Audi A8 2018 – 2020 Complete Service Repair Workshop Manual
SCREENSHOTS FROM THE MANUAL
VIDEO PREVIEW OF THE MANUAL:
DESCRIPTION:
00-General Information:
This is the General Information Section of the 2018-2020 Audi A8 Factory Service Manual.
01-Engine Mechanical:
This is the Engine Mechanical Section of the 2018-2020 Audi A8 Factory Service Manual.
02-Engine Servicing:
This is the Engine Servicing Section of the 2018-2020 Audi A8 Factory Service Manual.
03-Fuel Supply System:
This is the Fuel Supply System Section of the 2018-2020 Audi A8 Factory Service Manual.
04-Transmissions:
This is the Transmissions Section of the 2018-2020 Audi A8 Factory Service Manual.
05-Axles, Steering & Suspension:
This is the Axles, Suspension & Steering Section of the 2018-2020 Audi A8 Factory Service Manual.
06-Brake System:
This is the Brake System Section of the 2018-2020 Audi A8 Factory Service Manual.
07-HVAC:
This is the Heating & Air Conditioning Section of the 2018-2020 Audi A8 Factory Service Manual.
08-Communications, Audio:
This is the Communication-Audio Section of the 2018-2020 Audi A8 Factory Service Manual.
09-Electrical System:
This is the Electrical System Section of the 2018-2020 Audi A8 Factory Service Manual.
10-Body Repairs:
This is the Body Repairs Section of the 2018-2020 Audi A8 Factory Service Manual.
11-Audi A8 FSM 2018-20 Complete:
This is the complete 2018-2020 Audi A8 Factory Service Manual. It contains 9,247 pages of service information.
COMPREHENSIVE TABLE OF CONTENTS:
Contents
1 General information 1
11 — Change history — 1
12 Engine number 1
13 Vehicle identification number 2
14 Vehicle data sticker 3
15 Warnings for high-voltage vehicles 4
2 Preparations 9
21 Vehicle: raising 9
22 Engine cover panel: removing and installing 11
23 Noise insulation: removing and installing12
24 Window regulators: activating automatic open/close function 13
25 Vehicle diagnostic tester: connecting 14
3 Maintenance 16
31 Diesel particulate filter: reading out ash deposit volume19
32 Protective display films: removing if present 20
33 Event memory: reading out 20
34 Service interval display: resetting service event 21
35 Diagnostic work: performing 21
36 Emergency battery: reading out status 22
37 Battery: checking electrolyte level22
38 CO2 air conditioning system: inspecting protective film for pressure limiting valve 24
39 Air quality package: renewing fragrance vials 25
310 Brake pads: checking thickness 26
311 Tyres: checking condition and wear pattern, and checking and recording tread depth 26
312 Tyres: checking tyre pressures and adjusting if necessary 28
313 Tyres (except spare wheel): checking tyre pressures and adjusting to 35 bar if necessary
29
314 Swerve assist and turn-off assist: activating in MMI 29
315 Tyre Pressure Loss Indicator: storing changed tyre pressures 30
316 Tyre repair kit: checking that set is complete, and checking and recording expiry date30
317 Wheel bolts: tightening to specified torque31
318 Axles (front and rear): checking components for play, secure attachment and damage, and
checking protective boots31
319 Engine, gearbox, final drive and steering: checking for leaks and damage 34
320 Vehicle (from below): checking for damage 34
321 Underbody: checking trim, wheel housing liners, side members and pipes/wiring for damage,
and checking that they are properly secured 34
322 Roof insert for panorama sunroof: checking operation 35
323 Door hinges with separate door arrester: cleaning and lubricating 35
324 Windscreen/rear window washer system: checking spray pattern and adjusting if
necessary36
325 Wiper blades: checking for damage 38
326 Headlight washer system: checking operation 39
327 Headlights: checking for correct adjustment 39
328 Headlights and reversing lights, side lights, number plate lights, turn signals, hazard warning
lights: checking operation41
329 Luggage compartment lighting: checking operation 42
330 Glove box light, interior lighting and reading light: checking operation 42
331 Horn: checking operation43
332 Wi-Fi hotspot: activating in MMI 43
333 Seat belts: checking fixing device for latch plate, and checking locking action of automatic
belt retractor 43
334 Vehicle interior: removing protective covers for seats and carpet44
335 Vehicle interior: checking that it is clean and cleaning if necessary 44
336 Vehicle interior: removing any objects other than those protecting interior surfaces 44
Audi A8 2018 ➤
Maintenance – Edition 102019
Contents i
337 Vehicle interior and exterior: checking for and documenting any damage44
338 Instrument cluster: checking warning lamps 44
339 Warning triangle: checking availability 45
340 Seal on coolant expansion tank for high-voltage system: checking seal is present 45
341 First-aid kit: checking and recording expiry date45
342 Plenum chamber and water drains: checking for dirt and cleaning if necessary45
343 Connectivity box: checking emergency battery 46
344 Brake fluid: changing 47
345 Engine oil: draining52
346 Engine oil: extracting 53
347 Engine oil: renewing oil filter 54
348 Engine oil: filling up 56
349 Engine oil: checking oil level and correcting if necessary57
350 Spark plugs: renewing 58
351 Coolant level: checking (coolant level must reach at least top marking on coolant expansion
tank) 66
352 Cooling system for high-voltage system: checking anti-freeze protection and coolant level,
and correcting if necessary 69
353 Air cleaner: renewing filter element and cleaning housing 73
354 Dust and pollen filter: renewing 76
355 Water separator (fuel filter): draining 77
356 Fuel filter: renewing 78
357 Filter (water separator): renewing79
358 Fuel tank: adding fuel additive 81
