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Audi A4 Workshop Service & Repair Manual 2002

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🏷️ Basic Information Identification Make: Audi Model: A4 Year: 2002 Codes Chassis Code: B6 Generation: Third Generation (B6) 👋 Introduction Market Position Segment: Premium Compact Executive Sedan/Wagon Positioning: Positioned as Audi's entry-level luxury vehicle, competing with the BMW 3 Series, Mercedes-Benz C-Class, and Lexus IS. Competitive Analysis Competitors 2002: BMW 3 Series (E46), Mercedes-Benz C-Class (W203), Lexus IS 300, Infiniti G35 (introduced later in the generation). Key Features Design: Clean, sophisticated design with Audi's signature Singleframe grille (introduced on this generation). Drivetrain: Available with front-wheel drive or Audi's renowned Quattro all-wheel drive system. Interior Quality: High-quality interior materials, excellent fit and finish, comfortable seating. Ride And Handling: Balanced ride and handling, comfortable for daily driving, capable on winding roads, especially with Quattro. 📋 Manual Details Coverage Areas Primary Regions: Global (specifications may vary by market) Market Focus: North America, Europe Page Count Estimated Pages: 1500-2500+ (typical for comprehensive workshop manuals) Manual Type Type: Workshop Service & Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, cylinder head, crankshaft, pistons, connecting rods, timing belt/chain, lubrication system, cooling system, fuel injection system, emissions control. Engine Performance: Engine management systems, ignition system, diagnostics, tuning. Transmission Manual: Clutch, gearbox overhaul, gear shift mechanism, troubleshooting. Transmission Automatic: Automatic transmission overhaul (e.g., Tiptronic), torque converter, valve body, electronic control unit, fluid service. Drivetrain: Front-wheel drive axle, Quattro all-wheel drive system, rear differential, driveshafts, CV joints. Suspension: Front suspension (MacPherson struts, control arms), rear suspension (multi-link), shock absorbers, springs, wheel bearings, alignment specifications. Brakes: Brake system components (discs, pads, calipers, master cylinder, ABS modulator), hydraulic lines, parking brake, brake fluid specifications, bleeding procedures. Steering: Power steering system (hydraulic/electro-hydraulic), steering rack, steering column, tie rods, alignment. Electrical System: Battery, charging system (alternator), starter motor, ignition system, lighting system (headlights, taillights, interior), fuses, relays, wiring diagrams. Body And Interior: Body panels, doors, hood, trunk, interior trim, seats, HVAC system, power windows, central locking, sunroof. Climate Control: Air conditioning system (compressor, refrigerant, evaporator, condenser), heater core, climate control unit, diagnostic procedures. Safety Systems: Airbag system (SRS), seatbelt pre-tensioners, ABS, ESP (Electronic Stability Program). Diagnostics And Troubleshooting: OBD-II diagnostics, fault codes, diagnostic procedures for various systems, common problems and solutions. Procedures Included Maintenance: Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid replacement, transmission fluid changes, belt inspections/replacements. Repair: Engine component replacement (e.g., water pump, thermostat, alternator), clutch replacement, brake caliper rebuild, suspension component replacement, body panel repair, headlight/taillight replacement. Diagnostics: Reading and interpreting diagnostic trouble codes (DTCs), using scan tools, performing system tests, troubleshooting electrical issues, fuel system diagnostics. Adjustments: Wheel alignment adjustments, parking brake adjustment, headlamp aiming. Installation: Component installation (e.g., radio, speakers, trailer hitch - if applicable). Technical Depth Depth: Comprehensive, covering routine maintenance, troubleshooting, diagnostics, and complete component overhaul. Suitable for professional technicians and advanced DIYers. