Audi A4 1997 2001 User Manual
Page 1 of 7Central locking system (Avant), repairin
g
57-50
Central locking system (Ava nt),
repairing
Assembly overview
1 - Pressure and vacuum lines
2 - Right-front door actuator valve
Removing and installing page 57-12
3 - Vacuum line connectors
Disconnect vacuum line connectors
page 57-42
4 - Right-rear door actuator valve
Removing and installing page 58-14
5 - Fuel filling flap lock actuator
Removing and installing page 57-52
6 - Central locking system pump
Removing and installing page 57-56
7 - Rear lid lock actuator
Removing and installing page 57-53
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Page 2 of 7Central locking system (Avant), repairin
g
57-51
8 - Left-rear door actuator valve
Removing and installing same as for right
door
9 - Left-front door lock actuator
Removing and installing same as for right
door
10 - Distribution box
Connected with all other vac uum lines,
excluding lines for rear lid
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Page 3 of 7Central locking system (Avant), repairin
g
57-52
Fuel filling flap lock actuator, removing
and installing
- Disengage locking mechanism from angled plug and detach vacuum
line -2- from lock actuator -1-.
- To remove, press in locking lug (arrow) and pull lock actuator -1rearward and out.
- To install, push into case until snap indicates engagement.
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Page 4 of 7Central locking system (Avant), repairin
g
57-53
Rear lid lock actuator, removing and
installing
- Remove tailgate trim page 57-54 .
- Disengage lock system at plug for vacuum line -1- and remove from
lock actuator -2-.
- Press clamping pins (arrow) out and remove lock actuator -1- from lock
-2-.
- Clamping pins mu st be snapped back into expandi ng clips during
installation.
- Pry out using screwdriver if necessary.
Note:
Illustration shows component after removal.
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Page 5 of 7Central locking system (Avant), repairin
g
57-54
Fig. 1 Removing and installing tailgate trim
- Remove bolt -1-fro m han dl e well.
Torque: 1.5 Nm + 0.5 Nm (13 in. lb + 4 in. lb)
- Unclip lower rear hatch trim -2-.
- Unclip upper rear hatch trim -3-.
Note:
When installing the lower trim, guide bars must be inserted in upper trim.
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Page 6 of 7Central locking system (Avant), repairin
g
57-55
Fig. 2 Line routing
- Route pressure and vacuum lines through tie wraps -4- as shown in
diagram and snap into clips -3-.
- Snap harness connector -2- into lock actuator.
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Page 7 of 7Central locking system (Avant), repairin
g
57-56
Central locking system pump, removing
and installing
- Remove cover on side trim panel.
- Unhook tension strap -1- at arrow -A-.
- Remove insulation -4- with pump for central locking system -2- from
side panel.
- Fold back insulation and remove pump.
- Disengage vacuum line connectors and detach angled plug (arrow B-).
CAUTION!
After disconnecting all three vacuum line connectors from the
central locking system pump, ensure that the middle 6-pin harness
connector (power supply) is always plugged in last.
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Page 1 of 11Central locking system
57-39
Central locking system
Assembly overview
1 - Vacuum line
2 - Right-front door lock actuator
Removing and installing page 57-12
3 - Vacuum line connectors
Disengage harness connectors page 57-
42
Additional vacuum line connectors are
located at bottom of A-pillar and in boot at
B-pillar
4 - Right-rear door lock actuator
Removing and installing page 58-14
5 - Fuel filler flap lock actuator
Removing and installing page 57-46
6 - Central locking system pump
Removing and installing page 57-49
7 - Distribution box
Connected with all other wires excluding
wire for rear lid
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Page 2 of 11Central locking system
57-40
8 - Left-front door lock actuator
Removing and installing same as for right
door
9 - Rear lid lock actuator
Removing and installing page 57-47
10 - Left-rear door lock actuator
Removing and installing same as for right
door
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Page 3 of 11Central locking system
57-41
Repairing central locking system
For additional information Electrical Wiring
Diagrams, Troubleshooting & Component
Locations binder.
Notes:
After the car has been parked for a lengthy time
and/or after replacing the central locking system
pump, the central locking system will not
function properly until prompted repeatedly.
When the system is operating correctly, all
locks will close within 2 seconds.
If the pump operates for longer than 5 seconds,
there is a leak in the system.
