engine BPY/CBFA/CCTA......................29
Valvetrain Tightening Torques..............................................29
Valve Dimensions...................................................................29
Camshaft Tightening Sequence.........................................30
Camshaft Tightening Torque................................................30
Engine Lubrication 2.0L BPY/CBFA/CCTA.......................30
Lubrication System Components Tightening Torques.........30
Oil Filter Bracket Tightening Torques...................................31
Engine Cooling 2.0L BPY/CBFA/CCTA............................31
Cooling System Components (on Engine) Tightening
Torques............................................................................31
Cooling System Components (on Body) Tightening
Torques............................................................................31
Coolant Pump V50 Tightening Torques...............................31
Coolant Pump Tightening Torques......................................31
Recommended Coolant Mixture Ratios..................................32
Fuel Storage and Supply 2.0L BPY/CBFA/CCTA.............32
Fuel Pump Tightening Torques............................................32
Fuel Tank Tightening Torques..............................................32
Accelerator Pedal Module Tightening Torque......................32
EVAP Canister System Tightening Torques.........................32
Turbocharger 2.0L BPY/CBFA/CCTA...............................33
Turbocharger Tightening Torques........................................33
Charge Air Cooler Tightening Torques.................................34
Noise Booster Tightening Torques.......................................34
Fuel Injection 2.0L BPY/CBFA/CCTA...............................34
Fuel Injection System Data.....................................................34

ii Audi A3 Quick Reference Specification Book October 2010


Engine Cover/Air Filter Tightening Torques.........................34
Intake Manifold Tightening Torques.....................................35
High Pressure Pump Tightening Torques............................35
Exhaust System 2.0L BPY/CBFA/CCTA...........................35
Exhaust System Tightening Torques...................................35
Ignition System 2.0L BPY/CBFA/CCTA............................36
Ignition Tightening Torques..................................................36
Spark Plug Data.....................................................................36
Engine Mechanical, Fuel Injection & Ignition
3.2L BUB/CBRA............................................................ 37
Engine Removing and Installing 3.2L BUB/CBRA.........37
Engine Tightening Torques..................................................37
Assembly Mountings Tightening Torques............................37
Crankshaft/Cylinder Block 6-Cylinder 4V Engine
3.2L BUB/CBRA...............................................................38
Assembly Attachments Mounting Tightening Torques.........38
Drive Chain Tightening Torques..........................................38
Brake Booster Vacuum Pump Tightening Torques..............39
Sealing Flanges and Vibration Damper Tightening
Torques............................................................................39
Crankshaft Assembly Tightening Torque.............................39
Crankshaft Dimensions..........................................................39
Piston and Connecting Rod Tightening Torques.................39
Piston Ring End Gaps............................................................39
Piston Ring Clearance............................................................40
Piston and Cylinder Dimensions.............................................40
Cylinder Head 3.2L Engine BGP/BGQ..........................40
Cylinder Head Tightening Torques......................................40
Cylinder Head Removal Sequence.....................................40
Cylinder Head Tightening Sequence...................................41
Cylinder Head Cover Tightening Sequence........................41
Cylinder Head Cover Tightening Torque..............................41
Compression Pressures.........................................................42
Valvetrain 3.2L Engine BUB/CBRA................................42
Valvetrain Tightening Torques..............................................42
Valve Dimensions...................................................................42
Camshaft Tightening Sequence..........................................43
Camshaft Tightening Torques..............................................43
Engine Lubrication 3.2L BUB/CBRA.................................43
Lubrication System Components Tightening Torques.........43
Oil Filter Bracket Tightening Torques...................................43

Audi A3 Quick Reference Specification Book October 2010 iii


Engine Cooling 3.2L BUB/CBRA......................................44
Cooling System Components (on Engine) Tightening
Torques............................................................................44
Cooling System Components (on Body) Tightening
Torques............................................................................44
Recommended Coolant Mixture Ratios..................................44
Fuel Storage and Supply 3.2L BUB/CBRA.......................44
Fuel Pump Tightening Torques............................................44
Fuel Tank Tightening Torques..............................................45
Accelerator Pedal Module Tightening Torque......................45
EVAP Canister System Tightening Torques.........................45
Fuel Injection 3.2L BUB/CBRA.........................................45
Fuel Injection System Data.....................................................45
Intake Manifold Tightening Torques.....................................46
Air Filter Assembly Tightening Torques...............................46
Exhaust System 3.2L BUB/CBRA....................................46
Exhaust System Tightening Torques...................................46
Secondary Air Injection (AIR) System Tightening
Torques............................................................................47
Ignition System 3.2L BUB/CBRA......................................47
Ignition Tightening Torques..................................................47
Spark Plug Data.....................................................................47
Engine Mechanical, Fuel Injection & Ignition 2.0L
TDI CBEA....................................................................... 48
Engine Removing and Installing 2.0L TDI CBEA...........48
Engine Tightening Torques..................................................48
Assembly Mountings Tightening Torques............................49
Crankshaft/Cylinder Block 2.0L TDI CBEA.......................50
Fastener Tightening Specifications.........................................50
Accessory Assembly Bracket Tightening Sequence...............51
Ribbed Belt Pulley Side Sealing Flange Tightening
Specifications...................................................................52
Dual Mass Flywheel and Sealing Flange Tightening
Specifications...................................................................53
Crankshaft Assembly Tightening Torque.............................53
Crankshaft Dimensions..........................................................53
Piston and Connecting Rod Tightening Torques.................53
Piston Ring End Gaps............................................................54
Piston Ring Clearance............................................................54
Piston and Cylinder Dimensions.............................................54
Cylinder Head 2.0L TDI CBEA..........................................54
Cylinder Head Tightening Torques......................................54

iv Audi A3 Quick Reference Specification Book October 2010


Cylinder Head Tightening Sequence...................................55
Cylinder Head (Valve) Cover Tightening Sequence............55
Cylinder Head (Valve) Cover Tightening Torque..................56
Valvetrain 2.0L TDI CBEA.................................................56
Valvetrain Tightening Torques..............................................56
Valve Dimensions...................................................................56
Camshaft Tightening Sequence..........................................57
Camshaft Tightening Torques..............................................57
Engine Lubrication 2.0L TDI CBEA...................................58
Lubrication System Components Tightening Torques.........58
Oil Filter Bracket Tightening Torques...................................58
Engine Cooling 2.0L TDI CBEA........................................59
Cooling System Components (on Engine) Tightening
Torques............................................................................59
Cooling System Components (on Body) Tightening
Torques............................................................................59
Coolant Pump V50 Tightening Torques...............................60
Coolant Pump Tightening Torques......................................60
Recommended Coolant Mixture Ratios..................................60
Fuel Storage and Supply 2.0L TDI CBEA.........................60
Fuel Pump/ Fuel Tank Tightening Torques..........................60
Accelerator Pedal Module Tightening Torque......................60
Turbocharger 2.0L TDI CBEA...........................................61
Turbocharger Tightening Torques........................................61
Charge Air Cooler Tightening Torques.................................61
Noise Booster Tightening Torques.......................................61
Fuel Injection 2.0L TDI CBEA ..........................................62
Fastener Tightening Specifications Tightening Torques......62
Exhaust System 2.0L TDI CBEA......................................63
Exhaust System Tightening Torques...................................63
Glow Plug System 2.0L TDI CBEA...................................63
Glow Plug Data.......................................................................63
Manual Transmission................................................... 64
General, Technical Data......................................................64
02Q Manual Transmission Specifications...............................64
Clutch - 02Q........................................................................64
Pedal Cluster Tightening Torques........................................64
Over-Center Spring Tightening Torque................................64
Hydraulic System Tightening Torques.................................64
Slave Cylinder Tightening Torques......................................64
Clutch (Sachs) Tightening Torque.......................................65

Audi A3 Quick Reference Specification Book October 2010 v


Clutch - 02Q (continued).....................................................65
Clutch (LuK) Tightening Torque...........................................65
Cable Retainer Dimensions....................................................65
Shift Cable Retainer Tightening Torques.............................65
Manual Transmission Installing 02Q..............................66
02Q Selector Mechanism Tightening Torques.....................66
02Q Transmission (to Engine) Tightening Torques..............66
02Q Transmission Tightening Torques................................66
02Q Transmission Pendulum Support....................................67
02Q Transmission Housing and Shift Mechanism
Tightening Torques...........................................................67
02Q Installation Position of Shafts and Selector Rods in
Transmission....................................................................68
02Q Input Shaft, Output Shaft (Pinion Shaft), Differential
and Shift Forks Tightening Torques...............................68
02Q Transmission Housing and Clutch Housing
Tightening Torques...........................................................68
Automatic Transmission.............................................. 69
General, Technical Data......................................................69
02E Transmission Specifications............................................69
02E Direct Shift Capacities.....................................................69
Automatic Transmission Controls 02E..............................69
02E Selector Mechanism Tightening Torques.....................69
02E Selector Shaft Tightening Torque.................................70
02E Transmission Input Speed (RPM) Sensor G182 and
Clutch Oil Temperature Sensor G509 Tightening
Torque..............................................................................70
02E Direct Shift Gearbox (DSG) Mechatronic J743
Tightening Torques...........................................................70
02E Direct Shift Gearbox (DSG) Mechatronic J743
Tightening Sequence.......................................................70
02E Oil Pan Tightening Torques..........................................71
02E Drain Plug and Filter housing Tightening Torques.......71
Automatic Transmission Installing 02E.............................71
02E Oil Cooler Tightening Torque........................................71
02E Oil Pump Tightening Torques.......................................71
02E Transmission Mount Tightening Torques......................72
Suspension, Wheels, Brakes, Steering...................... 73
Front Suspension................................................................73
Front Axle Curb Weight Data...............................................73
Subframe Tightening Torques..............................................73
Control Arm Tightening Torques..........................................74
Stabilizer Bar Tightening Torques........................................74
vi Audi A3 Quick Reference Specification Book October 2010
Pendulum Support Tightening Torques...............................74
Suspension Strut Tightening Torques..................................74
Drive Axle Tightening Torques.............................................75
Wheel Bearing Housing Tightening Torques.......................75
Rear Suspension Front Wheel Drive................................76
Rear Axle Curb Weight Data...............................................76
Subframe Tightening Torques..............................................76
Left Rear Level Control System Sensor G76 Tightening
Torques............................................................................76
Wheel Bearing Housing Tightening Torques.......................77
Trailing Link Tightening Torques..........................................77
Lower Transverse Link Tightening Torque...........................77
Shock Absorbers Tightening Torques..................................77
Stabilizer Bar Tightening Torques........................................78
Rear Suspension All Wheel Drive.....................................78
Rear Axle Curb Weight Data...............................................78
Subframe Tightening Torques..............................................79
Left Rear Level Control System Sensor G76 Tightening
Torques............................................................................79
Wheel Bearing Housing Tightening Torques.......................79
Trailing Link Tightening Torques..........................................80
Lower Transverse Link Tightening Torque...........................80
Shock Absorbers Tightening Torques..................................80
Stabilizer Bar Tightening Torques........................................80
Drive Axle Tightening Torques.............................................80
Wheels, Tires, Wheel Alignment..........................................81
Wheel Bolts Tightening Torque............................................81
Tire Pressure Sensor Tightening Torque.............................81
Wheel Alignment Data............................................................81
Light Alloy Wheels with Metal Valve Tightening Torques.....82
Wheel Bolts Tightening Torques..........................................82
Brake System......................................................................83
Front Brakes Technical Data...............................................83
Rear Brakes Front Wheel Drive Technical Data..................83
Brake Master Cylinder and Brake Booster Technical
Data..................................................................................84
Hydraulic Unit, Brake Booster/Brake Master Cylinder ABS
Mark 70 (ABS/ASR) and 60 (ABS/EDL/ASR/ESP)
Tightening Torques...........................................................84
ABS System Components on Front and Rear Axles
Tightening Torques...........................................................84
ESP Sensor Unit G419 Tightening Torque..........................84
Front Wheel Brakes Brake Caliper FS III/FN 3/FNR-G
Tightening Torques...........................................................84
Audi A3 Quick Reference Specification Book October 2010 vii
Brake System (continued)...................................................85
Rear Brakes (Disc Brakes) Rear Brake C 38/C II 38
Tightening Torques...........................................................85
Parking Brake Lever Tightening Torque..............................85
Hydraulic Components Front Brake Caliper FS III/FN 3/
FNR-G Tightening Torques...........................................85
Hydraulic Components Rear Brake Caliper C 38/CII 38/
CII 41 Tightening Torques.............................................85
Hydraulic Unit, Brake Booster/Brake Master Cylinder
Tightening Torques...........................................................86
Steering...............................................................................86
Steering Column Tightening Torques..................................86
Steering Gear (Generation I and II) Tightening Torques......87
Body............................................................................... 88
Body Dimensions.................................................................88
Front Dimensions...................................................................88
Center Dimensions.................................................................90
Rear Dimensions....................................................................92
Floor Assembly Front Dimensions..........................................93
Floor Assembly Center Dimensions.......................................94
Floor Assembly Rear Dimensions..........................................95
Body Exterior.......................................................................96
Lock Carrier Service Position Tightening Torques...............96
Front Fender Tightening Torques........................................96
Noise Insulation Panel Tightening Torques.........................96
Underbody Trim Tightening Torques....................................96
Front Hood Tightening Torques...........................................96
Rear Lid Tightening Torques................................................96
Tank Flap Unit Tightening Torque........................................96
Front and Rear Door Tightening Torques............................97
Sunroof Tightening Torques.................................................97
Front Bumper Tightening Torques.......................................97
Rear Bumper Tightening Torques........................................97
Front and Rear Door Window Tightening Torques..............98
Front Wheel Housing Liner Tightening Torque....................98
Rear View Mirror Tightening Torques..................................98
Radiator Grille Tightening Torque........................................98
Strips and Trim Tightening Torques.....................................98
Body Interior........................................................................98
Storage Compartment Tightening Torques..........................98
Passenger Protection Tightening Torques...........................99
Interior Trim Tightening Torques..........................................99
Seat Frames Tightening Torques.......................................100

viii Audi A3 Quick Reference Specification Book October 2010


Heating and Air Conditioning.................................... 101
Refrigerant R134a Capacity..............................................101
Refrigerant (PAG) Oil Identification......................................101
Refrigerant (PAG) Oil Capacities..........................................101
Refrigerant Oil Distribution...................................................101
Refrigerant R134a Vapor Pressure Table.............................102
Physical Data of Refrigerant R134a.....................................102
A/C Refrigerant Pressure and Temperature Refrigerant
Circuit with Expansion Valve Specifications................103
A/C Refrigerant Pressure and Temperature Refrigerant
Circuit with Restrictor and Reservoir Specifications....105
Heating and Ventilation System Tightening Torques........106
A/C System Tightening Torques........................................106
A/C Refrigerant System Tightening Torques.....................106
Electrical Equipment.................................................. 107
Battery Tightening Torques................................................107
Generator Tightening Torques...........................................107
Generator 2.0LTFSI Tightening Torques............................107
2.0L TFSI Generator Mounting Bracket Bolts Tightening
Sequence.......................................................................107
Generator 3.2L Tightening Torques...................................108
Starter, 4 Cylinder Engine Tightening Torques..................108
Starter, 6 Cylinder Engine Tightening Torques..................108
Front Wiper Motor Tightening Torques..............................108
Washer Reservoir Tightening Torques...............................108
Rear Wiper/Washer Tightening Torques............................109
Headlamp Washer Spray Jets Tightening Torque.............109
Headlamp Tightening Torque.............................................109
Fog Lamp Tightening Torque.............................................109
Rear Lights in Rear Fender Tightening Torque..................109
Rear Lights in Rear Lid Tightening Torque........................109
Vehicle Level Sensors Tightening Torques........................109
DTC CHART..................................................................110

Audi A3 Quick Reference Specification Book October 2010 ix


General Information

Information
Decimal and Metric Equivalents

General
Distance/Length
To calculate: mm x 0.03937 = in.
mm in. mm in. mm in. mm in.
0.002 0.00008 0.01 0.0004 0.1 0.004 1 0.04
0.004 0.00016 0.02 0.0008 0.2 0.008 2 0.08
0.006 0.00024 0.03 0.0012 0.3 0.012 3 0.12
0.008 0.00031 0.04 0.0016 0.4 0.016 4 0.16
0.010 0.00039 0.05 0.0020 0.5 0.020 5 0.20
0.020 0.00079 0.06 0.0024 0.6 0.024 6 0.24
0.030 0.00118 0.07 0.0028 0.7 0.028 7 0.28
0.040 0.00157 0.08 0.0031 0.8 0.031 8 0.31
0.050 0.00197 0.09 0.0035 0.9 0.035 9 0.35
0.060 0.00236 0.10 0.0039 1.0 0.039 10 0.39
0.070 0.00276 0.20 0.0079 2.0 0.079 20 0.79
0.080 0.00315 0.30 0.0118 3.0 0.118 30 1.18
0.090 0.00354 0.40 0.0157 4.0 0.157 40 1.57
0.100 0.00394 0.50 0.0197 5.0 0.197 50 1.97
0.200 0.00787 0.60 0.0236 6.0 0.236 60 2.36
0.300 0.01181 0.70 0.0276 7.0 0.276 70 2.76
0.400 0.01575 0.80 0.0315 8.0 0.315 80 3.15
0.500 0.01969 0.90 0.0354 9.0 0.354 90 3.54
0.600 0.02362 1.00 0.0394 10.0 0.394 100 3.94
0.700 0.02756 2.00 0.0787 20.0 0.787
0.800 0.03150 3.00 0.1181 30.0 1.181
0.900 0.03543 4.00 0.1575 40.0 1.575
1.000 0.03937 5.00 0.1969 50.0 1.969
2.000 0.07874 6.00 0.2362 60.0 2.362
3.000 0.11811 7.00 0.2756 70.0 2.756
4.000 0.15748 8.00 0.3150 80.0 3.150
5.000 0.19685 9.00 0.3543 90.0 3.543
6.000 0.23622 10.00 0.3937 100.0 3.937
7.000 0.27559 20.00 0.7874
8.000 0.31496 30.00 1.1811
9.000 0.35433 40.00 1.5748
10.000 0.39370 50.00 1.9685
20.000 0.78740 60.00 2.3622
30.000 1.18110 70.00 2.7559
40.000 1.57480 80.00 3.1496
50.000 1.96850 90.00 3.5433
60.000 2.36220 100.00 3.9370
70.000 2.75591
80.000 3.14961
90.000 3.54331
100.000 3.93701

Audi A3 Quick Reference Specification Book October 2010 1


Tightening Torque
Nm-to-lbft (ftlb)
To calculate: Nm x 0.738 = lbft
lbft lbft lbft
Nm Nm Nm
(ftlb) (ftlb) (ftlb)
10 7 55 41 100 74
11 8 56 41 105 77
12 9 57 42 110 81
13 10 58 43 115 85
14 10 59 44 120 89
15 11 60 44 125 92
16 12 61 45 130 96
17 13 62 46 135 100
18 13 63 46 140 103
19 14 64 47 145 107
20 15 65 48 150 111
21 15 66 49 155 114
22 16 67 49 160 118
23 17 68 50 165 122
24 18 69 51 170 125
25 18 70 52 175 129
26 19 71 52 180 133
27 20 72 53 185 136
28 21 73 54 190 140
29 21 74 55 195 144
30 22 75 55 200 148
31 23 76 56 205 151
32 24 77 57 210 155
33 24 78 58 215 159
34 25 79 58 220 162
35 26 80 59 225 166
36 27 81 60 230 170
37 27 82 60 235 173
38 28 83 61 240 177
39 29 84 62 245 181
40 30 85 63 250 184
41 30 86 63 260 192
42 31 87 64 270 199
43 32 88 65 280 207
44 32 89 66 290 214
45 33 90 66 300 221
46 34 91 67 310 229
47 35 92 68 320 236
48 35 93 69 330 243
49 36 94 69 340 251
50 37 95 70 350 258
51 38 96 71 360 266
52 38 97 72 370 273
53 39 98 72 380 280
54 40 99 73 390 288
55 41 100 74 400 295

2 Audi A3 Quick Reference Specification Book October 2010


Nm-to-lbin (inlb), kgcm
To calculate: Nm x 885 = lbin Nm x 10.20 = kgcm

Information
General
lbin lbin
Nm kgcm Nm kgcm
(inlb) (inlb)
1 9 10 26 230 265
2 18 20 27 239 275
3 27 31 28 248 286
4 35 41 29 257 296
5 44 51 30 266 306
6 53 61 31 274 316
7 62 71 32 283 326
8 71 82 33 292 337
9 80 92 34 301 347
10 89 102 35 310 357
11 97 112 36 319 367
12 106 122 37 327 377
13 115 133 38 336 387
14 124 143 39 345 398
15 133 153 40 354 408
16 142 163 41 363 418
17 150 173 42 372 428
18 159 184 43 381 438
19 168 194 44 389 449
20 177 204 45 398 459
21 186 214 46 407 469
22 195 224 47 416 479
23 204 235 48 425 489
24 212 245 49 434 500
25 221 255 50 443 510

Ncm-to-lbin (inlb), kgcm


To calculate: Ncm x 0.089 = lbin Ncm x 0.102 = kgcm
lbin lbin
Ncm kgcm Ncm kgcm
(inlb) (inlb)
50 4 5 250 22 25
60 5 6 300 27 31
70 6 7 350 31 36
80 7 8 400 35 41
90 8 9 450 40 46
100 9 10 500 44 51
110 10 11 550 49 56
120 11 12 600 53 61
130 12 13 650 58 66
140 12 14 700 62 71
150 13 15 750 66 76
160 14 16 800 71 82
170 15 17 850 75 87
180 16 18 900 80 92
190 17 19 950 84 97
200 18 20 1000 89 102

Audi A3 Quick Reference Specification Book October 2010 3


kgcm-to-lbin (inlb), Ncm
To calculate: kgcm x 0.868 = lbin kgcm x 9.81 = Ncm
lbin lbin
kgcm Ncm kgcm Ncm
(inlb) (inlb)
5 4 49 110 95 1079
6 5 59 120 104 1177
7 6 69 130 113 1275
8 7 78 140 122 1373
9 8 88 150 130 1471
10 9 98 160 139 1569
20 17 196 170 148 1667
30 26 294 180 156 1765
40 35 392 190 165 1863
50 43 490 200 174 1961
60 52 588 210 182 2059
70 61 686 220 191 2157
80 69 785 230 200 2256
90 78 883 240 208 2354
100 87 981 250 217 2452

Warnings and Cautions


WARNINGS
Some repairs may be beyond your capability. If you lack the
skills, tools and equipment, or a suitable workplace for any
procedure described in this manual, we suggest you leave such
repairs to an authorized dealer service department or other
qualified shop.