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable, allowing quick navigation to specific topics. Printability: Printable, allowing for physical reference. Print Quality Quality: High-resolution scans/digital creation, ensuring clarity of diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1 Code: 1.8T (AWM/AWP) Engine 1 Type: Inline 4-cylinder, turbocharged, 20-valve, DOHC Engine 1 Displacement: 1.8 Liters (1781 cc) Engine 1 Horsepower: 170 hp @ 5900 rpm Engine 1 Torque: 164 lb-ft @ 1950 rpm (with overboost: 177 lb-ft) Engine 1 Bore X Stroke: 81.0 mm x 86.4 mm Engine 1 Compression Ratio: 9.5:1 Engine 2 Engine 2 Code: 2.0 (ALT) Engine 2 Type: Inline 4-cylinder, 20-valve, DOHC Engine 2 Displacement: 2.0 Liters (1984 cc) Engine 2 Horsepower: 130 hp @ 5700 rpm Engine 2 Torque: 131 lb-ft @ 3200 rpm Engine 2 Compression Ratio: 10.5:1 Engine 3 Engine 3 Code: 3.0 V6 (ASN/BBK) Engine 3 Type: V6, 30-valve, DOHC Engine 3 Displacement: 3.0 Liters (2976 cc) Engine 3 Horsepower: 220 hp @ 6300 rpm Engine 3 Torque: 200 lb-ft @ 3200 rpm Engine 3 Bore X Stroke: 82.5 mm x 92.8 mm Engine 3 Compression Ratio: 10.5:1 Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Premium Unleaded Gasoline (91 octane recommended for 1.8T and 3.0 V6) Performance Turbocharger: Garrett GT17 variable geometry turbocharger (VGT) for 1.8T model 🔧 Transmission Standard Transmission 1 Type: 5-speed Manual Transmission Optional Transmission 2 Type: 5-speed Tiptronic Automatic Transmission Features Drivetrain Options: Front-Wheel Drive (FWD) or Quattro All-Wheel Drive (AWD) Fluid Type Manual Transmission Fluid: G 052 171 A2 (or equivalent API GL-4, SAE 75W-90) Automatic Transmission Fluid: G 055 025 A2 (or equivalent ATF, e.g., LifeguardFluid 5) 📐 Dimensions Exterior Wheelbase: 104.4 inches (2652 mm) Length: 184.1 inches (4676 mm) Width: 69.9 inches (1775 mm) Height: 57.0 inches (1448 mm) Weights Curb Weight Min: 3219 lbs (1460 kg) (1.8T FWD...
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Tag: 2002 A4 Audi Car
Audi A4 Workshop Service & Repair Manual 2002
🏷️ Basic Information
Identification
Make:
Audi
Model:
A4
Year:
2002
Codes
Chassis Code:
B6
Generation:
Third Generation (B6)
👋 Introduction
Market Position
Segment:
Premium Compact Executive Sedan/Wagon
Positioning:
Positioned as Audi's entry-level luxury vehicle, competing with the BMW 3 Series, Mercedes-Benz C-Class, and Lexus IS.
Competitive Analysis
Competitors 2002:
BMW 3 Series (E46), Mercedes-Benz C-Class (W203), Lexus IS 300, Infiniti G35 (introduced later in the generation).
Key Features
Design:
Clean, sophisticated design with Audi's signature Singleframe grille (introduced on this generation).
Drivetrain:
Available with front-wheel drive or Audi's renowned Quattro all-wheel drive system.
Interior Quality:
High-quality interior materials, excellent fit and finish, comfortable seating.
Ride And Handling:
Balanced ride and handling, comfortable for daily driving, capable on winding roads, especially with Quattro.
📋 Manual Details
Coverage Areas
Primary Regions:
Global (specifications may vary by market)
Market Focus:
North America, Europe
Page Count
Estimated Pages:
1500-2500+ (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Service & Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine removal/installation, cylinder head, crankshaft, pistons, connecting rods, timing belt/chain, lubrication system, cooling system, fuel injection system, emissions control.
Engine Performance:
Engine management systems, ignition system, diagnostics, tuning.
Transmission Manual:
Clutch, gearbox overhaul, gear shift mechanism, troubleshooting.