When there is a leak in the system, the pump
must not run for more than 30 seconds. The
pump's control unit must shut it off at this point.
All the lock actuators are equipped with special
vacuum line connectors that must lock when
plugged in.
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Page 4 of 11Central locking system
57-42
Vacuum line connectors, disengaging
Note:
Do not simply pull on the lock actuators to
disconnect; the locking mechani sm in stall ed on
the harness connector must first be disengaged.
- To disengage lock, squeeze harness connector on locking mechanism
at arrows.
- Disconnect harness connector.
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Page 5 of 11Central locking system
57-43
Damaged vacuum line, repairing
- Remove damaged area using knife.
- Cut connecting line e.g. ET-Nr 533 862 225 to
proper length and push onto vacuum line.
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Page 6 of 11Central locking system
57-44
A-pillar vacuum line connector
- After removing lower A-pillar cover, vacuum line connector -2becomes accessible at bottom of A-pillar.
1 - Boot
3 - Line to distribution box
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Page 7 of 11Central locking system
57-45
B-pillar vacuum line connector
- Assemble seal -1- with cable slot at bottom.
- After removing boot -2-, vacuum line connector -3- can be removed by
disengaging locking mechanism from line -5-.
Note:
The 45 plug (arrow) must point toward front of vehicle.
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Page 8 of 11Central locking system
57-46
Lock actuator for fuel filling flap,
removing and installing
- Disengage locking mechanism from angled plug and detach vacuum
line -2-.
- To remove, press in locking lug arrow and pull lock actuator -1rearward and out.
3 - Vacuum line to the pump for central locking system
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Page 9 of 11Central locking system
57-47
Rear lid lock actuator, removing and
installing
Removing
- Separate harness connector and detach vacuum line.
- Disengage operating rod -4- from clip -3-.
- Remove hex nuts -6- and remove lock actuator -7- from rear lid lock.
- Push out retaining pin -3- (2x) remove expanding clip.
- Push clip -4- back and disconnect.
- Remove lock actuator -1- from rear lid lock.
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Page 10 of 11Central locking system
57-48
Installing
- Set lock cylinders in "open" position.
- Push ridged plate -1- to left. The first ridge of the plate -1- must snap
into the first groove on the grooved segment -2- .
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Page 11 of 11Central locking system
57-49
The pump for the central locking system is
Central locking system pump, removing
and installing
located in the right-rear of the luggage
compartment under the luggage compartment
trim.
- Fold back luggage compartment trim and remove insulation -3- with
pump for central locking system -1-.
- Disengage connecting line -2-.
- Open insulation, disengage electrical harness connectors and remove
connector -2- for vacuum line.
CAUTION!
After disconnecting all three connectors from the central locking
system pump, ensure that the middle 6-pin connector (for power
supply) is always plugged in last.
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Page 1 of 4Door mirrors
66-14
Door mirrors
Door mirrors, removing and installing
1 - Mirror housing
Can be removed from door without
removing mirror comp letely page 66-16
2 - Mirror adjustor
Before removing, remove mirror from door
- To remove, pry off mirror glass,
disconnect harness connectors for mirror
Note:
On vehicles with seat memory, door trim must be
removed before removing mirror adjustor.
3 - Door component carrier
heating, remove phillips head screws -6and take mirror adjustor -1- out of mirror
housing.
4 - Socket head screw
12 Nm (9 ft lb)
5 - Seal
Check for correct fit during installation.
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Page 2 of 4Door mirrors
66-15
6 - Phillips head screw
1 Nm (9 in. lb)
7 - Mirror glass
- To remove, use s pecial tool 80-200
(assembly lever).
Use fabric reinforced adhesive tape at top
and bottom to protect mirror housing from
paint damage
- Pry mirror out at bottom first, then top.
- To install, first insert mirror lens into
guide stud and friction finger in friction
spring, then press on.
Apply pressu re only to center of lens;
always wear protective gloves
8 - Friction finger
Friction finger -8- must be pushed into
friction spring -9- whe n in serting mirror
glass in housing
9 - Friction spring
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Page 3 of 4Door mirrors
66-16
Door mirror housing, replacing
- Remove mirror glass.
- Remove screws -4- (2x).
- Press back retainers -2- and take off cover -3- downward.
- Remove screws -1- at mirror adjusting unit (3x).
- Lift up housing -5- and remove.