Do not reuse any fasteners that have become worn or deformed


during normal use. Many fasteners are designed to be used only
once and become unreliable and may fail when used a second
time. This includes, but is not limited to, nuts, bolts, washers,
self-locking nuts or bolts, circlips and cotter pins. Always replace
these fasteners with new parts.

Never work under a lifted car unless it is solidly supported on


stands designed for the purpose. Do not support a car on cinder
blocks, hollow tiles or other props that may crumble under
continuous load. Never work under a car that is supported solely
by a jack. Never work under the car while the engine is running.

4 Audi A3 Quick Reference Specification Book October 2010


If you are going to work under a car on the ground, make sure
the ground is level. Block the wheels to keep the car from rolling.
Disconnect the battery negative (-) terminal (ground strap) to

Information
prevent others from starting the car while you are under it.

General
Never run the engine unless the work area is well ventilated.
Carbon monoxide kills.

Remove rings, bracelets and other jewelry so they cannot cause


electrical shorts, get caught in running machinery, or be crushed
by heavy parts.

Tie back long hair. Do not wear a necktie, a scarf, loose clothing,
or a necklace when you work near machine tools or running
engines. If your hair, clothing, or jewelry were to get caught in the
machinery, severe injury could result.

Do not attempt to work on your car if you do not feel well. You
increase the danger of injury to yourself and others if you are
tired, upset, or have taken medication or any other substance
that may keep you from being fully alert.

Illuminate your work area adequately but safely. Use a portable


safety light for working inside or under the car. Make sure
the bulb is enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel, vapors or oil.

Use a suitable container to catch draining fuel, oil, or brake


fluid. Do not use food or beverage containers that might mislead
someone into drinking from them. Store flammable fluids away
from fire hazards. Wipe up spills at once, but do not store oily
rags which can ignite and burn spontaneously.

Always observe good workshop practices. Wear goggles when


you operate machine tools or work with battery acid. Wear
gloves or other protective clothing whenever the job requires
working with harmful substances.

Greases, lubricants and other automotive chemicals contain


toxic substances, many of which are absorbed directly through
the skin. Read the manufacturer's instructions and warnings
carefully. Use hand and eye protection. Avoid direct skin contact

Disconnect the battery negative (-) terminal (ground strap)


whenever you work on the fuel or electrical system. Do not
smoke or work near heaters or other fire hazards. Keep an
approved fire extinguisher handy.

Audi A3 Quick Reference Specification Book October 2010 5


Friction materials (such as brake pads or shoes or clutch discs)
contain asbestos fibers or other friction materials. Do not create
dust by grinding, sanding, or cleaning with compressed air. Avoid
breathing dust. Breathing any friction material dust can lead to
serious diseases and may result in death.

Batteries give off explosive hydrogen gas during charging. Keep


sparks, lighted matches and open flame away from the top of the
battery. If hydrogen gas escaping from the cap vents is ignited, it
ignites the gas trapped in the cells and causes the battery
to explode.

Connect and disconnect battery cables, jumper cables or a


battery charger only with the ignition off. Do not disconnect the
battery while the engine is running.

Do not quick-charge the battery (for boost starting) for longer


than one minute. Wait at least one minute before boosting the
battery a second time.

Do not allow battery charging voltage to exceed 16.5 volts. If


the battery begins producing gas or boiling violently, reduce the
charging rate. Boosting a sulfated battery at a high charging rate
can cause an explosion.

The A/C system is filled with chemical refrigerant, which is


hazardous. The A/C system should be serviced only by trained
technicians using approved refrigerant recovery/recycling
equipment, trained in related safety precautions, and familiar
with regulations governing the discharging and disposal of
automotive chemical refrigerants.

Do not expose any part of the A/C system to high temperatures


such as open flame. Excessive heat increases system pressure
and may cause the system to burst.

Some aerosol tire inflators are highly flammable. Be extremely


cautious when repairing a tire that may have been inflated using
an aerosol tire inflator. Keep sparks, open flame or other sources
of ignition away from the tire repair area. Inflate and deflate the
tire at least four times before breaking the bead from the rim.
Completely remove the tire from the rim before attempting
any repair.

6 Audi A3 Quick Reference Specification Book October 2010


Some cars are equipped with a Supplemental Restraint System
(SRS) that automatically deploys airbags and pyrotechnic seat
belt tensioners in the event of a frontal or side impact. These

Information
are explosive devices. Handled improperly or without adequate

General
safeguards, they can be accidentally activated and cause
serious injury.

The ignition system produces high voltages that can be fatal.


Avoid contact with exposed terminals and use extreme care
when working on a car with the engine running or the ignition on.

Place jack stands only at locations specified by manufacturer.


The vehicle lifting jack supplied with the vehicle is intended for
tire changes only. Use a heavy duty floor jack to lift the vehicle
before installing jack stands.

Battery acid (electrolyte) can cause severe burns. Flush contact


area with water, seek medical attention.

Aerosol cleaners and solvents may contain hazardous or deadly


vapors and are highly flammable. Use only in a well ventilated
area. Do not use on hot surfaces (such as engines or brakes).

Do not remove coolant reservoir or radiator cap with the engine


hot. Burns and engine damage may occur.

CAUTIONS
If you lack the skills, tools and equipment, or a suitable workshop
for any procedure described in this manual, we suggest you
leave such repairs to an authorized dealer or other
qualified shop.

Before starting a job, make certain that you have all the
necessary tools and parts on hand. Read all the instructions
thoroughly and do not attempt shortcuts. Use tools appropriate
to the work and use only replacement parts meeting original
specifications. Makeshift tools, parts and procedures will not
make good repairs.

Use pneumatic and electric tools only to loosen threaded parts


and fasteners. Never use these tools to tighten fasteners,
especially on light alloy parts. Always use a torque wrench to
tighten fasteners to the tightening torque specification listed.

Audi A3 Quick Reference Specification Book October 2010 7


Be mindful of the environment and ecology. Before you drain the
crankcase, find out the proper way to dispose of the oil. Do not
pour oil onto the ground, down a drain, or into a stream, pond or
lake. Dispose of in accordance with Federal, State and
Local laws.

The control module for the Anti-lock Brake System (ABS) cannot
withstand temperatures from a paint-drying booth or a heat
lamp in excess of 95C (203F) and should not be subjected to
temperatures exceeding 85C (185F) for more than two hours.

Before doing any electrical welding on cars equipped with ABS,


disconnect the battery negative (-) terminal (ground strap) and
the ABS control module connector.

Always make sure the ignition is off before disconnecting the


battery.

Label battery cables before disconnecting. On some models,


battery cables are not color coded.

Disconnecting the battery may erase fault code(s) stored


in control module memory. Check for fault codes prior to
disconnecting the battery cables.

If a normal or rapid charger is used to charge the battery,


disconnect the battery and remove it from the vehicle to avoid
damaging paint and upholstery.

Do not quick-charge the battery (for boost starting) for longer


than one minute. Wait at least one minute before boosting the
battery a second time.

Connect and disconnect a battery charger only with the battery


charger switched off.

Sealed or "maintenance free" batteries should be slow-charged


only, at an amperage rate that is approximately 10% of the
battery's ampere-hour (Ah) rating.

Do not allow battery charging voltage to exceed 16.5 volts. If


the battery begins producing gas or boiling violently, reduce the
charging rate. Boosting a sulfated battery at a high charging rate
can cause an explosion.

8 Audi A3 Quick Reference Specification Book October 2010


Maintenance

Information
General

Audi A3 Quick Reference Specification Book October 2010 9


A3 2008 FLUID CAPACITY CHART
Vehicle
Engine oil A/C A/C
Manual Auto Rear Final Cooling Power
approx. qty. Brake Fluid Refrigerant Refrigerant Windshield
(Sales Trans Trans Drive System Steering
w/filter R134a oil Fluid
Code)
change
A3 2.0 TFSI 6-Spd 6-Spd DSG N/A 8.0L (8.5qt) Use only R134a Use PAG oil 3.5L (3.7qt)
4-door (BPY) (02Q) (02E) Electro- Refer to with R134a
FWD Mechanical Maintenance See Parts
4.6L (4.9qt) 2.3L (2.4qt) New Fill: (No Fluid) Manual Brake Catalog for See Parts
(8PA52C) 7.2L (7.6qt) Fluid, Changing refrigerant Catalog for
(8PA59C) capacity oil capacity
Manual Change:
6.0L (6.3qt)
(8PA52X) approx.
(8PA59X)
Auto

A3 3.2L V6 N/A 0AV/02D 12.3L (13.0qt)


4-door (CBRA)
Quattro New Fill:
5.5L (5.8qt) 0.95L (1.0 qt)
(8PA51L)

Haldex
Clutch

New Fill:
0.85L (0.9 qt)

Replacement:
0.65L
(0.7 qt / 22oz)

For proper fluid level and filling information, see the Maintenance and/or Repair Manual in ElsaWeb.
Refer to the owners Manual Vehicle Care - Checking and Filling for information on the following:
Engine oil quality standards and viscosity
Engine coolant information
Brake fluid standard
Always check with your Parts Department for the latest parts information.

2008 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to
other sites, without the prior expressed written permission of the publisher.

A3 - 2009 FLUID CAPACITY CHARTupdated 29 Jan 2010

Vehicle Engine oil Manual Auto Rear Final Cooling Power Windshield
Brake System A/C System
(Sales Code) approx. qty. Trans Trans Drive System Steering & Headlight
w/filter change Fluid
A3 2.0 TFSI 200 hp 6-Spd (02Q) n/A n/A 8.0L (8.5 qt)*** 1.0 L (1.1qt) Refrigerant 5.5L (5.8qt)
FWD (CCTA/CBFA) Electro- (approximately) Use only R134a
2.3L (2.4qt) Mechanical
(8PA59C) 4.6L (4.8qt) oil Pn (No Fluid) Refrig. Capacity Fluid Pn
Manual G 052 171 A2* Audi Brake Fluid 625 +/- 25 grams G 052 164*
A3 Audi oil Spec: nA 6-Spd DSG Capacity Specification:
VW 502 00**
FWD (02E) included with
Use synthetic oil Use new fluid only. Refrigerant oil
SAE 5W-40, New Fill: transmission.
(8PA59X) 6.9L - 7.2L Use a PAG oil
SAE 5W-30 or
Auto SAE 0W-40 (7.3qt - 7.6qt) FMVSS 116 DOT 4 with R134a
oil Pn or SAE J 1703
Change: G 052 182 A2* oil Pn & Capacity
5.2L (5.5qt) Fluid Pn 1) For Sanden use
approx. B 000 750 * 110 cc +/- 10 cc
A3 6-Spd DSG 0BR 2) For Zexel use
quattro (02E) 1.0L (1.1 qt) 120 cc +/- 15 cc
New Fill: oil Pn 3) For Denso use
(8PA59L) 6.9L (7.3qt) G 052 145 A1* 140 cc +/- 10 cc
Haldex Clutch G 052 300 A2*
Change: 0.7L (0.8qt) G 052 154 A2*
5.5L (5.8qt) oil Pn
approx. G 060 175 A2*
A3 S line 3.2L VR6 250 hp 0AV 12.3L (13.0qt)***
quattro (CBRA) oil Pn 0.95L (1.0 qt)
G 052 182 A2* oil Pn
(8PA51L) 5.5L (5.8qt) G 052 145 A1*
Bevel Box Haldex Clutch
Audi oil Spec: New Fill: New Fill:
VW 502 00** 0.9L (1.0qt) 0.85L (0.9 qt)
Use synthetic oil
SAE 5W-40, oil Pn Replacement:
SAE 5W-30 or G 052 145 S2*
SAE 0W-40 0.65L(0.7qt)
oil Pn
G 060 175 A2*

For proper fluid level and filling information, see the Repair Manual and/or Maintenance Manual in ElsaWeb.
* oil and fluid part numbers are for reference only. Always check with your Parts Department for the latest part information.
**Refer to Technical Bulletin 17-08-27 (2010043) for engine oils that meet this Audi oil standard.
*** Audi Coolant Additive Specification and Part number: (color is purple) G 12 plus-plus PN- G 012 A8G.

2009 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to
other sites, without the prior expressed written permission of the publisher.

10 Audi A3 Quick Reference Specification Book October 2010


A3 - 2010 FLUID CAPACITY CHART revised 23 December 2009

Information
Vehicle Engine oil Manual Auto Rear Final Cooling Power

General
Brake System A/C System Windshield
(Sales Code) approx. qty. Trans Trans Drive System Steering
Fluid
w/filter change
A3 2.0 TFSI 200 hp 6-Spd (02Q) n/A n/A 8.6L (9.1 qt)*** 1.0 L (1.1qt) Refrigerant 3.0L (3.1qt)
FWD (CCTA/CBFA) Electro- (approximately) Use only R134a
2.3L (2.4qt) Mechanical
(8PA59C) 4.6L (4.8qt) Refrig. Capacity Fluid Pn
(8PA5YC-PZEV) oil Pn Audi Brake Fluid 625 +/- 25 grams G 052 164*
Audi oil Spec: G 052 171 A2* Specification:
Manual VW 502 00**
Use synthetic oil Use new fluid only. Refrigerant oil
SAE 5W-40,
Use a PAG oil
SAE 5W-30 or
SAE 0W-40 FMVSS 116 DOT 4 with R134a
A3 nA or SAE J 1703
FWD - Auto oil Pn & Capacity
6-Spd DSG Capacity Fluid Pn 1) For Sanden use
(8PA59X) (02E) included with B 000 750 * 110 cc +/- 10 cc
(8PA5YX-PZEV) New Fill: transmission. 2) For Zexel use
6.9 - 7.2L 120 cc +/- 15 cc
A3 TDI 2.0L 140 hp (7.3 - 7.6qt) 8.7L (9.2 qt)*** 3) For Denso use
FWD (CBEA) 140 cc +/- 10 cc
Change: G 052 300 A2*
(8PA5PX) 4.0L (4.2qt) 5.2 5.5L G 052 154 A2*
(5.5 5.8 qt)
Audi oil Spec: approx.
VW 507 00**
A3 2.0 TFSI 200 hp oil Pn 02D / oAV 8.6L (9.1 qt)***
quattro (CCTA/CBFA) G 052 182 A2* 0.95L (1.0 qt)
oil Pn
(8PA59L) 4.6L (4.8qt) G 052 145 A1*
Auto
Audi oil Spec: Haldex Clutch
VW 502 00** new Fill:
Use synthetic oil Bevel Box
0.85L (0.9qt)
SAE 5W-40, New Fill:
Replacement:
SAE 5W-30 or 0.9L (1.0qt)
SAE 0W-40 0.65L(0.7qt)
oil Pn
oil Pn
G 052 145 S2*
G 060 175 A2*

For proper fluid level and filling information, see the Repair Manual and/or Maintenance Manual in ElsaWeb.
* oil and fluid part numbers are for reference only. Always check with your Parts Department for the latest part information.
**Refer to Technical Bulletin 17-09-12 (2010043) for engine oils that meet this Audi oil standard.
*** Audi Coolant Additive Specification and Part number: (color is purple) G 12 plus-plus PN- G 012 A8G.

2009 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to
other sites, without the prior expressed written permission of the publisher.

Audi A3 Quick Reference Specification Book October 2010 11


Vehicle Identification
VIN on Lower Edge of Front Window

The VIN is on the left side of the vehicle in the windshield, in the
area of the windshield wiper mount. It is visible from outside.

VIN on Suspension Strut Mount

The vehicle identification number B (chassis number)


is stamped into the upper inner longitudinal member.