Transmission Automatic:
Automatic transmission overhaul (e.g., Tiptronic), torque converter, valve body, electronic control unit, fluid service.
Drivetrain:
Front-wheel drive axle, Quattro all-wheel drive system, rear differential, driveshafts, CV joints.
Suspension:
Front suspension (MacPherson struts, control arms), rear suspension (multi-link), shock absorbers, springs, wheel bearings, alignment specifications.
Brakes:
Brake system components (discs, pads, calipers, master cylinder, ABS modulator), hydraulic lines, parking brake, brake fluid specifications, bleeding procedures.
Steering:
Power steering system (hydraulic/electro-hydraulic), steering rack, steering column, tie rods, alignment.
Electrical System:
Battery, charging system (alternator), starter motor, ignition system, lighting system (headlights, taillights, interior), fuses, relays, wiring diagrams.
Body And Interior:
Body panels, doors, hood, trunk, interior trim, seats, HVAC system, power windows, central locking, sunroof.
Climate Control:
Air conditioning system (compressor, refrigerant, evaporator, condenser), heater core, climate control unit, diagnostic procedures.
Safety Systems:
Airbag system (SRS), seatbelt pre-tensioners, ABS, ESP (Electronic Stability Program).
Diagnostics And Troubleshooting:
OBD-II diagnostics, fault codes, diagnostic procedures for various systems, common problems and solutions.
Procedures Included
Maintenance:
Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid replacement, transmission fluid changes, belt inspections/replacements.
Repair:
Engine component replacement (e.g., water pump, thermostat, alternator), clutch replacement, brake caliper rebuild, suspension component replacement, body panel repair, headlight/taillight replacement.
Diagnostics:
Reading and interpreting diagnostic trouble codes (DTCs), using scan tools, performing system tests, troubleshooting electrical issues, fuel system diagnostics.
Adjustments:
Wheel alignment adjustments, parking brake adjustment, headlamp aiming.
Installation:
Component installation (e.g., radio, speakers, trailer hitch - if applicable).
Technical Depth
Depth:
Comprehensive, covering routine maintenance, troubleshooting, diagnostics, and complete component overhaul. Suitable for professional technicians and advanced DIYers.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable, allowing quick navigation to specific topics.
Printability:
Printable, allowing for physical reference.
Print Quality
Quality:
High-resolution scans/digital creation, ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1 Code:
1.8T (AWM/AWP)
Engine 1 Type:
Inline 4-cylinder, turbocharged, 20-valve, DOHC
Engine 1 Displacement:
1.8 Liters (1781 cc)
Engine 1 Horsepower:
170 hp @ 5900 rpm
Engine 1 Torque:
164 lb-ft @ 1950 rpm (with overboost: 177 lb-ft)
Engine 1 Bore X Stroke:
81.0 mm x 86.4 mm
Engine 1 Compression Ratio:
9.5:1
Engine 2
Engine 2 Code:
2.0 (ALT)
Engine 2 Type:
Inline 4-cylinder, 20-valve, DOHC
Engine 2 Displacement:
2.0 Liters (1984 cc)
Engine 2 Horsepower:
130 hp @ 5700 rpm
Engine 2 Torque:
131 lb-ft @ 3200 rpm
Engine 2 Compression Ratio:
10.5:1
Engine 3
Engine 3 Code:
3.0 V6 (ASN/BBK)
Engine 3 Type:
V6, 30-valve, DOHC
Engine 3 Displacement:
3.0 Liters (2976 cc)
Engine 3 Horsepower:
220 hp @ 6300 rpm
Engine 3 Torque:
200 lb-ft @ 3200 rpm
Engine 3 Bore X Stroke:
82.5 mm x 92.8 mm
Engine 3 Compression Ratio:
10.5:1
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Premium Unleaded Gasoline (91 octane recommended for 1.8T and 3.0 V6)
Performance
Turbocharger:
Garrett GT17 variable geometry turbocharger (VGT) for 1.8T model
🔧 Transmission
Standard
Transmission 1 Type:
5-speed Manual Transmission
Optional
Transmission 2 Type:
5-speed Tiptronic Automatic Transmission
Features
Drivetrain Options:
Front-Wheel Drive (FWD) or Quattro All-Wheel Drive (AWD)
Fluid Type
Manual Transmission Fluid:
G 052 171 A2 (or equivalent API GL-4, SAE 75W-90)
Automatic Transmission Fluid:
G 055 025 A2 (or equivalent ATF, e.g., LifeguardFluid 5)
📐 Dimensions
Exterior
Wheelbase:
104.4 inches (2652 mm)
Length:
184.1 inches (4676 mm)
Width:
69.9 inches (1775 mm)
Height:
57.0 inches (1448 mm)
Weights
Curb Weight Min:
3219 lbs (1460 kg) (1.8T FWD Manual)
Curb Weight Max:
3638 lbs (1650 kg) (3.0 V6 Quattro Auto)
Cargo
Trunk Volume:
15.1 cubic feet (428 liters)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
4/5 Stars (Driver/Passenger)
IIHS Side Impact:
Good
Active Features
ABS:
Standard Anti-lock Braking System
Esp:
Optional Electronic Stability Program (ESP) or standard on higher trims/Quattro models
Traction Control:
Standard Traction Control (ASR)
Passive Features
Airbags:
Driver and front passenger airbags, front side airbags, available rear side airbags and full-length side curtain airbags.
Seatbelts:
3-point front seatbelts with pre-tensioners and load limiters, 3-point rear seatbelts.
💡 Technology Features
Infotainment
Audio System:
Standard Audi Symphony or optional Bose sound system. Audi Navigation Plus system available.
Climate Control:
Manual or optional Automatic Climate Control (Climatronic).
Driver Assistance
Cruise Control:
Standard on most models.
Connectivity
Phone Integration:
Optional Bluetooth preparation (Audi Music Interface not available on this generation).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 1 year, whichever comes first. Consult manual for exact intervals based on driving conditions.
Timing Belt Replacement:
For the 1.8T and 2.0 engines: Check manufacturer recommendations, typically around 70,000-90,000 miles (110,000-145,000 km). V6 engine uses a timing chain.
Fluid Specifications
Engine Oil Viscosity:
SAE 5W-40 or 5W-30 (e.g., VW 502.00/505.00 specification)
Coolant Type:
G 12 Plus (or equivalent G12/G12+ compatible coolant)
Brake Fluid Type:
DOT 4 (e.g., G 000 000 M2)
Known Issues
Ignition Coils:
Failure of ignition coils is common on the 1.8T engine, leading to misfires.
Oil Leaks:
Leaking valve cover gaskets and oil cooler seals are known issues.
E46 Alternator Bracket:
Failure of the alternator bracket on the 1.8T engine can lead to significant damage.
E46 ABS Sensor:
ABS wheel speed sensors can fail, triggering ABS and ESP warning lights.
E46 Coolant Flange:
Plastic coolant flange can become brittle and leak.
📚 Vehicle History
Brand Heritage
Brand Origin:
Germany, founded 1910 (as Auto Union AG).
Model Evolution
Model Introduction:
The A4 nameplate was introduced in 1994, replacing the Audi 80/90. The 2002 model represents the introduction of the second generation (B6) platform.
Generation B6 Timeline:
Introduced for the 2002 model year, produced until 2008 (with a facelift for 2005.5 model year).
Production
Manufacturing Locations:
Ingolstadt, Germany; Brussels, Belgium.
🏆 Awards & Recognition
Recognitions
Car And Driver Alist:
Car and Driver's 10Best Cars list multiple times for previous generations, often highly praised for its blend of luxury, performance, and Quattro.
Ward S 10Best:
Engines in the A4 (especially the 1.8T and V6 variants) have received Ward's 10Best Engines awards in prior years.
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