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Page 4 of 4Door mirrors
66-17
Power mirror adjuster, replacing
- Disconnect battery.
- Remove mirror glass.
- Remove screws -1- (3x)
Tightening torque: 1 Nm (9 in. lb)
- For mirror adjusting units with harness connectors, these should be
removed before disassembl y.
Note:
For mirror adjusting units with soldered wires, these should be separated
individually directly at the housing.
- Install wiring into connector housing enclosed with replacement unit.
Note:
Transfer wire routing from old power mirror adjuster using correct wiring
diagram.
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Page 1 of 8Rear bumper (Avant
)
63-16
Rear bumper (Avant)
Rear bumper, removing, installing and
assembly overview ( VIN 8D XA 200 000)
1 - Metal bolt
2 - Bracket
3 - Clip
4 - Spoiler
- To remove, remove metal bolts -1- and
take off bracket.
Removing and installing page 63-10
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Page 2 of 8Rear bumper (Avant
)
63-17
5 - Bumper
- Before removing, remove rear panel trim.
Repair Manual, Body-Interior, Repair Group 70
- Remove tailgate seal in area of loading
edge/side pan els.
- Fold luggage compartment cover
forward.
- Remove tie-downs left an d right at side
trim and unclip rear side trim.
Repair Manual, Body-Interior, Repair Group 70
- Carefully pull side trim at left and right
towards vehicle interior.
- Remove combination bolts -9-.
- Unclip bumper from bracket -2- in
direction of arrow and pull off towards
rear.
6 - Bracket
Removing from bumper page 63-19
7 - Cover strip
Removing page 63-19
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Page 3 of 8Rear bumper (Avant
)
63-18
8 - Support
9 - Combination bolt
10 - Console
- To remove, heat body with heat gun to
approx. 40 C (104 F) and pull off
support.
- To attach, heat body in adhesion area
with hot air injector to approx. 40 C
(104 F).
Adhesion surface must be free of dust and
grease
- Pull off protective foil and press on
support using special tool 3356
(application roller).
23 Nm (17 ft lb)
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Page 4 of 8Rear bumper (Avant
)
63-19
Bumper cover strip, removing
- Remove bumper page 63-1 .
- Release locking mechanism and unclip cover strip -3- from bumper -2-.
Removing bracket from bumper
- Remove bolts (arrows) and take bracket -1- out of bumper -2-.
Tightening torque: 23 Nm (17 ft lb)
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Page 5 of 8Rear bumper (Avant
)
63-20
Rear bumper, removing and installing (VIN
8D XA 200 001 )
1 - Bumper
Before removing, remove rear panel trim.
Repair Manual, Body-Exterior, Repair Group 70,
trim pieces.
Remove rear lid seal around loading edge
and sides.
Fold luggage compartment cover forward.
Remove tie-downs left and right at side trim
and unclip rear side trim.
Repair Manual, Body-Exterior, Repair Group 70,
trim pieces.
Carefully pull side trim at left and right
toward vehicle interior.
Remove screw w/washer assembly -6-.
Unclip bumper from bracket -4- and
remove toward rear.
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Page 6 of 8Rear bumper (Avant
)
63-21
2 - Spoiler
Removing and installing page 63-10 .
3 - Clip
4 - Bracket
To remove, remove metal bo lts -5- and
remove bracket -2-.
5 - Metal bolt
6 - Screw w/washer assembly
23 Nm
7 - Bracket
Removing from bumper page 63-22 .
8 - Cover strip
Removing page 63-22 .
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Page 7 of 8Rear bumper (Avant
)
63-22
Bumper cover strip, removing
- Remove rear bumper page 63-20 .
- Release locking mechanism and unclip cover strip -3- from bumper -2-.
- for removing impact absorber.
Fig. 1 Removing bracket from bumper
- Remove bolts (arrows) and take bracket -1- out of bumper -2-.
- Installation tightening torque 23 Nm.
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Page 8 of 8Rear bumper (Avant
)
63-23
Bracket for rear bumper, removing and
installing
1 - Bracket for rear bumper
The bracket has two parts. The front half
can be shifted to adjust the length.
2 - Combination bolts
1.5 Nm.
Tighten bolts in sequence -a-, -b-, -c- then -
d-.
3 - Metal bolt
1.5 Nm.
4 - Wheelhousing liner, rear
5 - Rear bumper
Removing and installing page 63-20 .
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