12 Audi A3 Quick Reference Specification Book October 2010


VIN Decoder

Identification
Vehicle

Audi A3 Quick Reference Specification Book October 2010 13


Series:
G= S4 and S6 Sedan
2 0 0 8 A u d i V IN D e c o d e r
A= A4 Cabrio 2dr

system
A4 Sedan H= A3

plant
Mfg. Make (1-3)
A6 Sedan ** K= A3 S-Line quattro
Audi Q7 quattro ** A4 Avant quattro
Sequential

Model (7&8)
Series: 2 0 0 8 A u d i V IN D e c o d e r

Check digit
R8 2dr A6 Avant quattro

Model year
L= G=
A8S4 and S6 Sedan

Assembly
A=
TT A4 Cabrio 2dr
Coupe Sedan
product number

RestraintRestraint
system
A4 Sedan
B=A4 Cabrio S-Line 2dr M=H=A8LA3Sedan

plant
Mfg. Make (1-3)

Engine Engine
A4 A6 Sedan
S-Line ** ** K=TTA3 S-Line quattro (position 12 - 17)

Series Series
Roadster
A6 Audi Q7**quattro **
S-Line N= A3 A4 Avant Pkg
w/Prem quattro
Sequential

Model (7&8)

Check digit
AudiR8Q72dr
Prem quattro TTA6 Avant quattro

Model year
Roadster with

Assembly
TT Coupe
TT Coupe
B=A4
w/PremPkg
Cabrio S-Line 2dr
L=Premium
M=
A8 Sedan
A8L
Pkg
Sedan
product number
D= A4 Cabrio q 2dr
A4 S-Line **
P= S8 Sedan 1 2 3 4 5 6 7 8 9 10 11 12 (position
13 14 1215- 17)
16 17
A4 Sedan quattro R= RS4TTSedan
Roadster
A5 A6
2drS-Line ** N=
S4A3 w/Prem
Cabrio Pkg
quattro T R U A F 3 8 J 8 8 1 0 0 0 4 9 9
A6Audi Q7quattro
Sedan Prem quattro
S5 TT
2drRoadster with

See back See back

2008
TT TT Coupe
Coupe w/PremPkg
quattro Premiumquattro
TT Roadster Pkg 8P = A3 D= VR6 3.2L 250hp A3 S-Line / TT
E= D= A4 Cabrio
A4 Cabrio q 2drq
S-Line P= S8 Sedan
S= A4 Avant S-Line q 1 2 3 4 5 6 7
8E = A4 / S4 / 8 9 10 11 12 13 142.0T 15
E= 4 cyl 200hp 16
A3 17
A4 A4 Sedan
S-Line quattro
quattro R= RS4 Sedan

Pass. Car WA1 = Audi - Europe: SUV


RS4
A5 A5 2dr 2dr
A6 Avant S-Line q
T R U A F 3 8 J 8 8 1 0 0F= 4A4cyl0
A= Ingolstadt
2.0T 200hp A3 / A4 / A4 Cabrio/
4 9 9

WAU = Audi - Germany:


S-Line S4 Cabrio quattro 8H = A4 / S4 q / TT
TT Roadster quattro

WUA = quattro GmbH -


TRU = Audi - Hungary:
A6 Sedan quattro S5 2dr D= Bratislava,Slovakia

2008
A6 Sedan S-Line q with Premium Pkg Cabriolet H= V6 3.1L 255hp A4/A4 Cab/A4 q/A6 q

Germany: Pass. Car


TT Coupe quattro 8P = A3 D= VR6 3.2L 250hp A3 S-Line / TT
Audi Q7 Prem S-Line q U= S4TT Roadster quattro
Avant 8T = A5/ S5 K= Karmann-Rheine V6 3.2L 265hp A5
E= A4 Cabrio S-Line q S= A4 Avant S-Line q 8E = A4 / S4 / N= Neckarsulm E= 4 cyl 2.0T 200hp A3
TT Coupe quattro Y= RS4 Cabrio quattro 4F = A6/S6 L= V8 4.2L 344hp S4 / S4 Avant & Cab
A4 S-Line quattro

WA1 = Audi - Europe: SUV


with Premium Pkg A6 Avant S-Line q RS4 1= F= 4 cyl 2.0T 200hp A3 / A4 / A4 Cabrio/
4E = A8/S8 A=Gyor
Ingolstadt N= V10 5.2L 435hp S6

WAU = Audi - Germany:


A5 S-Line 2dr TT Roadster quattro 8H = A4 / S4 A4 q / TT

Pass. Car

Pass. Car

WUA = quattro GmbH -


TRU = Audi - Hungary:
A6 Sedan S-Line q with Premium Pkg 4L = Audi Q7
Cabriolet D= Bratislava,Slovakia N= V6
H= V103.1L
5.2L 450hp
255hp S8 Cab/A4 q/A6 q
A4/A4

Germany: Pass. Car


Audi Q7 Prem S-Line q** Available
U= S4 Avant
in U.S. only 42
8T==R8
A5/ S5 K= Karmann-Rheine R= 12
V6 cyl
3.2L6.0L 450hp
265hp A5 A8L
TT Coupe quattro Y= RS4 Cabrio quattro 8J
4F==TT
A6/S6 N= Neckarsulm L= V8 4.2L
U= V8 420hp S4
4.2L 344hp RS4 / RS4
/ S4 Cab
Avant / R8
& Cab
with Premium Pkg 4E = A8/S8 1= Gyor
Calculate per V= V10
N= V8 4.2L
5.2L350hp A6S6
435hp q / A8 / A8L/ Q7

Pass. Car
4L = Audi Q7 NHTSA Code V8 4.2L
N= V10 5.2L354hp
450hpS5
S8
** Available in U.S. only 42 = R8 Y= 12
R= VR6cyl3.6L
6.0L280hp Q7
450hp A8L
8J = TT U= V8 4.2L 420hp RS4 / RS4 Cab / R8
Revision 3a - October 10, 2007
Calculate per V= V8 4.2L 350hp A6 q / A8 / A8L/ Q7
NHTSA Code V8 4.2L 354hp S5
Y= VR6 3.6L 280hp Q7

Revision 3a - October 10, 2007

2 0 0 8 A u d i V IN D e c o d e r
AirBags Frt. & Rear + Side Guard Air Curtain

6 Restraint system

plant plant
1 Mfg. Make (1-3)

2 0 0 8 A u d i V IN D e c o d e r Sequential
(7&8) (7&8)

digit digit

year year
Guard Air Curtain

system

11 Assembly
Dr/Pass + AirBag Dr/Pass + Advanced Front AirBag

product number
+ Side Guard Air Curtain

1 Mfg. Make (1-3)


***Early vehicles may use '6' instead of '7' or '5' instead of '9'.

EngineEngine

(position 12 - 17)
9 Check
Series Series

10 Model Model
7 Model

Sequential
Air Curtain

11 Assembly
Front Front AirBag

product number
5 or 9 ***= Side AirBags Front & Rear + Side Guard Air Curtain

6 Restraint
Side AirBag Front Dr/Pass

***Early vehicles may use '6' instead of '7' or '5' instead of '9'.
+ Side

(position 12 - 17)
9 Check
Model

10

12

13

14

15
16
17
2

8
Guard
Air Curtain
& Rear
+ Advanced

SideDr/Pass

Code Code
per 7 per

Sequential
& Rear
+ Side

5 = 2005Number Number
4 = 2004Product Product
12

13

14

15
16
17
Front Frt.

CalculateCalculate
2

8
Guard
AirBags
2008 Restraint System:

NHTSA NHTSA
Front

Front
Side AirBags
Dr/Pass
Front

Sequential
AirBag,

+ Side
KneeAirBag
Side AirBags
AirBags
+ Side
only) =
+ Side AirBags
System:

Front
+ AirBag

4 (A8 only) == Side


Knee AirBag

AirBag,

W = 1998
***= Side
4 (A4 Cabriolet

M = 1991
N = 1992

R = 1994
K = 1989

P = 1993

S = 1995

V = 1997

X = 1999
Y = 2000
T = 1996
1990

1 = 2001
2 = 2002
3 = 2003

6 = 2006
7 = 2007
8 = 2008
J = 1988
or 9 AirBags
All = Active

7 ***=
Dr/Pass
2008 Restraint

6 =orKnee
3 = Knee AirBag

W = 1998
6 or 7 ***=5Side
4 (A4 Cabriolet

M = 1991
=

N = 1992

R = 1994
K = 1989

P = 1993

S = 1995

V = 1997

X = 1999
Y = 2000
T = 1996
L = 1990

1 = 2001
2 = 2002
3 = 2003
4 = 2004
5 = 2005
6 = 2006
7 = 2007
8 = 2008
J = 1988
3=

L
All = Active

4 (A8 only)

14 Audi A3 Quick Reference Specification Book October 2010


Identification
Vehicle

Audi A3 Quick Reference Specification Book October 2010 15


Type Plate Location

The type plate (A) is fastened behind the right strut


tower on the plenum chamber.

Vehicle Data Sticker

The vehicle data sticker is located in the left rear of vehicle in the
spare wheel well under foam storage tray. The vehicle data sticker
can also be found in the customers service schedule.

16 Audi A3 Quick Reference Specification Book October 2010


Sales Codes
Engine
Engine Codes
BPY/CBFA/CCTA 2.0L 4-cylinder 4V turbo
CBEA 2.0L TDI 4-cylinder 4V turbo
BUB/CBRA 3.2L 6-cylinder 4V

Transmission
Transmission Codes
02Q 6-speed manual
02E 6-speed direct shift automatic

Vehicle Lifting

Codes
Sales
Lifting Points for Lifting Platform
and Trolley Jack

Vehicle
Lifting

Front: Place support plate on the floor longitudinal


reinforcement in the area of the stamped marking.

Audi A3 Quick Reference Specification Book October 2010 17


.
Rear: Place support plate on the floor longitudinal
reinforcement in the area of the stamped marking.

Note: Do not allow the support plate to touch the trailing arm
mounting tab, damage to the wheel guide can occur.

18 Audi A3 Quick Reference Specification Book October 2010


General, Technical Data
Engine Number Location
2.0L BPY/CBFA/CCTA

The engine number (engine code and serial number) is located at


the left on the engine/transmission partition. The engine code is also
stamped on the right side of the cylinder head and on the cylinder
block. In addition, a sticker with the engine code and serial number
is affixed to the timing belt cover. The engine code is also on the
vehicle data plate.
Engine Mech., Fuel
Injection & Ignition

Audi A3 Quick Reference Specification Book October 2010 19


Engine Number Location 3.2L BUB/CBRA

The engine number (engine code and serial number) is located


at the front near the crankshaft ribbed belt pulley . In addition,
a sticker with the engine code and serial number is affixed to the
cylinder head cover. The engine code is also located on the vehicle
data plate.

Engine Number Location 2.0L TDI CBEA

The engine number (engine code and serial number) is located


at the front on the engine/transmission joint. In addition, a sticker
with the engine code and serial number is affixed to the toothed
belt guard. Engine codes beginning with C are four-digit. The first 3
digits of the engine code stand for the displacement and mechanical
structure of the engine. They are stamped in the cylinder block,
including the serial number. The fourth digit describes the engine
output and torque and depends on the
Engine Control Module (ECM).
20 Audi A3 Quick Reference Specification Book October 2010
Engine Data
Code letters BPY/CBFA/CCTA
Displacement liter 1.984
Output kW at 1/rpm 147/5700
Torque Nm at rpm 280/2000
Bore diameter mm 82.5
Stroke mm 92.8
Compression ratio 10.5
RON 98 1)
Fuel injection and ignition system FSI
Ignition sequence 1-3-4-2
Knock Sensor (KS) Yes
Charging Yes
Exhaust Gas Recirculation (EGR) No
Variable intake manifold No
Variable valve timing Yes
Secondary Air Injection (AIR) No
1)
Unleaded RON 95 is also permissible, although with reduced power.

Code letters BUB/CBRA


Displacement liter 3,189
Output kW at 1/rpm 184/6300
Torque Nm at rpm 320/2800 to 3200
Bore Diameter mm 84
Stroke mm 95.9
Compression ratio 10.85
RON 98 1)
Fuel injection and ignition system Motronic
Firing order 1-5-3-6-2-4
Exhaust Gas Recirculation (EGR) No
Turbocharger No
Knock control Yes
Variable valve timing Yes
Variable intake manifold Yes
Secondary Air Injection (AIR) system Yes
1)
Unleaded RON 95 is also permissible, although with reduced power.
Engine Mech., Fuel
Injection & Ignition

Audi A3 Quick Reference Specification Book October 2010 21


Code letters CBEA
Displacement liter 1.968
Output kW at RPM 103/4200
Torque Nm at RPM 320/1750to2500
Bore diameter mm 81.0
Stroke mm 95.5
Compression ratio 16.5
CZ at least 51
Ignition sequence 1-3-4-2
Exhaust Gas Recirculation (EGR) Yes
Exhaust temperature control Yes
Turbocharger Turbocharger
Glow plugs Steel glow plugs
Charge air cooler Yes
Oxygen Sensor (O2S) regulation Heated Oxygen Sensor
(HO2S) 1
Particulate filter Yes
Valve per cylinder 4

22 Audi A3 Quick Reference Specification Book October 2010


Engine Mechanical,
Fuel Injection & Ignition
2.0L BPY/CBFA/CCTA
Engine Removing and Installing
2.0L BPY/CBFA/CCTA
Engine Tightening Torques
Component Bolt Size Nm
Bolts, nuts M6 10
M8 20
M10 45
M 12 65

Assembly Mountings Tightening Torques


Component Nm
Mounting-to-body (always replace) 40 plus an
additional 90
( turn)
Mounting/bracket-to-body (always replace) 60 plus an
additional 90
( turn)
Support-to-mounting at body (always replace) 20 plus an
additional 90
( turn)
Transmission assembly mount-to-body (always replace) 60 plus an
additional 90
( turn)
Transmission assembly mounting/bracket-to-body 40 plus an
(always replace) additional 90
( turn)
Pendulum support mounting-to-body (always replace) 100 plus an
additional 90
( turn)
Pendulum support mounting/bracket-to-body (always 40 plus an
replace) additional 90
Engine Mech., Fuel
Injection & Ignition

( turn)

Audi A3 Quick Reference Specification Book October 2010 23


Crankshaft/Cylinder Block 4-Cylinder
4V Turbo Engine 2.0L BPY/CBFA/CCTA
Assembly Attachments Mounting
Tightening Torques
Component Nm
Generator-to-engine bolt and nut 23
Accessory assembly bracket bolt 45
Air conditioner compressor bolt 25
Pulley with divided toothed belt guard bolt 10 plus an
additional 90
( turn)
Divided toothed belt tensioner bolt 23
Upper toothed belt cover bolt 10
Camshaft gear-to-rear toothed belt cover bolt 50 plus an
additional 180
( turn)
Rear toothed belt cover bolt 10
Semi-automatic tensioning roller-to-rear toothed belt 25
cover bolt
Damper roller-to-rear toothed belt cover bolt 25
Coolant pump bolt 15
Damper roller-to-sealing flange bolt 35
Crankshaft toothed belt gear-to-sealing flange bolt 90 plus an
additional 90
( turn)
Engine mount bolt 45
Knock Sensor (KS) 1 G61 bolt 20
Knock Sensor (KS) 2 G66 bolt 20
Oil filter bracket-to-engine bolt 15 plus an
additional 90
( turn)
Engine Speed (RPM) sensor G28-to-intake manifold 10
support-to-engine bolt
Coolant thermostat housing with coolant thermostat-to- 15
engine bolt

24 Audi A3 Quick Reference Specification Book October 2010


Accessory Assembly Bracket
Tightening Sequence

Sealing Flange Tightening Torques


Component Nm
Crankshaft toothed belt gear-to-sealing flange on belt 90 plus an
pulley side-to-cylinder block bolt additional 90
( turn)
Sealing flange on belt pulley side-to-cylinder block bolt 15

Flywheel/Drive Plate Tightening Torques


Component Nm
Flywheel/drive plate-to-cylinder block bolt 60 plus an
additional 90
( turn)
Dual mass flywheel-to-crankshaft 60 plus an
additional 90
( turn)

Crankshaft Assembly Tightening Torques


Component Nm
Bearing cap-to-cylinder block bolts 65 plus an
additional 90
( turn)
Engine Mech., Fuel
Injection & Ignition

Sensor wheel-to-crankshaft bolts 10 plus an


additional 90
( turn)

Audi A3 Quick Reference Specification Book October 2010 25


Crankshaft Dimensions
Honing dimension, Crankshaft bearing Connecting rod
dimensions in mm pins-diameter bearing pins-diameter
Basic dimension 54.00 -0.017 47.80 -0.022
-0.037 -0.042
1st oversize 53.75 -0.017 47.55 -0.022
-0.037 -0.042
2nd oversize 53.50 -0.017 47.30 -0.022
-0.037 -0.042
Stage III 53.25 -0.017 47.05 -0.022
-0.037 -0.042

Identification on Crankshaft Bearing, Top

Arrow points in direction of travel.


The upper bearing shells are allocated to the cylinder block with the
correct thickness from the factory. Colored spots identify the bearing
thicknesses. The letters marked on the lower sealing surface of the
cylinder block identify which bearing thickness must be installed in
which location. If the color markings can no longer be read, use the
blue bearing shell. The lower crankshaft bearing shells are always
shipped as a replacement part with a yellow color marking.
Letter on cylinder block Color of bearing
G Yellow
B Blue
W White

26 Audi A3 Quick Reference Specification Book October 2010


Piston and Connecting Rod Tightening Torques
Component Nm
Connecting rod bearing cap-to-connecting rod bolts 30 plus an
additional 90
( turn)
Pressure relief valve-to-oil spray jet 27

Piston Ring End Gaps


Piston ring Gap
New Wear limit
Compression rings mm 0.20 to 0.40 0.8
Oil scraping ring mm 0.25 to 0.50 0.8

Piston Ring Clearance


Piston ring Ring to groove clearance
New Wear limit
Compression rings mm 0.06 to 0.09 0.20
Oil scraping ring mm 0.03 to 0.06 0.15

Piston and Cylinder Dimensions


Honing dimension Piston diameter Cylinder bore
diameter
Basic dimension mm 82.465 1) 82.51
1)
Dimension without graphite coating (thickness 0.02 mm). The graphite coating
wears away.

Cylinder Head - 2.0L Engine - BPY/CBFA/


CCTA
Cylinder Head Tightening Torques
Component Nm
Cylinder head cover bolt 10
Valve housing-to-cylinder head cover bolt 4
Camshaft adjustment valve 1 N205-to-housing bolt 4
Engine Mech., Fuel
Injection & Ignition

Cable bracket-to-housing bolt 10


Housing-to-cylinder block bolt 10
Transport strap-to-cylinder block bolt 25
Stud bolt for intake manifold 10
Camshaft Position (CMP) sensor G40-to-cylinder block 10
bolt
Stud bolt for tensioning roller 10
Stud bolt for exhaust manifold 20

Audi A3 Quick Reference Specification Book October 2010 27


Cylinder Head Tightening Sequence

Step Component Nm
1 Tighten bolts 1 through 10 using a torque 40
wrench
2 Tighten bolts 1 through 10 using a Torx an additional
key 90 ( turn)
3 Tighten bolts 1 through 10 using a Torx an additional
key 90 ( turn)

Cylinder Head (Valve) Cover


Tightening Sequence

Cylinder Head (Valve) Cover


Tightening Torques
Component Nm
Cylinder head cover-to-cylinder head 10
Toothed belt guard-to-cylinder block 10 1)
1)
Insert with locking fluid

28 Audi A3 Quick Reference Specification Book October 2010


Compression Pressures
Engine code New bar Wear limit Difference
positive bar positive between
pressure pressure cylinders
bar positive
pressure
BPY/CBFA/CCTA 11.0 to 14.0 7.0 max. 3.0

Valvetrain 2.0L Engine


BPY/CBFA/CCTA
Valvetrain Tightening Torques
Component Nm
Camshaft sprocket-to-cylinder head bolt 50 plus an
additional 180
( turn)
Bearing bracket bolts 8 plus an
additional 90
( turn)
Camshaft adjuster-to-exhaust camshaft bolt 20 plus an
additional 45
( turn)
Chain tensioner bolts 10
Camshaft Position (CMP) sensor G40-to-cylinder head 10
bolt

Valve Dimensions Engine Mech., Fuel


Injection & Ignition

Dimension Intake valve Exhaust valve


Diameter a mm 33.75 to 33.95 27.90 to 28.10
Diameter b mm 5.98 5.95
c mm 103.97 101.87
45 45

Audi A3 Quick Reference Specification Book October 2010 29


Camshaft Tightening Sequence

Camshaft Tightening Torque


Component Nm
Camshaft bolts 8 plus an
additional 90
( turn)

Engine Lubrication 2.0L BPY/CBFA/CCTA


Lubrication System Components
Tightening Torques
Component Nm
Sealing flange-to-engine bolt 15
Oil pump with balance shaft drive-to-cylinder block bolt 15 plus an
additional 90
( turn)
Oil pan bolt 15
Oil drain plug-to-oil pan bolt 15
Oil level thermal sensor G266 protective cap bolt 10
Chain sprocket-to-oil pump with balance shaft drive bolt 20 plus an
additional 90
( turn)
Oil pump with balance shaft drive cover-to-oil pump with 9
balance shaft drive bolt
Oil pump with balance shaft drive cover bolt 40
Chain sprocket-to-oil pump cover-to-inner rotor-to-outer 20 plus an
rotor-to-oil pump with balance shaft drive bolt additional 90
( turn)
Chain tensioner with tensioning rail-to-oil pump with 15
balance shaft drive bolt

30 Audi A3 Quick Reference Specification Book October 2010


Oil Filter Bracket Tightening Torques
Component Nm
Oil pressure switch F1-to-oil filter bracket 20
Oil pressure switch F1 bolt 15
Oil cooler bracket-to-oil filter bracket bolts 15
Oil filter bracket bolts 15
Oil filter housing-to-oil filter element 25

Engine Cooling 2.0L BPY/CBFA/CCTA


Cooling System Components (on Engine)
Tightening Torques
Component Nm
Coolant line upper bolt 23
Coolant line lower bolt 40
Engine Coolant Temperature (ECT) sensor G62 10
connecting piece-to-engine bolt
Engine Coolant Temperature (ECT) sensor G62 coolant 5
line-to-engine bolt
Coolant thermostat housing coolant line bolt 5
Coolant thermostat housing-to-engine bolts 15
Coolant pump-to-engine bolts 15

Cooling System Components (on Body)


Tightening Torques
Component Nm
Expansion tank bolt 5
Coolant fan-to-air shroud bolts 10
Air shroud-to-radiator bolts 5

Coolant Pump V50 Tightening Torques


Component Nm
Coolant line upper nut 3
Coolant line lower nut 5
Engine Mech., Fuel
Injection & Ignition

Coolant pump-to-bracket bolt 5

Coolant Pump Tightening Torques


Component Nm
Coolant pump-to-cylinder block 15
Toothed belt guard-to-cylinder block 10 1)
1)
Insert with locking fluid.

Audi A3 Quick Reference Specification Book October 2010 31


Recommended Coolant Mixture Ratios
Frost protection to Anti-freeze quantity G 12 Water
-25C 40% 3.2L 4.8L
-35C 50% 4.0L 4.0L

Fuel Storage and Supply


2.0L BPY/CBFA/CCTA
Fuel Pump Tightening Torques
Component Nm
Fuel tank bolt 26
Fuel delivery unit locking ring 110

Fuel Tank Tightening Torques


Component Nm
Fuel tank-to-chassis bolts M6 (always replace) 10
Fuel tank-to-chassis bolts M8 (always replace) 26
Heat shield for fuel tank (all wheel drive) 26
Fuel filler tube protective plate bolts 8
Flange with fuel filter locking ring 110
Fuel filter bracket bolt 3
Bolt cup for fuel filter 3

Accelerator Pedal Module Tightening Torque


Component Nm
Accelerator pedal module-to-body bolt 9

EVAP Canister System Tightening Torques


Component Nm
EVAP canister-to-body bolt 8
Air filter housing bolt 4
Leak Detection Pump (LDP) V144 bracket-to-LDP V144 4
bolt
Leak Detection Pump (LDP) V144 bracket-to-LDP V144 6
nut
Bracket for Leak Detection Pump (LDP)-to-wheel 8
housing

32 Audi A3 Quick Reference Specification Book October 2010


Turbocharger 2.0L BPY/CBFA/CCTA
Turbocharger Tightening Torques
Component Nm
Exhaust manifold stud bolt-to-turbocharger nuts 20
Coolant return line-to-turbocharger bolt 35
Coolant return line bracket-to-turbocharger, upper bolt 23
Coolant return line bracket-to-turbocharger, lower bolt 9
Turbocharger bracket bolt 30
Turbocharger bracket-to-fastening strip bolt 23
Turbocharger bracket-to-fastening strip nut 30
Oil supply line-to-turbocharger nut 30
Turbocharger bolt 9
Oil supply line-to-turbocharger bolt 30
Coolant supply line-to-turbocharger bolt 35
Coolant supply line bracket bolt 23
Coolant supply line bolt 35
Oil return line bolts 9
Oil return line-to-turbocharger bolts 9
Heat shield bolts 9
Wastegate bypass regulator valve N75 bolts 3
Ring connection bolt 8
Connection-to-turbocharger bolt 7
Bracket-to-turbocharger bolt 7
Turbocharger recalculating valve N249-to-turbocharger 7
bolt
Exhaust manifold/turbocharger-to-cylinder head (replace 20
nuts)
Oil supply line-to-exhaust turbocharger 30
Oil return line-to-exhaust turbocharger 9
Coolant supply line-to-turbocharger 35
Bracket for turbocharger-to-cylinder block (Use hot bolt 30
paste. See ETKA [Electronic Parts Catalog.])
Turbocharger bracket-to-turbocharger (Use hot bolt 30
paste. See ETKA [Electronic Parts Catalog.])
Right charge air pipe-to-oil pan 10
Vacuum diaphragm-to-turbocharger 10
Engine Mech., Fuel
Injection & Ignition

Audi A3 Quick Reference Specification Book October 2010 33


Charge Air Cooler Tightening Torques
Component Nm
Air charge cooler bearing-to-air charge cooler 5
Charge air pipe-to-charge air hose bolt 10
Charge air pipe (with charge air pressure sensor G31) 8
bolt
Charge Air Pressure Sensor G31 to charge air pipe bolts 5

Noise Booster Tightening Torques


Component Nm
Plenum chamber bulkhead bolts 8
Spacer sleeves-to-noise booster-to-noise amplifier 8
bracket bolts
Noise amplifier bracket bolts 8

Fuel Injection 2.0L BPY/CBFA/CCTA


Fuel Injection System Data
Engine codes BPY/CBFA/CCTA
Idle check
Idle speed RPM 620 to 800
Engine Control Module (ECM)
System designation Motronic MED 9.1
Replacement part number ETKA (electronic parts catalog)
Engine Speed (RPM) limitation RPM Approximately 6800
Fuel pressure
Low pressure bar Approximately 6.0
High pressure bar Approximately 40 to 120

Engine Cover/Air Filter Tightening Torques


Component Nm
Mass Air Flow (MAF) sensor G70-to-upper section of air 3
filter/engine cover bolt
Air filter lower part bolts 3
Heat shield-to-air filter lower part bolts 3

34 Audi A3 Quick Reference Specification Book October 2010


Intake Manifold Tightening Torques
Component Nm
Retaining clip-to-intake manifold bolt 3
Intake manifold support bonded rubber bushing-to-intake 10
manifold nuts
Retaining clip stud bolt 10
Intake flap motor V157 with intake manifold runner 7
position sensor G336 bolt
Intake manifold support bolt 25
Throttle valve control module J338 bolts 7
Intake Air Temperature (IAT) sensor G42-to-intake 5
manifold bolt
Mounting bolts for intake manifold 9
Bolt for intake manifold support 23
Nut for intake manifold support 10
Fuel supply line-to-high pressure pump 27
Fuel return line-to-high pressure pump (replace banjo 17
fitting)

High Pressure Pump Tightening Torques


Component Nm
High pressure pump with fuel pressure regulator valve 10
N276 bolts
Fuel pressure regulator valve N276 supply line 30
Fuel pressure regulator valve N276 return line 25
Low fuel pressure sensor G410-to-high pressure pump 15
with fuel pressure regulator valve N276

Exhaust System 2.0L BPY/CBFA/CCTA


Exhaust System Tightening Torques
Component Nm
Catalytic converter-to-exhaust manifold stub bolts nuts 40
Oxygen Sensor (O2S) behind Three Way Catalytic 55
Converter (TWC) G130
Rear clamping sleeve nut 25
Engine Mech., Fuel
Injection & Ignition

Center muffler suspended mount bolts 25


Front clamp sleeve nut 25
Oxygen Sensor (O2S) G39 55
Front exhaust pipe-to-turbocharger 40
Tunnel bridge-to-body 25
Mount-to-subframe 25

Audi A3 Quick Reference Specification Book October 2010 35


Ignition System 2.0L BPY/CBFA/CCTA
Ignition Tightening Torques
Component Nm
Spark plug 30
Knock Sensor (KS) 1 G61 bolt 20
Knock Sensor (KS) 2 G66 bolt 20
Camshaft Position (CMP) sensor G40 bolt 10

Spark Plug Data


Engine code BPY/CBFA/CCTA
Ignition sequence 1-3-4-2
Spark plugs
VW/Audi 101 905 631 B
Manufacturers designation F6KPP 332 S
Electrode gap 0.7 to 0.8 mm
Torque specifications 30 Nm

36 Audi A3 Quick Reference Specification Book October 2010


Engine Mechanical,
Fuel Injection & Ignition
3.2L BUB/CBRA
Engine Removing and Installing
3.2L BUB/CBRA
Engine Tightening Torques
Component Bolt size Nm
Bolts, nuts M6 10
M8 20
M10 45
M12 65

Assembly Mountings Tightening Torques


Component Nm
Mounting-to-body (always replace) 40 plus an
additional 90
( turn)
Mounting/bracket-to-body (always replace) 60 plus an
additional 90
( turn)
Support-to-mounting at body (always replace) 20 plus an
additional 90
( turn)
Transmission assembly mount-to-body (always replace) 60 plus an
additional 90
( turn)
Transmission assembly mounting/bracket-to-body 40 plus an
(always replace) additional 90
( turn)
Pendulum support mounting-to-body (always replace) 100 plus an
additional 90
( turn)
Pendulum support mounting/bracket-to-body (always 40 plus an
replace) additional 90
Engine Mech., Fuel
Injection & Ignition

( turn)

Audi A3 Quick Reference Specification Book October 2010 37


Crankshaft/Cylinder Block 6-Cylinder
4V Engine 3.2L BUB/CBRA
Assembly Attachments Mounting
Tightening Torques
Component Nm
Assembly bracket bolts 23
Bracket with lower relay pulley for ribbed belt for A/C 25
compressor-to-assembly bracket bolt
Air conditioner compressor-to-assembly bracket bolts 25
Belt pulley/vibration damper bolt 100 plus an
additional 90
( turn)
Generator-to-assembly bracket bolt 25
Bracket with upper relay pulley for ribbed belt for 8
generator and coolant pump-to-assembly bracket bolt
Engine mount-to-assembly bracket bolts 40 plus an
additional 90
( turn)
Vacuum pump for brake booster bracket-to-cylinder block 10
bolt
Oil filter bracket with attachments-to-cylinder block bolt 23
Thermostat housing bolts 10
Intake manifold support bolts 25
Engine mount and thermostat housing assembly bracket- 25
to-cylinder block bolt
Cylinder block bracket bolts 25
Coolant pump-to-cylinder block bolts 10
Cylinder block locking bolt 30
Knock Sensor (KS) 1 G61-to-cylinder block bolt 20
Knock Sensor (KS) 2 G66-to-cylinder block bolt 20
Trim strip-to-cylinder block bolt 10

Drive Chain Tightening Torques


Component Nm
Chain tensioner bolts 40
Chain sprocket for exhaust camshaft-to-engine bolt 60 plus an
additional 90
( turn)
Pin for tensioning track 10

38 Audi A3 Quick Reference Specification Book October 2010


Brake Booster Vacuum Pump
Tightening Torques
Component Nm
Vacuum pump-to-control housing cover 10
Coolant pipe-to-bracket 10

Sealing Flanges and Vibration Damper


Tightening Torques
Component Nm
Belt pulley/vibration damper-to-cylinder block bolt 70
Sealing flange on belt pulley side-to-cylinder block bolts 10
Vibration damper-to-crankshaft 100 plus an
additional
90 ( turn)
Control housing cover bolts 25
Engine Speed (RPM) sensor G28-to-control housing 5
cover bolts
Tensioning element-to-auxiliary component bracket 35
Sealing plug-to-cylinder block at rear 30

Crankshaft Assembly Tightening Torque


Component Nm
Bearing cap-to-cylinder block bolts 30 plus an
additional 180
( turn)

Crankshaft Dimensions
Reconditioning Crankshaft bearing Connecting rod
dimension pins-diameter bearing pins-
(dimensions in mm) diameter
Basic dimension 59.95 to 59.978 53.95 to 53.978

Piston and Connecting Rod Tightening Torques


Component Nm
Connecting rod bearing cap-to-connecting rod bolts 30 plus an
additional 90
Engine Mech., Fuel
Injection & Ignition

( turn)
Pressure relief valve-to-oil spray jet 27

Piston Ring End Gaps


Piston ring (dimensions in mm) New Wear limit
Compression ring 0.20 to 0.40 1.00
Tapered ring 0.20 to 0.40 1.00
Oil scraping ring 0.25 to 0.50 1.00
Audi A3 Quick Reference Specification Book October 2010 39
Piston Ring Clearance
Piston ring (dimensions in mm) New Wear limit
Compression ring 0.04 to 0.09 0.15
Tapered ring 0.03 to 0.06 0.15
Oil scraping ring 0.02 to 0.06 0.15

Piston and Cylinder Dimensions


Honing dimension Piston diameter Cylinder bore
(dimensions in mm) diameter
Basic dimension 83.965 1) 84.010
1)
Dimension without graphite coating (thickness 0.02 mm). The graphite coating
wears away.

Cylinder Head 3.2L Engine BGP/BGQ


Cylinder Head Tightening Torques
Component Nm
Cylinder head cover bolt 10
Chain case cover-to-cylinder block bolts 10
Chain case cover-to-cylinder head 10
Coolant distribution housing-to-chain case cover 10
Chain tensioner for camshaft timing chain 40
Camshaft adjustment valve 1 N205-to-cylinder block bolt 2
Camshaft Position (CMP) sensor G40-to-cylinder block 10
bolt
Lifting eye 23

Cylinder Head Removal Sequence

40 Audi A3 Quick Reference Specification Book October 2010


Cylinder Head Tightening Sequence

Insert the longer cylinder head bolts


in the middle holes of cylinder head.
Step Component Nm
1 Tighten bolts 1 through 6 using a torque 30
wrench
2 Tighten bolts 1 through 6 using a torque 50
wrench
3 Tighten bolts 1 through 6 using a Torx key an additional
90 ( turn)
4 Tighten bolts 1 through 6 using a Torx key an additional
90 ( turn)

Cylinder Head Cover Tightening Sequence Engine Mech., Fuel


Injection & Ignition

Cylinder Head Cover Tightening Torque


Component Nm
Cylinder head cover-to-cylinder head 10

Audi A3 Quick Reference Specification Book October 2010 41


Compression Pressures
New bar positive Wear limit bar positive Difference between
pressure pressure cylinders bar positive
pressure
10.0 to 13.0 7.5 max. 3.0

Valvetrain 3.2L Engine BUB/CBRA


Valvetrain Tightening Torques
Component Nm
Bearing bracket bolts 8 plus an
additional 90
( turn)
Chain sprocket for exhaust camshaft bolt 60 plus an
additional 90
( turn)
Camshaft adjuster for intake camshaft bolt 60 plus an
additional 90
( turn)

Valve Dimensions

Dimension Short intake Long intake Short Long


valve valve exhaust exhaust
valve valve
Diameter mm 31.00 31.00 27.00 27.00
a
Diameter mm 5.96 5.96 5.94 5.94
b
c mm 102.20 136.10 102.50 136.40
45 45 45 45

42 Audi A3 Quick Reference Specification Book October 2010


Camshaft Tightening Sequence

Camshaft Tightening Torques


Component Nm
Bearing cap-to-cylinder head 5 plus an
additional 45
( turn)
Control housing-to-cylinder head 8

Engine Lubrication 3.2L BUB/CBRA


Lubrication System Components
Tightening Torques
Component Nm
Oil pump drive cover 8
Oil filter bracket with attachments-to-cylinder block bolt 23
Oil pump-to-cylinder block bolt 23
Intermediate shaft 10
Oil level thermal sensor G266 10
Oil pan-to-cylinder block 12
Oil drain plug 30
Oil pan-to-transmission 40
Engine Mech., Fuel
Injection & Ignition

Oil Filter Bracket Tightening Torques


Component Nm
Oil filter bracket bolts 23
Oil pressure switch F1-to-oil filter bracket 25
Oil filter housing-to-oil filter element 25
Oil cooler bracket-to-oil filter bracket bolts 25
Intake line-to-oil pump 10
Audi A3 Quick Reference Specification Book October 2010 43
Engine Cooling 3.2L BUB/CBRA
Cooling System Components (on Engine)
Tightening Torques
Component Nm
Coolant pump bracket-to-accessory assembly bracket 10
Connecting pieces-to-coolant thermostat-to-coolant 10
thermostat housing
Coolant thermostat housing-to-cylinder block bolt 10
Coolant pump-to-cylinder block 8
Coolant distribution housing-to-pipe connection nut 10
ATF cooler coolant line nut (only for vehicles with 10
automatic transmission)

Cooling System Components (on Body)


Tightening Torques
Component Nm
Expansion tank bolt 3
Radiator-to-bracket 5
Coolant fan-to-fan shroud 10
Fan shroud-to-radiator 5
Radiator support 10
Condenser-to-radiator 5

Recommended Coolant Mixture Ratios


Frost protection to Anti-freeze quantity G 12 Water
-25C 40% 3.6L 5.4L
-35C 50% 4.5L 4.5L

Fuel Storage and Supply 3.2L BUB/CBRA


Fuel Pump Tightening Torques
Component Nm
Fuel tank bolt 26
Fuel delivery unit locking ring 110

44 Audi A3 Quick Reference Specification Book October 2010


Fuel Tank Tightening Torques
Component Nm
Fuel tank-to-chassis bolts M6 (always replace) 10
Fuel tank-to-chassis bolts M8 (always replace) 26
Heat shield for fuel tank (all wheel drive) 26
Fuel filler tube protective plate bolt 8
Flange with fuel filter locking ring 110
Fuel filter bracket bolt 3
Bolt cup for fuel filter 3

Accelerator Pedal Module Tightening Torque


Component Nm
Accelerator pedal module-to-body bolt 9

EVAP Canister System Tightening Torques


Component Nm
EVAP canister-to-body bolt 8
Air filter housing bolt 4
Leak Detection Pump (LDP) V144 bracket-to-LDP V144 4
bolt
Leak Detection Pump (LDP) V144 bracket-to-LDP V144 6
nut
Bracket for leak detection pump-to-wheel housing 8

Fuel Injection 3.2L BUB/CBRA


Fuel Injection System Data
Engine code BUB/CBRA
Idle check
Engine idle speed RPM 680
Engine Control Module (ECM) (Replace ECM)
System designation Motronic ME 7.1.1
Replacement part number ETKA (electronic parts catalog)
Engine Speed (RPM) limitation RPM Approximately 6500
Engine Mech., Fuel
Injection & Ignition

Audi A3 Quick Reference Specification Book October 2010 45


Intake Manifold Tightening Torques
Component Nm
Intake manifold-to-cylinder head 13
Intake manifold support-to-intake manifold 20
Throttle valve control module J338-to-intake manifold 10
Vacuum reservoir-to-intake manifold 5
Guide tube for oil dipstick-to-intake manifold 5
Mass Air Flow (MAF) sensor-to-upper section of air filter 1.5
housing

Air Filter Assembly Tightening Torques


Component Nm
Mass Air Flow (MAF) sensor G70 with Intake Air 3
Temperature (IAT) sensor G42 bolt
Upper air filter housing 5
Lower section of air filter bolts 10

Exhaust System 3.2L BUB/CBRA


Exhaust System Tightening Torques
Component Nm
Front exhaust pipe-to-exhaust manifold 40
Catalytic converter-to-front exhaust pipe 23
Oxygen sensor in front exhaust pipe 55
Exhaust system bracket-to-subframe 23
Exhaust manifold-to-cylinder head 23
Front exhaust pipe-to-exhaust manifold 40
Exhaust manifold heat shield-to-cylinder head 20
Oxygen sensor before catalytic converter in front exhaust 55
pipe
Dome brace-to-body or bracket 20
Oxygen sensor behind catalytic converter in catalytic 55
converter

46 Audi A3 Quick Reference Specification Book October 2010


Secondary Air Injection (AIR) System
Tightening Torques
Component Nm
Secondary Air Injection (AIR) system combivalve-to- 10
bracket
Throttle valve control module J338-to-intake manifold 10
Secondary Air Injection (AIR) pump-to-bracket 10
Secondary Air Injection (AIR) pump bracket M6 10
To cylinder block M8 20

Ignition System 3.2L BUB/CBRA


Ignition Tightening Torques
Component Nm
Spark plug 30
Knock Sensor (KS) 1 G61 bolt 20
Knock Sensor (KS) 2 G66 bolt 20
Camshaft Position (CMP) sensor G40 bolt 10

Spark Plug Data


Engine code BUB/CBRA
Ignition sequence
Spark plugs
VW/Audi 101 905 600
Manufacturers designation PZFR5J-11
Electrode gap 1.0 to 1.1 mm
Tightening torque 30 Nm
Engine Mech., Fuel
Injection & Ignition

Audi A3 Quick Reference Specification Book October 2010 47


Engine Mechanical,
Fuel Injection & Ignition
2.0L TDI CBEA
Engine Removing and Installing
2.0L TDI CBEA
Engine Tightening Torques
Components Bolt Size Nm
Bolts and nuts M6 10
M7 15
M8 20
M10 40
M12 65
Bracket 2) 3)
Bracket to engine mount 20plus an
additional 90
( turn)
Bracket to body 20plus an
additional 90
( turn)
Engine support 1) 2)
Engine mount to body 40plus an
additional 90
( turn)
Engine mount to body 40plus an
additional 90
( turn)
Engine mount to engine support 60plus an
additional 90
( turn)
Exceptions:
Driveshaft heat shield to the cylinder block 35
Front underbody crossmember to the body 23
1)
For bolt tightening clarification, refer to ELSA, Subframe Assembly Overview, items
6, 10 and 11.
2)
Always replace.
3)
For bolt tightening clarification, refer to ELSA, Subframe Assembly Overview,
items 8 and 9.

48 Audi A3 Quick Reference Specification Book October 2010


Assembly Mountings Tightening Torques

Item Component Nm
1, 3, 10 M12 x 55 80
5 M12 x 65 80
6, 7, 8 M10 x 50 40
9 M12 x 70 80
2, 4 Starter, securing. Refer to top of form, bottom of form,
Electrical Equipment;Rep. Gr.27;Removal and Installation
A Alignment sleeves for centering
Engine Mech., Fuel
Injection & Ignition

Audi A3 Quick Reference Specification Book October 2010 49


Crankshaft/Cylinder Block
2.0L TDI CBEA
Fastener Tightening Specifications
Component Nm
Bearing cap (always replace) 65plus an
additional 90
( turn)
Bracket for assemblies 23 1)
Connecting rod (always replace) 30plus an
additional 90
( turn)
Dual mass flywheel (always replace) 60 plus an
additional 90
( turn)
Engine Speed (RPM) sensor 4.5
Generator 25
Pressure relief valve 27
Sealing flange, transmission side 15
Vibration damper (always replace) 10plus an
additional 90
( turn)
1)
For bolt tightening clarification, refer to ELSA, Ribbed Belt Drive with Tensioner and
A/C Compressor Assembly Overview, items 5, 7, 14 and 15.

50 Audi A3 Quick Reference Specification Book October 2010


Accessory Assembly Bracket
Tightening Sequence

Item Bolt
1 and 2 M10 x 52
3 and 6 M10 x 30
4 and 5 M10 x 60
Step Component Nm
1 Install bolts 1 through 6 Hand-tighten
2 Tighten bolts 1 through 6 40
Engine Mech., Fuel
Injection & Ignition

3 Tighten bolts 3 and 6 an additional


45 ( turn)
4 Tighten bolts 1, 2, 4 and 5 an additional
90 ( turn)

Audi A3 Quick Reference Specification Book October 2010 51


Ribbed Belt Pulley Side Sealing Flange
Tightening Specifications

Step Component Nm
1 Install bolts 1 through 10 Hand-tighten
2 Tighten bolts 1 through 6 diagonally in
stages to 15
3 Tighten bolts 7 through 10 15

52 Audi A3 Quick Reference Specification Book October 2010


Dual Mass Flywheel and Sealing Flange
Tightening Specifications

Step Component Nm
1 Install bolts 1 through 6 by hand Hand-tighten
2 Tighten bolts 1 through 6 diagonally in
stages to 15

Crankshaft Assembly Tightening Torque


Component Nm
Bearing cap-to-cylinder block bolts 65 plus an
additional 90
( turn)

Crankshaft Dimensions
Honing Dimension, Crankshaft Bearing Connecting Rod
dimensions in mm Pin-Diameter Pins-Diameter
Basic dimensions 54.00 0.022 50.90 0.022
0.042 0.042
Engine Mech., Fuel
Injection & Ignition

Piston and Connecting Rod Tightening Torques


Component Nm
Connecting rod bearing cap-to-connecting rod bolts 30 plus an
additional 90
( turn)
Pressure relief valve-to-oil spray jet 27

Audi A3 Quick Reference Specification Book October 2010 53


Piston Ring End Gaps
Piston ring Gap
New Wear limit
Compression rings mm 0.20 to 0.40 0.8
Oil scraping ring mm 0.25 to 0.50 0.8

Piston Ring Clearance


Piston ring Ring to groove clearance
New Wear limit
Compression rings mm 0.06 to 0.09 0.20
Oil scraping ring mm 0.03 to 0.06 0.15

Piston and Cylinder Dimensions


Honing Dimension, Piston Diameter Cylinder Bore
dimensions in mm Diameter
Basic dimension 80.96 1) 81.01
1)
Measurement with coating (thickness = 0.02 mm). The coating wears off.

Cylinder Head 2.0L TDI CBEA


Cylinder Head Tightening Torques
Component Nm
Camshaft stub 100
Camshaft position sensor 10
Camshaft toothed belt gear 25
Coolant pump 15
Crankshafts - toothed belt gear (always replace) 120 + 90
Engine lifting eye 20
Heat shield 5
Idler roller, nut and bolt 2) 20
Idler roller (always replace) 3) 50 + 90
Rear toothed belt guard 9
Tensioning roller 20 + 45
1)
For bolt tightening clarification, refer to ELSA, Toothed Belt Assembly Overview,
items 3 and 6.
2)
For bolt tightening clarification, refer to ELSA, Toothed Belt Assembly Overview,
item 20.

54 Audi A3 Quick Reference Specification Book October 2010


Cylinder Head Tightening Sequence

Step Component Nm
1 Tighten bolts 1 through 10 30
2 Tighten bolts 1 through 10 50
3 Tighten bolts 1 through 10 an additional
90 ( turn)
4 Tighten bolts 1 through 10 an additional
90 ( turn)

Cylinder Head (Valve) Cover


Tightening Sequence
Engine Mech., Fuel
Injection & Ignition

Audi A3 Quick Reference Specification Book October 2010 55


Cylinder Head (Valve) Cover Tightening Torque
Component Nm
Cylinder head cover-to-cylinder head in sequence 9

Valvetrain 2.0L TDI CBEA


Valvetrain Tightening Torques
Component Nm
Camshaft toothed belt gear 25
Idler roller 50 plus an
additional 90
( turn)
Tensioning roller 20 plus an
additional 45
( turn)

Valve Dimensions

Dimension Intake Valve Exhaust Valve


Diameter a mm 28.10 26.00
Diameter b mm 5.975 5.965
c mm 99.30 99.10
45 45

56 Audi A3 Quick Reference Specification Book October 2010


Camshaft Tightening Sequence

Camshaft Tightening Torques


Component Nm
Tighten guide frame bolts and nut 1 through 24 in 2 stages in sequence as
follows:
Camshaft guide frame bolts 10
Engine Mech., Fuel
Injection & Ignition

Audi A3 Quick Reference Specification Book October 2010 57


Engine Lubrication 2.0L TDI CBEA
Lubrication System Components
Tightening Torques
Component Nm
Balance shaft spur gear 20plus an
additional 90
( turn)
Bracket for wiring harness 10
Cap 25
Connecting piece 33
Hub for the intermediate sprocket 90plus an
additional 90
( turn)
Locking bolt 25
Oil dipstick guide tube 9
Oil drain plug 30
Oil level thermal sensor 91
Oil pump 9
Oil pressure switch 20
Oil suction pipe 9
Oil supply line, union nut 22
Suction line 92
202

Oil Filter Bracket Tightening Torques


Component Nm
Oil filter bracket bolts 15 plus an
additional 90
( turn)
Oil pressure switch F1-to-oil filter bracket 20
Oil filter element cap 25
Intake line-to-oil pump 9

58 Audi A3 Quick Reference Specification Book October 2010


Engine Cooling 2.0L TDI CBEA
Cooling System Components (on Engine)
Tightening Torques
Component Nm
Bracket for Exhaust Gas Recirculation (EGR) cooler 2.7
pump 5) 40
Connecting piece 3) 9
Connecting piece 2) 15
Connecting piece 6) 15
Coolant fan, nut 5
Coolant line 9
Coolant pump 40
Engine pre-warmer clamp secured on the bracket 10
Fan rib 5
Front coolant line 4) 13
40
Left coolant line 9
Radiator 9
Right coolant line 9
Ventilation pipe 10
4/2-Way valve with thermostat 15
1)
For bolt tightening clarification, refer to ELSA, Coolant Pipes, Coolant Temperature
Sensors and Coolant Pump Assembly Overview, items 3 and 4.
2)
For bolt tightening clarification, refer to ELSA, Connection Diagram, Coolant Hoses,
item 19.
3)
For bolt tightening clarification, refer to ELSA, Coolant Pipes, Coolant Temperature
Sensors and Coolant Pump Assembly Overview, item 18.
4)
For bolt tightening clarification, refer to ELSA, Coolant Pipes, Coolant Temperature
Sensors and Coolant Pump Assembly Overview, items 27 and 28.
5)
For bolt tightening clarification, refer to ELSA, Coolant Pipes, Coolant Temperature
Sensors and Coolant Pump Assembly Overview, items 3 and 4.
6)
For bolt tightening clarification, refer to ELSA, Coolant Pump and Coolant
Thermostat Assembly Overview, item 7.

Cooling System Components (on Body)


Tightening Torques
Component Nm
Engine Mech., Fuel
Injection & Ignition

Expansion tank bolt 5


Coolant fan-to-air shroud bolts 10
Air shroud-to-radiator bolts 5

Audi A3 Quick Reference Specification Book October 2010 59


Coolant Pump V50 Tightening Torques
Component Nm
Coolant line upper nut 3
Coolant line lower nut 5
Coolant pump-to-bracket bolt 5

Coolant Pump Tightening Torques


Component Nm
Coolant pump-to-cylinder block 15
Toothed belt guard-to-cylinder block 10 1)
1)
Insert with locking fluid.

Recommended Coolant Mixture Ratios


Frost protection to Anti-freeze quantity G 12 Water
-25C (-11F) 40% 3.2L 4.8L
-35C (-29F) 50% 4.0L 4.0L

Fuel Storage and Supply 2.0L TDI CBEA


Fuel Pump/ Fuel Tank Tightening Torques
Component Nm
Accelerator pedal module 9
Brackets 2) 9
20
Filter housing cover 5
Fuel filter housing 10
Fuel tank 1) 11
26
Heat shield, lock washer 2
Locking ring 110
1)
For bolt tightening clarification, refer to ELSA, Fuel Tank with Attachments Assembly
Overview, items 10 and 12.
2)
For bolt tightening clarification, refer to ELSA, Auxiliary Fuel Pump Assembly
Overview, items 2, 3, 4, 8 and 9.

Accelerator Pedal Module Tightening Torque


Component Nm
Accelerator pedal module-to-body bolt 9

60 Audi A3 Quick Reference Specification Book October 2010


Turbocharger 2.0L TDI CBEA
Turbocharger Tightening Torques
Component Nm
Air guide pipe 9
Brace for the turbocharger, banjo bolt (always replace) 60
Bracket for wiring harness 8
Charge air pressure sensor/Intake Air Temperature (IAT) 5
sensor
Clamp (always replace) 7
Connecting pipe, nut 20
Control pipe (always replace) 23
Control wire 23
Filter for Exhaust Gas Recirculation (EGR) system
Hex stud 20
Nut 23
Heat shield 20
Intake scoop 8
Left air guide pipe 9
Mount 5
Oil return line 15
Oil supply line bracket 10
Oil supply line 22
Turbocharger, nut (always replace) 23
Warm air collector plate 8

Charge Air Cooler Tightening Torques


Component Nm
Air charge cooler bearing-to-air charge cooler 5
Charge air pipe-to-charge air hose bolt 10
Charge air pipe (with charge air pressure sensor G31) 8
bolt
Charge air pressure sensor G31-to-charge air pipe bolts 5

Noise Booster Tightening Torques


Component Nm
Engine Mech., Fuel
Injection & Ignition

Plenum chamber bulkhead bolts 8


Spacer sleeves-to-noise booster-to-noise amplifier 8
bracket bolts
Noise amplifier bracket bolts 8

Audi A3 Quick Reference Specification Book October 2010 61


Fuel Injection 2.0L TDI CBEA
Fastener Tightening Specifications
Tightening Torques
Component Nm
Air filter lower section 8
Air filter upper section 1.5
Bracket for the control wire, nut 9
Bracket for the differential pressure sensor 9
Camshaft Position (CMP) sensor 10
Connecting pipe to cooler for Exhaust Gas Recirculation 20
(EGR)
Control wire attach to the exhaust 45
Differential pressure sensor 8
Engine Speed (RPM) sensor 4.5
Exhaust Gas Recirculation (EGR) 10
Exhaust gas temperature sensor connection 45
Exhaust pressure sensor 1 8
Fuel high pressure pump 20
Fuel pressure regulator valve 80
Fuel pressure sensor 100
Fuel rail 22
Heated Oxygen Sensor (HO2S) with Oxygen Sensor 50
(O2S) heater
High-pressure line between the high pressure pump and 10
fuel rail
High-pressure lines between the fuel rail and the 10
injectors
High-pressure line connections 25
Hub with sensor ring, nut 95
Injection unit cover 5
Intake manifold 8
Mass Air Flow (MAF) sensor 1.5
Oxygen Sensor (O2S) behind Three Way Catalytic 50
Converter (TWC) with Oxygen Sensor (O2S) 1 (behind
Three Way Catalytic Converter (TWC)) heater
Tensioning bracket, nut 10
Throttle valve control module with throttle position sensor 10
Toothed belt gear for the high pressure pump 20 plus an
additional 90
( turn)

62 Audi A3 Quick Reference Specification Book October 2010


Exhaust System 2.0L TDI CBEA
Exhaust System Tightening Torques
Component Nm
Bracket for the control pipe 9
Clamp (always replace) 2) 3.5
7
Clamping sleeve, nut 23
Connecting pipe 23
Control pipe bracket, nut 23
Control pipe 23
EGR temperature sensor 20
Exhaust Gas Temperature (EGT) sensor 45
Exhaust Gas Recirculation (EGR) motor 2 8
Filter for Exhaust Gas Recirculation (EGR) system 23
EGR vacuum regulator solenoid valve with EGR 10
potentiometer
Heat shield, nut 9
Housing for Exhaust Gas Recirculation (EGR) system 8
Intake flap motor 1) 10
Lower bracket for the particulate filter, nut 23
Pipe to cooler for exhaust gas recirculation 20
Particulate filter with catalytic converter 23
Radiator 8
Rear crossmember, nut 23
Suspended mount 23
Upper bracket for the particulate filter 23
1)
For bolt tightening clarification, refer to ELSA, EGR Vacuum Regulator Solenoid
Valve and EGR Potentiometer Assembly Overview, items 10 and 11.
2)
For bolt tightening clarification, refer to ELSA, Particulate Filter and NOx Absorption
Catalytic Converter Assembly Overview, items 3, 5 and 10.

Glow Plug System 2.0L TDI CBEA


Glow Plug Data
Engine Mech., Fuel
Injection & Ignition

Component Nm
Glow plug with combustion chamber pressure sensors 17
(on vehicles with engine code CBEA)

Audi A3 Quick Reference Specification Book October 2010 63


Manual Transmission
General, Technical Data
02Q Manual Transmission Specifications
Manual transmission 6 speed 02Q
Code letters GVT
Manufactured from 02.05
to
Application Model
Audi A3 2004
Engine 2.0L - 147 kW Turbo-FSI
Drive shaft flange diameter 107 mm
Transmission oil capacities 2.3 liters
Clutch mechanism Hydraulic
Obtain the following information from EKTA (electronic parts catalog):
Gear oil specification
Allocation of clutch plate

Clutch - 02Q
Pedal Cluster Tightening Torques
Component Nm
Self-locking nut 25
Hex nut 25

Over-Center Spring Tightening Torque


Component Nm
Clutch pedal to mounting bracket (replace self-locking 25
nut)

Hydraulic System Tightening Torques


Component Nm
Self-locking nut 25
Hydraulic system bolts 20

Slave Cylinder Tightening Torques


Component Nm
Metal slave cylinder-to-transmission (always replace 12
bolts)
Plastic slave cylinder-to-transmission (always replace 15
bolts)

64 Audi A3 Quick Reference Specification Book October 2010


Clutch (Sachs) Tightening Torque
Component Nm

Transmission
Bolt M7 20

Manual
Clutch (LuK) Tightening Torque
Component Nm
Bolt M6 13

Cable Retainer Dimensions

Allocation of cable retainers Dimension a


Shift cable-to-transmission shift lever 10 mm
Selector cable-to-relay lever 8 mm

Shift Cable Retainer Tightening Torques

Component Nm
Shift mechanism housing-to-body 8
Cable mounting bracket-to-transmission 20

Audi A3 Quick Reference Specification Book October 2010 65


Manual Transmission Installing 02Q
02Q Selector Mechanism Tightening Torques
Component Nm
Selector housing-to-body M8 25
Selector housing-to-body M6 8

02Q Transmission (to Engine)


Tightening Torques

Replace bolts 1 through 5.


Item Bolt Nm
1 to 2 M12 x 55 80
With threaded stud M8
3 M12 x 70 80
Installed from the engine side
4 M10 x 50 40
5 M10 x 105 40
6 to 7 M12 x 165 80
With threaded stud M8
Also starter-to-transmission
A, B Alignment sleeves for centering

02Q Transmission Tightening Torques


Component Nm
Transmission plate-to-transmission 60 plus an
additional 90
( turn)
Transmission-to-left assembly mounting 60 plus an
additional 90
( turn)

66 Audi A3 Quick Reference Specification Book October 2010


02Q Transmission Pendulum Support

Transmission
Manual
Component Nm
Bolt 1 100 plus an
additional 90
( turn)
Bolt 2 40 plus an
additional 90
( turn)
Bolt - 3 40 plus an
additional 90
( turn)

Component Nm
Small cover plate for flywheel 10
Right drive axle heat shield-to-cylinder block 25
Cable mounting bracket-to-transmission 20
Ground (GND) wire-to-upper starter bolt 23
Bracket for electrical wiring-to-lower starter bolt 23

02Q Transmission Housing and Shift


Mechanism Tightening Torques
Component Nm
Back up light switch F4 20
Selector shaft locking bolt 30
Clutch housing bolts (always replace) 15 plus an
additional 90
( turn)
Selector mechanism bolts (always replace) 20

Audi A3 Quick Reference Specification Book October 2010 67


02Q Installation Position of Shafts and
Selector Rods in Transmission

Component
1 - Input shaft
2 - Output shaft 1st to 4th gears
3 - Output shaft for 5th/6th and reverse gear
4 - Reverse shaft
A - Selector rod for 3rd and 4th gear
B - Selector rod for 1st and 2nd gear
C - Selector rod for 5th and 6th gear
D - Reverse gear shift fork

02Q Input Shaft, Output Shaft (Pinion Shaft),


Differential and Shift Forks Tightening Torques
Component Nm
Reverse gear shift fork internal Torx head bolt 25
Bearing mount nuts 25 plus an
additional 90
( turn)
Drive flange shaft with spring countersunk bolt 33
Shield for right drive axle 25

02Q Transmission Housing and Clutch Housing


Tightening Torques
Component Nm
Self-locking socket head cap bolt (always replace) 20
Oil drain plug 30

68 Audi A3 Quick Reference Specification Book October 2010


Automatic Transmission
General, Technical Data
02E Transmission Specifications
Direct-shift transmission 02E Front-wheel drive
Transmission Code letters HBQ
Manufactured from to 05.04
Application Model
Audi A3 2004
Engine 2.0L - TFSI 147 kW 4-cylinder

Transmission
Note: If replacement parts are required for a repair, always refer to transmission code

Automatic
letters of the transmission.

Direct shift transmission 02E All Wheel Drive


Transmission Code letters GYC HJZ HQA
Manufactured from 02.03 08.04 11.05
to 08.04
Application Model Audi A3 Audi A3 Audi A3
2004 2004 2004
Engine 3.2L - 3.2L - 3.2L -
184 kW 184 kW 184 kW
6-cylinder 6-cylinder 6-cylinder

02E Direct Shift Capacities


Capacities Direct shift transmission 02E
Initial fill in factory 7.2L
Replacement capacity in service Approximately 6.0L
Lubricant: DSG oil
The oil is obtained as a replacement part.

Automatic Transmission Controls 02E


02E Selector Mechanism Tightening Torques
Component Nm
Selector lever and selector mechanism bolt with spring 3.5
Shift housing nuts 10
Selector lever and selector mechanism hex bolt with 8
washer
Selector lever cable adjustment bolt (02E) 13

Audi A3 Quick Reference Specification Book October 2010 69


02E Selector Shaft Tightening Torque
Component Nm
Selector shaft lever-to-transmission 20

02E Transmission Input Speed (RPM) Sensor


G182 and Clutch Oil Temperature Sensor G509
Tightening Torque
Component Nm
Sensor 10

02E Direct Shift Gearbox (DSG) Mechatronic


J743 Tightening Torques
Component Nm
Pendulum support overflow tube (8mm hex socket head) 3
Mechatronic cover bolts 10
Oil pump cover bolts (install bolts in a diagonal 8
sequence)
Cable bracket on large cover nuts 10

02E Direct Shift Gearbox (DSG) Mechatronic


J743 Tightening Sequence

Component Nm
Direct Shift Gearbox (DSG) Mechatronic J743-to- 13
transmission (10 x bolt M6) (always replace bolts)
Transmission fluid pump cover-to-transmission (always 8
replace bolts)

70 Audi A3 Quick Reference Specification Book October 2010


02E Oil Pan Tightening Torques

Transmission
Automatic
Component Nm
Oil pan-to-transmission housing (5 x bolt M6) 16

02E Drain Plug and Filter housing


Tightening Torques
Component Nm
Oil drain plug, M24 45
Oil filter housing 20

Automatic Transmission Installing 02E


02E Oil Cooler Tightening Torque
Component Nm
Oil cooler bolts (always replace bolts) 20 plus an
additional 90
( turn)

02E Oil Pump Tightening Torques


Step Component Nm
1 Oil pump bolts (all four) 5 plus an
additional 90
( turn)
2 Oil pump countersunk bolt 8
3 Oil pump bolts (remaining 3) 8 plus an
additional 90
( turn)
4 Oil pump cover (tighten diagonally) 8

Audi A3 Quick Reference Specification Book October 2010 71


02E Transmission Mount Tightening Torques

Component Nm
Transmission mount-to-body (always replace bolts) 40 plus an
additional 90
( turn)
Transmission mount-to-transmission support (always 60 plus an
replace bolts) additional 90
( turn)

72 Audi A3 Quick Reference Specification Book October 2010


Suspension, Wheels, Brakes,
Steering
Front Suspension
Front Axle Curb Weight Data

Suspension, Wheels,
Brakes, Steering
Only tighten the respective bolts/nuts when dimension a between
the wheel hub center and the lower edge of the wheel housing is
reached.
Suspension Standing height a in mm
Basic suspension 382 10
Heavy duty suspension 402 10

Subframe Tightening Torques


Threaded connection Thread Nm
To body M12 x 1.5 x 70 plus an
100 additional 90
( turn)
To console M12 x 1.5 70 plus an
x 75 additional 90
( turn)
Console-to-body M12 x 1.5 70 plus an
x 90 additional 90
( turn)
Left front level control system sensor G78- M6 x 16 9
to-console
Shielding plate M6 self- 6
tapping

Audi A3 Quick Reference Specification Book October 2010 73


Control Arm Tightening Torques
Threaded connection Thread Nm
To console M12 x 1.5 x 70 plus an
110 additional 180
( turn)
To ball joint M10 60
Mounting bracket-to-body M12 x 1.5 70 plus an
x 90 additional 90
( turn)
Mounting bracket-to-console M10 x 76 50 plus an
additional 90
( turn)
Left front level control system sensor G78 M6 9

Stabilizer Bar Tightening Torques


Threaded connection Thread Nm
To subframe M8 x 80 70 plus an
additional 90
( turn)
To coupling rod M12 65
Coupling rod-to-suspension strut M12 65

Pendulum Support Tightening Torques


Threaded connection Thread Nm
To subframe M14 x 1.5 100 plus an
x 70 additional 90
( turn)
To transmission M10 x 35 40 plus an
additional 90
( turn)
M10 x 75 40 plus an
additional 90
( turn)

Suspension Strut Tightening Torques


Threaded connection Thread Nm
To body M8 x 26 15 plus an
additional 90
( turn)
To wheel bearing housing M12 x 1.5 70 plus an
x 80 additional 90
( turn)
Strut mounting-to-piston rod M14 x 1.5 60

74 Audi A3 Quick Reference Specification Book October 2010


Drive Axle Tightening Torques
Threaded connection Thread Nm
To wheel hub with wheel bearing M16 x 1.5 200 plus an
x 80 additional 180
( turn)
To transmission flange, first to 10 Nm, then M8 x 48 40
in a diagonal sequence M10 x 52 70
M10 x 23 70
Intermediate shaft to mounting bracket M8 x 25 20

Wheel Bearing Housing Tightening Torques


Threaded connection Thread Nm
Wheel hub with wheel bearing M12 x 1.5 70 plus an
x 45 additional 90
( turn)
Ball joint 75
Shielding plate M6 x 10 12
Front speed sensor M6 x 16 8
Tie rod end M12 x 1.5 20 plus an

Suspension, Wheels,
additional 90

Brakes, Steering
( turn)

Audi A3 Quick Reference Specification Book October 2010 75


Rear Suspension Front Wheel Drive
Rear Axle Curb Weight Data

Only tighten the respective bolts/nuts when dimension a between


the wheel hub center and the lower edge of the wheel housing is
reached.
Suspension Standing height a in mm
Basic suspension 380 10
Heavy duty suspension 400 10

Subframe Tightening Torques


Threaded connection Thread Nm
To lower transverse link M12 x 1.5 95
To upper transverse link M12 x 1.5 95
To body M12 x 1.5 90 plus an
x 90 additional 90
( turn)
To tie rod M12 x 1.5 90 plus an
x 90 additional 90
( turn)

Left Rear Level Control System Sensor G76


Tightening Torques
Threaded connection Thread Nm
To subframe M5 x 20 5
To lower transverse link M5 x 20 5

76 Audi A3 Quick Reference Specification Book October 2010


Wheel Bearing Housing Tightening Torques
Threaded connection Thread Nm
To lower transverse link M12 x 1.5 90 plus an
x 75 additional 90
( turn)
To upper transverse link M14 x 1.5 130 plus an
x 95 additional 90
( turn)
To tie rod M14 x 1.5 130 plus an
x 95 additional 90
( turn)
To wheel hub with wheel bearing M16 x 1.5 180 plus an
x 70 additional 180
( turn)
To speed sensor M6 x 16 8
To shielding plate M6 x 12 10

Trailing Link Tightening Torques


Threaded connection Thread Nm

Suspension, Wheels,
To wheel bearing housing M12 x 25 90 plus an

Brakes, Steering
additional 90
( turn)
To mounting bracket M12 x 1.5 90 plus an
x 80 additional 90
( turn)
Mounting bracket-to-body M10 x 35 50 plus an
additional 45
( turn)

Lower Transverse Link Tightening Torque


Threaded connection Thread Nm
Stone impact protection on transverse link M6 x 12 8

Shock Absorbers Tightening Torques


Threaded connection Thread Nm
To wheel bearing housing M14 x 1.5 180
x 70
To shock absorber mount M10 x 1.0 25
To body M10 x 35 50 plus an
additional 45
( turn)

Audi A3 Quick Reference Specification Book October 2010 77


Stabilizer Bar Tightening Torques
Threaded connection Thread Nm
To subframe M8 x 35 20 plus an
additional 90
( turn)
To coupling rod M10 40
Coupling rod-to-wheel bearing housing M10 40

Rear Suspension All Wheel Drive


Rear Axle Curb Weight Data

Only tighten the respective bolts/nuts when dimension a between


the wheel hub center and the lower edge of the wheel housing is
reached.
Suspension Standing height a in mm
Basic suspension 380 10
Heavy duty suspension 400 10

78 Audi A3 Quick Reference Specification Book October 2010


Subframe Tightening Torques
Threaded connection Thread Nm
To lower transverse link M12 x 1.5 95
To upper transverse link M12 x 1.5 95
To body M12 x 1.5 x 90 plus an
125 additional 90
( turn)
To tie rod M12 x 1.5 x 90 plus an
100 additional 90
( turn)
To front crossmember M10 x 115 50 plus an
additional 180
( turn)
To final drive M12 x 1.5 60 plus an
x 85 additional 90
( turn)

Left Rear Level Control System Sensor G76


Tightening Torques

Suspension, Wheels,
Threaded connection Thread Nm

Brakes, Steering
To subframe M5 x 20 5
To lower transverse link M5 x 20 5

Wheel Bearing Housing Tightening Torques


Threaded connection Thread Nm
To lower transverse link M12 x 1.5 90 plus an
x 75 additional 90
( turn)
To upper transverse link M14 x 1.5 130 plus an
x 95 additional 90
( turn)
To tie rod M14 x 1.5 130 plus an
x 95 additional 90
( turn)
To wheel hub with wheel bearing M12 x 1.5 180 plus an
x 45 additional 180
( turn)
To shielding plate M6 x 12 10
To speed sensor M6 x 16 8

Audi A3 Quick Reference Specification Book October 2010 79


Trailing Link Tightening Torques
Threaded connection Thread Nm
To wheel bearing housing M12 x 25 90 plus an
additional 90
( turn)
To mounting bracket M12 x 1.5 90 plus an
x 80 additional 90
( turn)
Mounting bracket-to-body M10 x 35 50 plus an
additional 45
( turn)

Lower Transverse Link Tightening Torque


Threaded connection Thread Nm
Stone impact protection on transverse link M6 x 12 8

Shock Absorbers Tightening Torques


Threaded connection Thread Nm
To wheel bearing housing M14 x 1.5 180
x 70
To shock absorber mount M10 x 1.0 25
To body M10 x 35 50 plus an
additional 45
( turn)

Stabilizer Bar Tightening Torques


Threaded connection Thread Nm
To subframe M8 x 30 20 plus an
additional 90
( turn)
To coupling rod M10 x 55 40
Coupling rod-to-wheel bearing housing M10 40

Drive Axle Tightening Torques


Threaded connection Thread Nm
To final drive M8 x 48 20 plus an
additional 90
( turn)
To wheel hub M16 x 1.5 200 plus an
x 80 additional 180
( turn)

80 Audi A3 Quick Reference Specification Book October 2010


Wheels, Tires, Wheel Alignment
Wheel Bolts Tightening Torque
Component Nm
Wheel bolts-to-wheel hub for all vehicles 120

Tire Pressure Sensor Tightening Torque


Component Nm
Union nut-to-tire pressure sensor 8

Wheel Alignment Data


Front axle UA0 UA1/UA9 UA2 Rough UA3/UB3
Standard Sport terrain Sport
suspension suspension suspension suspension
quattro
GmbH
Toe setting for 5 5 5 5 5 5 5 5
each wheel
Overall toe 10 10 10 10 10 10 10 10

Suspension, Wheels,
Camber (in -30 30 -41 30 -14 30 -46 30

Brakes, Steering
straight-ahead
position) 1)
Maximum max. 30 max. 30 max. 30 max. 30
permissible
difference
between sides
Toe-out angle 1 38 20 1 40 20 1 38 20 2 59 20
with steering
wheel turned
20 2)
After-run 7 34 30 7 47 30 7 17 30 8 07 30
Maximum max. 30 max. 30 max. 30 max. 30
permissible
difference
between sides
Max. steering 41 40 41 39
angle at inner
gear
1)
Camber is not adjustable. Only slight corrections are possible by moving subframe
with consoles.
2)
The angle of the outside wheel is less by this amount. Depending on manufacturer,
it may be indicated as negative on the alignment computer.

Audi A3 Quick Reference Specification Book October 2010 81


Rear axle UA0 UA1/UA9 UA2 Rough UA3/UB3
Standard Sport terrain Sport
suspension suspension suspension suspension
quattro
GmbH
Overall toe 25 10 25 10 25 10 25 10
Toe setting for 12.5 5 12.5 5 12.5 5 12.5 5
each wheel
Maximum max. 20 max. 20 max. 20 max. 20
permissible
deviation from
the direction of
rotation
Camber -1 20 30 -1 20 30 -1 20 30 -1 20 30
Maximum max. 30 max. 30 max. 30 max. 30
permissible
difference
between sides

Light Alloy Wheels with Metal Valve


Tightening Torques
Component Nm
Metal valve hex nut 4
Decoration element self-locking hex socket bolts 5

Wheel Bolts Tightening Torques


Vehicle type Number Nm
of wheel
bolts/nuts
Audi models except RS 2 and RS 4 5 120
(type 8D)
PAX wheels 5 140

82 Audi A3 Quick Reference Specification Book October 2010


Brake System
Front Brakes Technical Data
Front axle
Brake caliper PR- 1ZF 1ZE 1ZP 1LJ 1ZD 1LK
No.
Front brake caliper FSIII FN3 FN3 FN3 FN3 FNR-
G-57
Piston mm 54 54 54 54 54 57
Brake disc PR-No. 1ZF 1ZE 1ZE 1LJ 1LJ 1LK
Front brake mm 280, 280, 288 312 312 345
disc 288 288
Brake disc mm 22 25 25 25 25 30
thickness,
ventilated
Brake disc mm 19 21 21 21 21 27
wear limit
Brake pads
Pad thickness, mm 14 14 14 14 14 -

Suspension, Wheels,
new (not

Brakes, Steering
including
backing plate)
Brake pad mm 2 2 2 2 2 -
wear limit
(not including
backing plate)

Rear Brakes Front Wheel Drive Technical Data


Rear wheel brake, front-wheel drive
Brake caliper PR-No. 1KQ 1KD 1KE 1KZ
Rear brake caliper C38 C38 CII 41HR CII 38HR
Piston mm 38 38 41 38
Brake disc 1KQ, 1KD, 1KF, 1KE 1KZ,1KJ,
1KD 1KQ, 1KU
Rear brake disc mm 255 255 260 286
Brake disc thickness, mm 10 10 12 12
not ventilated
Brake disc thickness, mm - -
ventilated
Brake disc wear limit mm 7 7 9 9
Brake pads
Pad thickness, new (not mm 12 12 12 12
including backing plate)
Brake pad wear limit mm 2 2 2 2
(not including backing
plate)

Audi A3 Quick Reference Specification Book October 2010 83


Brake Master Cylinder and Brake Booster
Technical Data
Component diameter in
mm
Brake master cylinder 22
Brake booster (left-hand drive) 10

Hydraulic Unit, Brake Booster/Brake Master


Cylinder ABS Mark 70 (ABS/ASR) and
60 (ABS/EDL/ASR/ESP) Tightening Torques
Component Nm
ABS control module J104 inner Torx bolts 4
ABS hydraulic unit N55 bracket hex bolts 8
Air filter housing 10
Brake lines to hydraulic unit, M10 and M12 14

ABS System Components on Front and Rear


Axles Tightening Torques
Component Nm
ABS speed sensor-to-wheel bearing housing, front 8
ABS speed sensor-to-stub axle, rear 8

ESP Sensor Unit G419 Tightening Torque


Component Nm
ESP sensor unit-to-bracket 20

Front Wheel Brakes Brake Caliper FS III/FN 3/


FNR-G Tightening Torques
Component Nm
Brake disc Phillips/Torx bolts 5
Brake caliper guide pins 30
ABS speed sensor-to-wheel bearing housing 8
Brake line-to-brake caliper 19
Wheel bearing housing with fastened brake carrier ribbed 190
bolt (FN3/FNR-G)
Brake hose bracket bolt (FNR-G) 25
Brake line-to-brake hose (FNR-G) 12

84 Audi A3 Quick Reference Specification Book October 2010


Rear Brakes (Disc Brakes) Rear Brake C 38/
C II 38 Tightening Torques
Component Nm
ABS speed sensor-to-stub axle, rear 8
Wheel bearing housing multi-point socket head bolts 90 plus an
additional 90
( turn)
Cover plate hex head bolts (hex head bolt M6 x 10 9
changed from Torx bolt M6 x 12) (Replace hex head bolt
with hex head bolt and Torx bolt with Torx bolt) (C38/
CII 41)
Cover plate torx bolts (hex head bolt M6x10 changed 12
from Torx bolt M6x12 ) (Replace hex head bolt with hex
head bolt and Torx bolt with Torx bolt)
Brake disc Phillips head bolt 4
Brake line-to-brake hose 14
Brake caliper self-locking hex bolts (always replace) 35
Brake line-to-brake caliper 14

Suspension, Wheels,
Parking Brake Lever Tightening Torque

Brakes, Steering
Component Nm
Parking brake lever hex nuts 15

Hydraulic Components Front Brake Caliper


FS III/FN 3/FNR-G Tightening Torques
Component Nm
Brake caliper bleed valve 10
Brake caliper bleed valve (FNR-G) 12
Brake caliper guide pins 30 (18 ft lb)

Hydraulic Components Rear Brake Caliper


C 38/CII 38/CII 41 Tightening Torques
Component Nm
Brake caliper bleed valve 10
Brake caliper with parking brake cable lever self locking 35
hex bolts

Audi A3 Quick Reference Specification Book October 2010 85


Hydraulic Unit, Brake Booster/Brake Master
Cylinder Tightening Torques
Component Nm
Pedal assembly self-locking hex nuts 25
Heat shield self-locking hex nuts (always replace) 20
Master brake cylinder/secondary piston circuit-to- 14
hydraulic unit brake line

Master brake cylinder/primary piston circuit-to-hydraulic 14


control unit brake line

Brake system vacuum pump V192-to-bracket 18


Bracket-to-automatic transmission 18
Shield-to-bracket 10
Master brake cylinder at brake booster (always replace) 25
Brake lines-to-main brake cylinder 14
Brake booster-to-foot pedal assembly/cross panel 25
(always replace)
ESP sensor unit-to-bracket 20

Steering
Steering Column Tightening Torques
Threaded connection Thread Nm
Strut-to-bracket M8 x 100 20
Mounting bracket-to-strut M8 x 20 25
Steering column-to-bracket M8 x 35 20
Strut-to-body M8 x 48 25
Universal joint-to-steering gear M8 x 32 20 plus an
additional 90
( turn)
Lower steering column trim-to-steering 3.5
column switch module
Steering wheel on steering column 50
Handle-to-steering column adjustment 3.5
clamping lever
Steering column electronic systems control 0.4
module J527-to-steering column switch
module

86 Audi A3 Quick Reference Specification Book October 2010


Steering Gear (Generation I and II)
Tightening Torques
Threaded connection Thread Nm
To subframe M10 x 76 50 plus an
additional 90
( turn)
To shielding plate M6 self- 6
tapping
Tie rod end-to-wheel bearing housing M12 x 1.5 20 plus an
additional 90
( turn)
Tie rod end-to-tie rod M16 x 1.5 55
Tie rod-to-steering rack M16 x 1.5 100

Suspension, Wheels,
Brakes, Steering

Audi A3 Quick Reference Specification Book October 2010 87


Body
Body Dimensions
Front Dimensions

88 Audi A3 Quick Reference Specification Book October 2010


Body

Component mm
a 940 2
b 1350 2
c 1557 2
d 1119 2
e 1466 2

Audi A3 Quick Reference Specification Book October 2010 89


Center Dimensions

90 Audi A3 Quick Reference Specification Book October 2010


Body

Component mm
f 1187 2
g 1534 2
h 935 2
i 1437 2

Audi A3 Quick Reference Specification Book October 2010 91


Rear Dimensions

Component mm
j 915 2
k 1124 2
l 852 2
m 1009 2

92 Audi A3 Quick Reference Specification Book October 2010


Floor Assembly Front Dimensions

Body

Component mm
a 956 2
b 1003 2
c 874 2
d 892 2
e 836 2

Audi A3 Quick Reference Specification Book October 2010 93


Floor Assembly Center Dimensions

Component mm
f 1834 2
g 1220 2
h 1531 2

94 Audi A3 Quick Reference Specification Book October 2010


Floor Assembly Rear Dimensions

Body

Component mm
j 1075 2
k 1386 2
l 985 2
m 987 2

Audi A3 Quick Reference Specification Book October 2010 95


Body Exterior
Lock Carrier Service Position
Tightening Torques
Component Nm
Lock carrier bolts, upper 8
Lock carrier bolts, lower 60

Front Fender Tightening Torques


Component Nm
Front fender bolts 10
Fender connecting piece hex nut 7.5

Noise Insulation Panel Tightening Torques


Component Nm
Noise insulation panel side bolts 2
Noise insulation panel end bolts 6

Underbody Trim Tightening Torques


Component Nm
Underbody cover hex nuts 2
Rear underbody bolts 2

Front Hood Tightening Torques


Component Nm
Hood hex nut 22
Gas filled strut ball studs 14
Hood hinge bolts 21
Hood catch nuts 11
Release lever bracket bolts 2.0
Hood lock bolts 12

Rear Lid Tightening Torques


Component Nm
Rear lid bolts 21
Gas filled strut ball studs 21
Rear lid hinge hex head nut 21
Rear lid latch bracket nuts 20
Rear lid handle unlock switch E234 bolts 4
Rear lid lock bolts 21

Tank Flap Unit Tightening Torque


Component Nm
Fuel filler flap 1

96 Audi A3 Quick Reference Specification Book October 2010


Front and Rear Door Tightening Torques
Component Nm
Outer door plate bolts (bolt has point and thinner washer) 32
Inner door part bolts (bolt without point but with thick 32
washer)
Inner door part bolts (bolt with point and thick washer) 32
Upper door hinge 32
Lower door hinge 32
Door lock to inner door part bolt 25
Side impact protection bolts 20
Side impact protection nuts 20

Sunroof Tightening Torques


Component Nm
Spring glider bolts (always replace) 1.8
Electrical drive motor bolts 3.5
Slotted guide rail Torx bolts 5
Installation unit bolts 8

Front Bumper Tightening Torques


Component Nm
Bumper cover bolts (3 on top) 8.5
Bumper cover screw (3 per side) 1.5
Vent grille screw 1.5
Left guide piece bolts 1.5
Right guide piece bolts 1.5
Bumper shock absorber bolt 23
Bumper carrier bolts 23
Lower part of spoiler bolts 1.5
Body

Rear Bumper Tightening Torques


Component Nm
Rear bumper cover bolts T-24 2
Rear bumper cover screws 1.5
Rear bumper cover cap nuts 4
Securing strip hex nuts 4
Guide trim hex nuts 2
Crossmember bolts 23

Audi A3 Quick Reference Specification Book October 2010 97


Front and Rear Door Window
Tightening Torques
Component Nm
Window regulator bolts 8
Window regulator motor bolts 3.5
Window guide trim bolts 2

Front Wheel Housing Liner Tightening Torque


Component Nm
Wheel housing liner bolts 2

Rear View Mirror Tightening Torques


Component Nm
Mirror base plate bolts 8
Assembly component bolts 1

Radiator Grille Tightening Torque


Component Nm
Radiator grille bolts 2

Strips and Trim Tightening Torques


Component Nm
Sill panel extension bolts 2
Retaining strip-to-sill panel bolts 1.2

Body Interior
Storage Compartment Tightening Torques
Component Nm
Front center console bolts 3.5
Front center armrest 14
Storage compartment/ashtray unit bolts 3.5
Instrument panel center vent bolts 3.5
Center instrument panel trim bolts 3.5
Steering column trim bolts 3.5
Drivers side trim bolts 3
Sun visor bolts 4
Glove compartment bolts 3.5
Drivers side footwell cover bolts 2.5
Roof grab handle bolts 4

98 Audi A3 Quick Reference Specification Book October 2010


Passenger Protection Tightening Torques
Component Nm
Seatbelt-to-outer floor assembly anchorage point 55
Belt anchor bolt 55
Front seat belt height adjuster bolt 55
Belt latch-to-seat bolt 20
Automatic belt retractor bolt 55
Rear center 3-point seatbelt belt latch hex nut 55
Rear center lap belt bolt 55
Rear double belt latch bolt 55
Airbag control module J234 nuts 8
Passenger side airbag unit bolts 10
Side airbag bolts 10
Side head curtain airbag cap nuts 5
Front door crash sensor bolts 5
Rear wheel housing crash sensor bolts 7

Interior Trim Tightening Torques


Component Nm
Instrument panel bolts 3
Instrument panel above tunnel bolts 8
Instrument panel aligning bolts 2
Footwell trim bolts 1.5
Instrument panel below heating or A/C mechanism (2 9
bolts)
Instrument panel tunnel area bolts 20
Instrument panel tunnel area nuts 18
Fuse holder bolts 2
Fuse holder nuts 18
Door trim handle molding area bolts 1.5
Body

Door trim handle molding area (4 surrounding bolts) 2


Door mirror triangle cover bolt 2
Upper A-pillar and B-pillar trim airbag emblem bolt 4
B-pillar trim bolts 4
C-pillar trim nut 1.5
Side trim bolts 2
Rear lid trim handle recess bolts 2
Luggage compartment cover side storage compartment 1.5
bolts
Luggage compartment side trim bolts 8
Molded headliner bolts 2

Audi A3 Quick Reference Specification Book October 2010 99


Seat Frames Tightening Torques
Component Nm
Front seat frame bolts 40
Tunnel-side side trim on front seat 2
Seat bracket and operation lever bolts 3.5
Front seat backrest bolts (always replace) 34.5
Bucket seat pan bolts 24
Rear seat center backrest bolt 9
Rear seat belt buckle-to-floor bolt 40
Rear seat side upholstery bolt 8
Rear seat side upholstery nut 8
Rear seat storage unit with center armrest bolts 9

100 Audi A3 Quick Reference Specification Book October 2010


Heating and Air Conditioning
Refrigerant R134a Capacity
A/C compressor Manufacturer Total capacity (grams)
7SEU17C Denso 525 25
PXE16 Sanden 525 25
DSC17E Zexel 525 25

Refrigerant (PAG) Oil Identification


Obtain using following Part No.:
7SEU17C; Denso G 052 300 A2
PXE16; Sanden G 052 154 A2
DSC17E; Zexel G 052 200 A2

Refrigerant (PAG) Oil Capacities


Model Production Total capacity (cm3)
1K0 820 803 G Sanden from 10.04 110 10
1K0 820 803 K Sanden from 10.04 110 10
1K0 820 803 E Denso from 10.04 140 10
1K0 820 803 H Zexel from 10.04 120 10

Refrigerant Oil Distribution


Component Approximate % of total amount of
oil in component
A/C compressor 50
Condenser 10
Suction hose 10
Evaporator 20
Fluid Reservoir 10
Air Conditioning
Heating &

Audi A3 Quick Reference Specification Book October 2010 101


Refrigerant R134a Vapor Pressure Table
Temperature in C Pressure in bar
(positive pressure) of R134a
-45 -0.61
-40 -0.49
-35 -0.34
-30 -0.16
-25 0.06
-20 0.32
-15 0.63
-10 1.00
-5 1.43
0 1.92
5 2.49
10 3.13
15 3.90
20 4.70
25 5.63
30 6.70
35 7.83
40 9.10
45 10.54
50 12.11
55 13.83
60 15.72
65 17.79
70 20.05
75 22.52
80 25.21
85 28.14
90 31.34

Physical Data of Refrigerant R134a


Chemical formula CH2FCF3 or CF3CH2F
Chemical designation Tetrafluoroethane
Boiling point at 1 bar - 26.5C
Solidification point -101.6C
Critical temperature 100.6C
Critical pressure 40.56 bar (absolute)

102 Audi A3 Quick Reference Specification Book October 2010


A/C Refrigerant Pressure and Temperature
Refrigerant Circuit with Expansion Valve
Specifications

A - Low pressure side of refrigerant circuit.


B- High pressure side of refrigerant circuit.
Air Conditioning
Heating &

Audi A3 Quick Reference Specification Book October 2010 103


Component Aggregate Pressure Temperature in
state of (bar positive degrees Celsius
refrigerant pressure)
1 - Evaporator, from Vapor Approximately Approximately
input to output 1.2 bar -7C
(Approximately (Approximately
1.8 bar) -1C
2 - A/C compressor Gas Approximately Approximately
A- side 1.2 bar -1C
(Approximately (Approximately +
1.8 bar) 1C)
3 - A/C compressor Gas Approximately Approximately +
B- side 14 bar 65C
4 - Condenser Gas, vapor, Approximately Approximately +
fluid 14 bar 55C at outlet
5 - Receiver Fluid Approximately Approximately +
14 bar 55C
6 - Charging and Fluid Approximately Approximately +
evacuating valve 14 bar 55C
B- side
7 - Expansion valve Fluid, released Approximately Approximately +
as vapor 14 bar 55C, reduced to
-7C
8 - Charging and Gas Approximately Approximately
evacuating valve 1.2 bar -7C
A- side (Approximately (Approximately
1.8 bar) -1C)

104 Audi A3 Quick Reference Specification Book October 2010


A/C Refrigerant Pressure and Temperature
Refrigerant Circuit with Restrictor and
Reservoir Specifications

Arrows show direction of refrigerant flow


Component Aggregate Pressure Temperature in
state of (bar positive degrees Celsius
refrigerant pressure)
1 - A/C Gas up to 20 bar up to + 70C
compressor B-
side
2 - Condenser From gas to up to 20 bar up to + 70C
vapor to fluid
3 - Restrictor From fluid to B-side up to 20 B-side up to +
vapor bar, A-side greater 60C, A-side
than 1.5 bar warmer than - 4C
4 - Evaporator From vapor to Greater than 1.5 Warmer than - 4C
gas bar
5 - Reservoir Gas
6 - A/C Gas
compressor A-
side
Air Conditioning
Heating &

Audi A3 Quick Reference Specification Book October 2010 105


Heating and Ventilation System
Tightening Torques
Component Nm
Fresh air blower V2 bolt 1
Coolant pipe clamps 2.5
Connecting flange between heater core connections 2
Auxiliary heater heating element Z35 voltage supply and 6
ground connection mounting nut
Heating and ventilation unit cable bracket bolts 5
Assembly carrier bracket bolts 8
Heating and ventilation unit bracket bolts 10

A/C System Tightening Torques


Component Nm
Shielding plate nut 6
Refrigerant lines-to-engine compartment bolts 12
Assembly carrier bracket bolts 8
Climatronic control module J255 with A/C control head 2.5
E87-to-center instrument control panel bolts
A/C compressor-to-bracket 25

A/C Refrigerant System Tightening Torques


Component Nm
Coolant line bracket hex nuts 20
Fluid reservoir with dryer bolts 4.2 0.7
Refrigerant lines-to-A/C compressor bolts 22 1
A/C compressor hex bolts 25
Shielding plate nut 6
Refrigerant lines-to-expansion valve bolts 12
Expansion valve combination bolts 5
Condenser bracket bolt 5 0.5
Radiator bolts 5 0.5

106 Audi A3 Quick Reference Specification Book October 2010


Electrical Equipment
Battery Tightening Torques

Equipment
Electrical
Location/Fastener Nm
Battery post terminals/nuts M6 6
Battery post terminals/additional terminal M6 6
nuts
Battery hold-down bracket/bolt M8 x 35 22

Generator Tightening Torques


Location/Fastener Nm
B+ wire-to-generator/nut M8 15
Harness retainer-to-generator M5 3.2
Voltage regulator-to-generator/screw M4 2
Protective cap-to-generator M5 4.5
Ribbed belt pulley with freewheel-to- M10 80
generator/nut
Ribbed belt pulley without freewheel-to- M10 65
generator/nut

Generator 2.0LTFSI Tightening Torques


Location/fastener Nm
Generator-to-mounting bracket/bolts M8 x 90 23
Tensioner-to-mounting bracket/bolts M8 x 90 23
Mounting bracket-to-engine block/bolts M10 x 45 40
A/C compressor-to-mounting bracket M8 x 100 23

2.0L TFSI Generator Mounting Bracket Bolts


Tightening Sequence

Component Nm
ABCDEF 40

Audi A3 Quick Reference Specification Book October 2010 107


Generator 3.2L Tightening Torques
Component Nm
Generator-to-bracket bolt 23
Tensioning roller-to-bracket bolt 50
Terminal 30/B+-to-generator 16
A/C compressor-to-bracket bolt 25
Air cleaner housing (bottom section)-to-bracket screw 10
Radiator cowl-to-radiator screw 5
Coolant pipe-to-bracket bolt 10
Secondary air pump-to-bracket bolt 10

Starter, 4 Cylinder Engine Tightening Torques


Component Nm
Starter-to-transmission bolt 80
Bracket for electrical wires bolt 23
Terminal B+-to-starter nut 16
Ground cable-to-starter bolt 23

Starter, 6 Cylinder Engine Tightening Torques


Component Nm
Starter-to-transmission bolt 40
Bracket for electrical wires bolt 23
Terminal B+-to-starter nut 16
Ground wire-to-transmission 22
Air cleaner housing (bottom section)-to-bracket screw 10
Bracket for air cleaner housing (bottom section)-to- 10
transmission screw

Front Wiper Motor Tightening Torques


Component Nm
Wiper motor-to-wiper frame bolt 9
Wiper crank-to-wiper motor nut 18
Wiper frame-to-plenum chamber bolt 8

Washer Reservoir Tightening Torques


Component Nm
Washer fluid reservoir Top 2.5
To longitudinal member Bottom 7
Filler neck for washer fluid reservoir-to-wheel housing 2.5

108 Audi A3 Quick Reference Specification Book October 2010


Rear Wiper/Washer Tightening Torques
Component Nm

Equipment
Wiper motor-to-rear lid screw 8

Electrical
Wiper arm nut 12

Headlamp Washer Spray Jets


Tightening Torque
Component Nm
Washer jet-to-bumper screw 2.5

Headlamp Tightening Torque


Component Nm
Headlamp housing-to-lock carrier screw 6

Fog Lamp Tightening Torque


Component Nm
Fog lamp housing-to-bumper screw 5

Rear Lights in Rear Fender Tightening Torque


Component Nm
Rear light housing/nuts 3.5

Rear Lights in Rear Lid Tightening Torque


Component Nm
Rear light housing/nuts 3.5

Vehicle Level Sensors Tightening Torques


Component Nm
Left front level control system sensor G78/ M6 9
bolts
Left rear level control system sensor G76/ M5 5
bolts

Audi A3 Quick Reference Specification Book October 2010 109


DTC CHART
DTC Error Message Malfunction Criteria and
Threshold Value
P000A Intake (A) Camshaft Position Difference between target and
Slow Response Bank 1 actual > 8 CRK and adjustment
angle > 2.5 CRK
P0010 Intake (A) Camshaft Position Signal voltage > 4.4 - 5.6 V
Actuator Circuit/Open
(Bank 1)
P0011 Intake (A) Camshaft Position Difference between target and
Timing - Over-Advanced actual > 8 CRK and adjustment
(Bank 1) angle < 2.5 CRK
P0016 Crankshaft Position Permissible deviation
Camshaft Position Correlation < -11 CRK
OR
Permissible deviation
> 11 CRK
P025A Fuel Pump Signal voltage > 4.4 - 5.6 V
P025C Fuel Pump Signal voltage< 2.15 - 3.25 V
P025D Fuel Pump Signal current > 1.1 A
P0030 HO2S Heater Control Circuit Heater voltage 2.34 - 3.59 V
(Bank 1, Sensor 1)
P0031 HO2S Heater Control Circuit Heater voltage < 2.34 V
Low (Bank 1, Sensor 1)
P0032 HO2S Heater Control Circuit Heater voltage > 3.59 V
High (Bank 1, Sensor 1)
P0036 HO2S Heater Control Circuit Heater voltage 4.50 - 5.50 V
(Bank 1, Sensor 2)
P0037 HO2S Heater Control Circuit Heater voltage < 3.00 V
Low (Bank 1, Sensor 2)
P0038 HO2S Heater Control Circuit Heater current > 2.70 - 5.50 A
High (Bank 1, Sensor 2)
P0068 MAP/MAF Throttle Position Plausibility with fuel system
Correlation Load calculation < -22%
Plausibility with fuel system
Load calculation > 22%
P0070 Ambient Air Temperature Ambient air temperature
Sensor Circuit < -50C

110 Audi A3 Quick Reference Specification Book October 2010


DTC Error Message Malfunction Criteria and
Threshold Value
P0071 Ambient Air Temperature Difference in value between
Sensor Range/Performance ECT and AAT at engine start
(depending on engine off time)
> 24.75C
and
Difference in value between
ECT and IAT at engine start
(depending on engine off time)
> 24.75C
P0072 Ambient Air Temperature Ambient air temperature > 76C

DTC Chart
Sensor Circuit Low
P0087 Fuel Rail/System Pressure - Fuel trim activity 0.90 - 1.15
Too Low Output value rail pressure
controller > 2 MPa
Difference between target and
actual pressure > -16.38 bar
P0100 Mass or Volume Air Flow A MAF sensor signal 0 s
Circuit
P0101 Mass Air Flow Circuit Range/ Mass air flow vs.
Performance upper threshold model
< 60 - 800 kg/h
lower threshold model
< 0 - 400 kg/h
Load calculation > 18%
Fuel system < -17%
P0102 Mass or Volume Air Flow A MAF sensor signal < 66 s
Circuit Low
P0103 Mass or Volume Air Flow A MAF sensor signal > 4500 s
Circuit High
P0106 Manifold Absolute Pressure/ Difference of boost pressure
Barometric Pressure Circuit signal vs. altitude sensor signal
Range/Performance > 230 hPa
OR
Difference of boost pressure
signal vs. altitude sensor signal
< -130 hPa
P0111 Intake Air Temperature Sensor Difference in value IAT - ECT
1 Circuit Range/Performance at engine start (depending on
engine off time) > 24.75C
Difference in value IAT - AAT
at engine start < 24.75C
P0112 Intake Air Temperature Sensor IAT > 141C
1 Circuit Low Input

Audi A3 Quick Reference Specification Book October 2010 111


DTC Error Message Malfunction Criteria and
Threshold Value
P0113 Intake Air Temperature Sensor IAT < -46C
1 Circuit High Input
P0116 Engine Coolant Temperature Difference in value between
Sensor 1 Circuit Range/ ECT and AAT at engine start
Performance (depending on engine off time)
> 24.75C
and
Difference in value between
ECT and IAT at engine start
(depending on engine off time)
> 24.75C
P0117 Engine Coolant Temperature ECT >140C
Sensor 1 Circuit Low
P0118 Engine Coolant Temperature ECT < -40C
Sensor 1 Circuit High
P0121 Throttle/Pedal Position Sensor TPS 1 - TPS 2 > 6.30%
A Circuit Range/Performance Actual TPS 1 calculated value
> TPS 2 calculated value
TPS 1 calculated value
> 9.00%
P0122 Throttle/Pedal Position Sensor Signal voltage < 0.20 V
A Circuit Low
P0123 Throttle/Pedal Position Sensor Signal voltage > 4.81 V
A Circuit High
P0130 O2 Sensor Circuit (Bank 1 O2S ceramic temperature
Sensor 1) < 640C
P0131 O2 Sensor Circuit (Bank 1 Virtual mass < 1.75 V
Sensor 1) Low Voltage Nernst voltage < 1.50 V
Adjustment voltage < 0.30 V
P0132 O2 Sensor Circuit (Bank 1 Virtual mass > 3.25 V
Sensor 1) High Voltage Nernst voltage > 4.40 V
Adjustment voltage > 7 V
P0133 O2 Circuit Slow Response Signal dynamic slope check
(Bank 1 Sensor 1) O2S signal front vs. modeled
O2S signal ratio < 0.60 and
2 times
OR
O2S signal front vs. modeled
O2S signal ratio < 0.15 and
5 times

112 Audi A3 Quick Reference Specification Book October 2010


DTC Error Message Malfunction Criteria and
Threshold Value
P0135 O2 Heater Circuit (Bank 1 Heater duty cycle >100%
Sensor 1) O2S ceramic temperature,
< 715C
Time after O2S heater on
40 Sec.
Difference between measured
calibration resistance in ECM
and set value > 45 Ohms
P0136 O2 Circuit (Bank 1 Sensor 2) Delta voltage one step at
heater switching > 2.00 V

DTC Chart
Number of checks 4
P0137 O2 Circuit Low Voltage (Bank Signal voltage < 0.06 V for
1 Sensor 2) > 3 Sec.
Reaction at closed loop
enrichment = no reaction
P0138 O2 Circuit High Voltage (Bank Signal voltage > 1.08 V for
1 Sensor 2) > 5 Sec.
P0139 O2 Circuit Slow Response EWMA filtered transient time
(Bank 1 Sensor 2) at fuel cutoff > 1.2 Sec.
In voltage range of 201 -
401 mV
Number of checks = 3
P0140 O2 Circuit No Activity Signal voltage
Detected (Bank 1 Sensor 2) Signal voltage 0.40 - 0.60 V
for > 3 Sec.
Sensor voltage load pulse vs.
no pulse 2.80 V
Internal resistance
> 40 K Ohms
Exhaust temperature > 600C
P0141 O2 Heater Circuit Heater circuit internal resistance
(Bank 1 Sensor 2) 792 - 4560 Ohms
P0169 Incorrect Fuel Composition Fuel quantity incorrect
Fuel correction factor incorrect
Internal check failed
P0171 System Too Lean (Bank 1) At idle
Adaptive value > 5.02%
At part load
Adaptive value > 21%
P0172 System Too Rich (Bank 1) At idle
Adaptive value < -5.02%
At part load
Adaptive value < -21%

Audi A3 Quick Reference Specification Book October 2010 113


DTC Error Message Malfunction Criteria and
Threshold Value
P0190 Fuel Rail Pressure Sensor A Signal voltage > 4.8 V
Circuit
P0191 Fuel Rail Pressure Sensor Actual pressure > 20.6 MPa
Circuit Range/Performance
P0192 Fuel Rail Pressure Sensor A Signal voltage < 0.2 V
Circuit Low
P0201 Cylinder 1 Injector Circuit/ Low side signal current < 2.1 A
Open
P0202 Cylinder 2 Injector Circuit/ Low side signal current < 2.1 A
Open
P0203 Cylinder 3 Injector Circuit/ Low side signal current < 2.1 A
Open
P0204 Cylinder 4 Injector Circuit/ Low side signal current < 2.1 A
Open
P0221 Throttle/Pedal Position TPS 1 - TPS 2 > 6.30%
Sensor/Switch B Circuit Actual TPS 2 calculated value
Range/Performance > TPS 1 calculated value
TPS 2 calc. value > 9.00%
P0222 Throttle/Pedal Position Signal voltage < 0.20 V
Sensor/Switch B Circuit Low
P0223 Throttle/Pedal Position Signal voltage > 4.81 V
Sensor/Switch B Circuit High
P0234 Turbocharger/Supercharger A Difference of set value boost
Overboost Condition pressure vs. altitude sensor
signal > 200 - 1275 hPa
P0236 Turbocharger Boost Sensor A Difference in boost pressure vs.
Circuit Range/Performance altitude sensor > 230 hPa OR
< -130 hPa
P0237 Turbocharger/Supercharger Signal voltage < 0.2 V
Boost Sensor A Circuit Low
P0238 Turbocharger/Supercharger Signal voltage > 4.88 V
Boost Sensor A Circuit High
P0243 Turbocharger/Supercharger Signal voltage > 5.6 - 4.4 V
Wastegate Solenoid A
P0245 Turbocharger/Supercharger Signal voltage < 3.25 - 2.15 V
Wastegate Solenoid A Low
P0246 Turbocharger/Supercharger Signal current > 2.2 A
Wastegate Solenoid A High
P025A Fuel Pump Module A Control Signal voltage 4.40 - 5.60 V
Circuit/Open

114 Audi A3 Quick Reference Specification Book October 2010


DTC Error Message Malfunction Criteria and
Threshold Value
P025C Fuel Pump Module A Control Signal voltage 2.15 - 3.25 V
Circuit Low
P025D Fuel Pump Module A Control Signal current > 1.10 A
Circuit High
P0261 Cylinder 1 Injector Circuit Low Signal current < 2.1 A
P0262 Cylinder 1 Injector Circuit High Signal current > 14.70 A
P0264 Cylinder 2 Injector Circuit Low Signal current < 2.1 A
P0265 Cylinder 2 Injector Circuit High Signal current > 14.70 A

DTC Chart
P0267 Cylinder 3 Injector Circuit Low Signal current < 2.1 A
P0268 Cylinder 3 Injector Circuit High Signal current > 14.70 A
P0270 Cylinder 4 Injector Circuit Low Low side signal current < 2.1 A
P0271 Cylinder 4 Injector Circuit High Signal current > 14.70 A
P0299 Turbocharger/Supercharger A Difference of set boost pressure
Underboost Condition vs. actual boost pressure value
> 150 hPa
P0300 Random Misfire Detected Emission threshold 1st interval
Misfire Rate (MR) > 3.0%
Catalyst damage misfire rate
(MR) > 2.9% - 20%
P0301 Cylinder 1 Misfire Detected Emission threshold 1st interval
Misfire Rate (MR) > 2.5%
Catalyst damage Misfire Rate
(MR) > 2.5% - 21%
P0302 Cylinder 2 Misfire Detected Emission threshold 1st interval
Misfire Rate (MR) > 2.1%
Catalyst damage Misfire Rate
(MR) > 2.5% - 21%
P0303 Cylinder 3 Misfire Detected Emission threshold 1st interval
Misfire Rate (MR) > 2.1%
Catalyst damage Misfire Rate
(MR) > 2.5% - 21%
P0304 Cylinder 4 Misfire Detected Emission threshold 1st interval
Misfire Rate (MR) > 2.1%
Catalyst damage Misfire Rate
(MR) > 2.5% - 21%
P0321 Ignition/Distributor Engine Comparison of counted teeth
Input Circuit Range/ vs. reference = incorrect
Performance Monitoring reference gap
failure
P0322 Ignition/Distributor Engine Camshaft signal > 3
Input Circuit No Signal Engine speed = no signal

Audi A3 Quick Reference Specification Book October 2010 115


DTC Error Message Malfunction Criteria and
Threshold Value
P0324 Knock Control System Error Signal fault counter
(combustion) > 24
or
Signal fault counter
(measuring window) > 2.00
P0327 Knock Sensor 1 Circuit Low Lower threshold < -70 V
Input (Bank 1) or for signal range check
Lower threshold < 0.6 - 1.6 V
P0328 Knock Sensor 1 Circuit High Upper threshold > 1.00 V
Input (Bank 1) or for signal range check
> 21.7 - 115.9 V
P0340 Camshaft Position Sensor Cam adaption values out of
A Circuit (Bank 1 or single range
sensor) > 20 KW
< -20 KW
Difference of adapted and
actual values > 9 KW
P0341 Camshaft Position Sensor A Signal pattern incorrect
Circuit Range/Performance
(Bank 1 or single sensor)
P0342 Camshaft Position Sensor A Signal voltage low
Circuit Low (Bank 1 or single Crankshaft signals = 8
sensor)
P0343 Camshaft Position Sensor A Signal voltage high
Circuit High (Bank 1 or single Crankshaft signals = 8
sensor)
P0351 Ignition Coil A Primary/ Signal current -0.25 to -2.0 mA
Secondary Circuit Internal check failed
P0352 Ignition Coil B Primary/ Signal current -0.25 to -2.0 mA
Secondary Circuit Internal check failed
P0353 Ignition Coil C Primary/ Signal current -0.25 to -2.0 mA
Secondary Circuit Internal check failed
P0354 Ignition Coil D Primary/ Signal current -0.25 to -2.0 mA
Secondary Circuit Internal check failed

116 Audi A3 Quick Reference Specification Book October 2010


DTC Error Message Malfunction Criteria and
Threshold Value
P0420 Catalyst System Efficiency Front:
Below Threshold (Bank 1) Oxygen Storage Capacity
(OSC) vs. OSC of borderline
catalyst < 0.40
Front catalyst < 1.00
Main catalyst < 1.00
Main:
Oxygen Storage Capacity
(OSC) vs. OSC of borderline
catalyst < 0.40

DTC Chart
Front catalyst < 0.90
while value for front catalyst
< 2.00
P0441 Evaporative Emission System Deviation < 9% lambda
Incorrect Purge Flow controller and 30% idle
controller
P0442 Evaporative Emission System Time for pressure drop < 1.55 -
Leak Detected (small leak) 1.75 Sec.
P0444 Evaporative Emission System Signal voltage > 4.40 - 5.40 V
Purge Control Valve A Circuit
Open
P0455 Evaporative Emission System Time for pressure drop
Leak Detected (gross leak/no < 0.95 Sec.
flow)
P0456 Evaporative Emission System Time for pressure drop
Leak Detected (very small < 4.5 - 6.0 Sec.
leak)
P0458 Evaporative Emission System Signal voltage 2.15 - 3.25 V
Purge Control Valve Circuit
Low
P0459 Evaporative Emission System Signal current > 2.2 A
Purge Control Valve Circuit
High
P050A Cold Start Idle Air Control Out of range low:
System Performance Engine speed deviation
< -80 RPM
Out of range high:
Engine speed deviation
> 80 RPM
OR
RPM controller P portion and
I portion < -15 Nm
Integrated deviation of RPM
low and high > 2000 RPM

Audi A3 Quick Reference Specification Book October 2010 117


DTC Error Message Malfunction Criteria and
Threshold Value
P0501 Vehicle Speed Sensor A VSS signal < 6 km/h
Range/Performance
P0503 Vehicle Speed Sensor A Vehicle speed > 290 km/h
Intermittent/Erratic/High
P0506 Idle Air Control System - RPM Idle speed deviation < -80 RPM
Lower Than Expected and RPM controller torque value
calculated max value OR
Integrated deviation of engine
low and high > 2000 RPM
P0507 Idle Air Control System - RPM Idle speed deviation > 80 RPM
Higher Than Expected and RPM controller torque value
calculated min value
P053F Cold Start Fuel Pressure Difference between target
Performance pressure vs. actual pressure:
> 1.50 MPa
OR
< -1.50 MPa
P052A Cold Start Intake A Camshaft Difference between target and
Position Timing Over- actual position > 6 CRK
Advanced (Bank 1)
P0606 Control Module Processor ECM internal check failure
NOTE: BARO sensor is also
located in the ECM and is not
serviceable, requiring ECM
replacement.
P062B Internal Control Module Fuel Internal logic failure
Injector Control Performance
P0638 Throttle Actuator Control Time to close to reference
Range/Performance - Bank 1 point > 0.6 Sec.
and
TPS 1 voltage NOT 0.40 -
0.80 V
TPS 2 signal voltage NOT
4.20 - 4.60 V
TPS 1 and TPS 2 NOT 4.82 -
5.18 V
P0641 Sensor Reference Voltage A Signal voltage deviation
Circuit/Open > 0.3 V
P0651 Sensor Reference Voltage B Signal voltage deviation
Circuit/Open > 0.3 V
P0657 Actuator Supply Voltage A Signal voltage > 4.4 - 5.6 V
Circuit/Open

118 Audi A3 Quick Reference Specification Book October 2010


DTC Error Message Malfunction Criteria and
Threshold Value
P0658 Actuator Supply Voltage A Signal voltage < 2.15 - 3.25 V
Circuit Low
P0659 Actuator Supply Voltage A Signal current > 1.1 A
Circuit High
P0697 Sensor Reference Voltage C Signal voltage deviation
Circuit/Open > 0.3 V
P12A1 Fuel Rail Pressure Sensor Pressure control activity
Inappropriately Low > 0.20 MPa
Fuel trim activity < 0.80

DTC Chart
Difference between actual
pressure vs. target pressure
-16.38 to 16.38 MPa
P12A2 Fuel Rail Pressure Sensor Pressure control activity
Inappropriately High < -0.05 MPa
Fuel trim activity > 1.65
Difference between target
pressure and actual pressure
-16.38 to 16.38 MPa
P12A4 Fuel Rail Pump Control Valve Fuel trim activity 0.90 to 1.15
Stuck Closed Pressure control activity
< -6 MPa
System Deviation
< 16.38 MPa
P150A Engine Off Timer Performance Difference between engine off
time and ECM after run time
< -12 Sec. or > 12 Sec.
P2008 Intake Manifold Runner Signal voltage 4.40 - 5.60 V
Control Circuit/Open (Bank 1)
P2009 Intake Manifold Runner Signal voltage 3.25 - 2.15 V
Control Circuit Low (Bank 1)
P2010 Intake Manifold Runner Signal current > 2.20 A
Control Circuit High (Bank 1)
P2014 Intake Manifold Runner Signal voltage > 4.75 V
Position Sensor/Switch Circuit
(Bank 1)
P2015 Intake Manifold Runner Deviation intake flap target
Position Sensor/Switch Circuit position vs. actual position
Range/Performance (Bank 1) > 25% and actual position
0 to 100%
P2016 Intake Manifold Runner Signal voltage < 0.25 V
Position Sensor/Switch Circuit
Low (Bank 1)

Audi A3 Quick Reference Specification Book October 2010 119


DTC Error Message Malfunction Criteria and
Threshold Value
P2088 A Camshaft Position Actuator Signal voltage < 2.15 - 3.25 V
Control Circuit Low Bank 1
P2089 A Camshaft Position Actuator Signal current > 2.2 A
Control Circuit High Bank 1
P2096 Post Catalyst Fuel Trim Deviation lambda control
System Too Lean Bank 1 < -0.025
P2097 Post Catalyst Fuel Trim Integral part of lambda control
System Too Rich Bank 1 > 0.03%
P2101 Throttle Actuator A Control Duty cycle > 80%
Motor Circuit Range/ Deviation throttle value angles
Performance vs. calculated value 4 - 50%
ECM power stage no failure
P2106 Throttle Actuator Control Internal check failed
System - Forced Limited
Power
P2122 Throttle/Pedal Position Signal voltage < 0.6 V
Sensor/Switch D Circuit Low
P2123 Throttle/Pedal Position Signal voltage > 4.8 V
Sensor/Switch D Circuit High
P2127 Throttle/Pedal Position Signal voltage < 0.27 V
Sensor/Switch E Circuit Low
P2128 Throttle/Pedal Position Signal voltage > 2.43 V
Sensor/Switch E Circuit High
P2138 Throttle/Pedal Position Signal voltage: Difference
Sensor/Switch D/E Voltage between signal APP1 and
Correlation APP2 > 0.17 - 0.70 V
P2146 Fuel Injector Group A Supply Signal current < 2.6 A
Voltage Circuit/Open or
Signal current > 14.90 A
P2149 Fuel Injector Group B Supply Signal current < 2.6 A
Voltage Circuit/Open or
Signal current > 14.90 A
P2177 System Too Lean Off Idle - Adaptive value > 28%
Bank 1
P2178 System Too Rich Off Idle - Adaptive value < -21%
Bank 1
P2181 Cooling System Performance Cooling system temperature too
low after a sufficient mass air
flow integral 74 - 84C
P2184 Engine Coolant Temperature ECT outlet < -43C
Sensor 2 Circuit Low

120 Audi A3 Quick Reference Specification Book October 2010


DTC Error Message Malfunction Criteria and
Threshold Value
P2185 Engine Coolant Temperature ECT outlet > 141C
Sensor 2 Circuit High
P2187 System Too Lean At Idle - Adaptive value > 5.02%
Bank 1
P2188 System Too Rich At Idle - Adaptive value < -5.02%
Bank 1
P2195 O2 Sensor Signal Biased/ Delta lambda of 2nd lambda
Stuck Lean - Bank 1, Sensor 1 control loop > 0.06
P2196 O2 Sensor Signal Biased/ Delta lambda of 2nd lambda

DTC Chart
Stuck Rich - Bank 1, Sensor 1 control loop < -0.06
P2231 O2 Sensor Signal Circuit Delta O2S signal front > 190 uA
Shorted to Heater Circuit -
Bank 1, Sensor 1
P2237 O2 Sensor Positive Current O2S signal front 1.49 - 1.51 V
Control Circuit/Open - Bank 1, Delta lambda controller > 0.10
Sensor 1 OR
O2S signal front < 1.70 V
Fuel cutoff > 3 sec.
P2243 O2 Sensor Reference Voltage O2S signal front < 0.30 V and
Circuit/Open - Bank 1, Internal resistance
Sensor 1 > 1000 Ohms
O2S signal front > 3.25 V and
Internal resistance
> 1000 Ohms
P2251 O2 Sensor Negative Current O2S signal front 1.47 - 1.53 V
Control Circuit/Open - Bank 1, Internal resistance
Sensor 1 > 1000 Ohms
P2270 O2 Sensor Signal Stuck Lean O2S signal rear < 0.603 V
Bank 1, Sensor 2
P2271 O2 Sensor Signal Stuck Rich O2S signal rear > 0.603 V
Bank 1, Sensor 2
P2279 Intake Air System Leak Threshold to detect a defective
system > 1.33 - 1.60
P2293 Fuel Pressure Regulator 2 Difference between target
Performance pressure vs. actual pressure:
> 1.50 MPa
OR
< -1.50 MPa
P2294 Fuel Pressure Regulator 2 Signal voltage 1.40 - 3.20 V
Control Circuit/Open Signal pattern incorrect
P2295 Fuel Pressure Regulator 2 Signal voltage 1.40 - 3.20 V
Control Circuit Low

Audi A3 Quick Reference Specification Book October 2010 121


DTC Error Message Malfunction Criteria and
Threshold Value
P2296 Fuel Pressure Regulator 2 Signal voltage > 3.20 V
Control Circuit High
P2300 Ignition Coil A Primary Control Signal current > 24.0 mA
Circuit Low
P2301 Ignition Coil A Primary Control Signal current > 5.1 - 7.0 mA
Circuit High
P2303 Ignition Coil B Primary Control Signal current > 24.0 mA
Circuit Low
P2304 Ignition Coil B Primary Control Signal current > 5.1 - 7.0 mA
Circuit High
P2306 Ignition Coil C Primary Control Signal current > 24.0 mA
Circuit Low
P2307 Ignition Coil C Primary Control Signal voltage > 5.1 - 7.0 mA
Circuit High
P2309 Ignition Coil D Primary Control Signal current > 24.0 mA
Circuit Low
P2310 Ignition Coil D Primary Control Signal voltage > 5.1 - 7.0 mA
Circuit High
P2400 Evaporative Emission System Signal voltage > 4.4 - 5.6 V
Leak Detection Pump Control
Circuit/Open
P2401 Evaporative Emission System Signal voltage > 2.15 to 3.25 V
Leak Detection Pump Control
Circuit Low
P2402 Evaporative Emission System Signal current > 3 A
Leak Detection Pump Control
Circuit High
P2403 Evaporative Emission System Low signal voltage > 0.5 Sec.
Leak Detection Pump Sense
Circuit/Open
P2404 Evaporative Emission System High signal voltage > 12 Sec.
Leak Detection Pump Sense Number of checks = 30
Circuit Range/Performance Cumulative time of high signal
voltage during pumping
> 10 Sec.
P2414 O2 Sensor Exhaust Sample Threshold 1 - Signal voltage
Error Bank 1, Sensor 1 3.1 - 4.81 V
Threshold 2 - Signal voltage
2.5 to 3.20 V
P2626 O2 Sensor Positive Current O2S signal front > 4.81 V
Trim Circuit/Open Bank 1
Sensor 1

122 Audi A3 Quick Reference Specification Book October 2010


DTC Error Message Malfunction Criteria and
Threshold Value
P3081 Engine Temperature Too Low Difference between ECT and
modeled ECT > 10 K
U0001 High Speed CAN Bus failure
Communication Bus
U0002 High Speed CAN Global time out failure
Communication Bus
Performance
U0101 Lost Communication with TCM Time out failure. No message
received by ECM

DTC Chart
U0121 Lost Communication With CAN communication with ABS
Anti-Lock Brake System time out.
(ABS) Control Module
U0146 Lost Communication With CAN communication with
Gateway A gateway time out
U0155 Lost Communication With No messages received from
Instrument Panel Cluster cluster
(IPC) Control Module
U0302 Software Incompatibility with Manual transmission vehicle,
Transmission Control Module TCM coded as automatic
transmission vehicle
U0402 Invalid Data Received From Implausible message received
TCM from TCM
U0415 Invalid Data Received From Speed sensor initialization
Anti-Lock Brake System failed
(ABS) Control Module Speed sensor low voltage
error failed
Speed sensor error failed
U0422 Invalid Data Received From Ambient temperature value
Body Control Module initialization failure
U0423 Invalid Data Received From Implausible messages
Instrument Panel Cluster received from Instrument Panel
Control Module Cluster (IPC) or Ambient Air
Temperature (AAT) value 00h
U0447 Invalide Data Received From CAN message incorrect
Gateway A

Audi A3 Quick Reference Specification Book October 2010 123


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A3QUICKSPEC0610