359 Reducing agent (AdBlue®): filling up tank completely 82
360 Vehicle doors: removing edge protection86
361 Vehicle exterior: checking unprotected areas for dirt, and cleaning if necessary86
362 Vehicle exterior: removing protective film86
363 Vehicle cover: checking position and correcting if necessary 87
364 Vehicle cover: removing according to manufacturer’s instructions 87
365 Paintwork, trims, side windows and wiper blades: checking cleanliness87
366 Body: checking vehicle paintwork for damage and corrosion from below and with bonnet, rear
lid and doors open87
367 Brake discs: checking for surface rust and operating brakes to clean if necessary 87
368 Parking brake: releasing 88
369 Static event memory: working through 88
370 Transport mode: deactivating 88
371 Transport mode: checking activation and activating if necessary89
372 Shipping mode: deactivating 90
373 Battery: reading out status90
374 Connecting vehicle diagnostic tester and sending diagnostic log91
375 Battery: connecting stationary battery charging unit (min 30A, charging voltage max 148 V
on IV characteristic curve)91
376 Battery: determining and recording state of charge (SOC) 93
377 Mirror hanger indicating defective battery: renewing battery on affected vehicles95
378 Brake fluid (vehicles older than 12 months): changing 95
379 Brake fluid: checking fluid level 95
380 Brake system: checking condition of brake hoses, and checking that caps are fitted on bleeder
screws 96
381 Data sheet for Radio Equipment Directive: printing and placing in glove compartment 96
382 Suspension struts on front and rear axle: removing locking elements and correctly fitting
bump stops97
383 ERA-GLONASS: checking emergency call function 99
384 Vehicles parked outdoors: locking100
385 Poly V-belt for ancillaries: renewing 100
386 Emergency call function: checking status LED 100
387 Road test100
Audi A8 2018 ➤
Maintenance – Edition 102019
ii Contents
388 Stock vehicles: observing measures specified in Maintenance table for stock vehicles (see
“Before handing vehicle over to customer”) 101
389 Mode 3 charging cable: checking that cable is present and complete 101
390 Charging system: checking that system is present and complete101
391 Charging socket: checking for dirt and damage 102
392 Accessories: installing 102
393 Checklist “Documentation of cleaning and care routine”: checking that list is present 102
394 “Stock vehicle maintenance” checklist: signing and placing in vehicle wallet 103
395 Cleaning and care: checking that required measures have been carried out on time 103
396 Stock vehicle care management: deciding and recording date of next check 103
397 Display instruments: setting time and date103
398 Automatic gearbox: engaging “park” 103
399 Interior mirror: calibrating compass 103
3100 Instrument cluster: resetting driver information system 104
3101 Vehicle keys: checking operation and recording number of keys given to customer 104
3102 Luggage compartment: removing protective film and felt pieces104
3103 Owner’s literature: checking that all documents are present 104
3104 Passenger airbag: checking key switch on/off and setting to “on”104
3105 Service wallet: affixing vehicle data sticker 105
3106 Service Schedule: entering Delivery Inspection 105
3107 Vehicle key: removing from ignition lock105
3108 Vehicle key(s), wheel covers and owner’s literature: checking availability and recording
number present 106
3109 Sun visors: checking that they are folded up and folding up if necessary106
3110 Luggage compartment cover and sun blind: checking that they are rolled up and rolling up if
necessary106
4 Exhaust emissions test 107
41 Petrol engines: performing exhaust emissions test 107
42 Diesel engines: performing exhaust emissions test 114
Audi A8 2018 ➤
Maintenance – Edition 102019
Contents
00 – Technical data 1
1 Identification 1
2 Safety precautions2
21 Safety precautions when working on the high-voltage system 2
22 Safety precautions when working in the vicinity of high-voltage components 3
23 Safety precautions for all vehicles3
3 Repair instructions4
31 Rules for cleanliness when working on the high-voltage battery4
32 Painting work on vehicles with high-voltage system 4
33 Repair instructions for all vehicles4
4 Assessing high-voltage system risk level5
41 Necessary qualifications 5
42 Work that requires high-voltage system to be de-energised 5
10 – Removing and installing engine8
1 Safety precautions8
2 Removing and installing engine 9
21 Removing engine9
22 Separating engine and gearbox 50
23 Removing engine from scissor-type assembly platform 56
24 Securing engine to engine and gearbox support58
25 Installing engine 60
3 Assembly mountings 67
31 Exploded view – assembly mountings 67
32 Supporting engine in installation position70
33 Removing and installing engine mountings 72
34 Removing and installing power unit mounting senders 76
35 Calibrating electrohydraulic engine mounting 77
36 Removing and installing gearbox mountings 77
4 Engine cover panel81
13 – Crankshaft group82
1 Safety precautions82
2 Cylinder block (pulley end)83
21 Exploded view – cylinder block (pulley end) 83
22 Exploded view – sealing flange (pulley end) 83
23 Removing and installing poly V-belts 83
24 Removing and installing tensioner for poly V-belt83
25 Removing and installing vibration damper83
26 Removing and installing bracket for ancillaries 84
27 Removing and installing engine support84
28 Renewing crankshaft oil seal (pulley end)85
29 Removing and installing sealing flange (pulley end) 85
3 Cylinder block (gearbox end) 86
4 Crankshaft87
5 Balance shaft 88
6 Pistons and conrods 89
15 – Cylinder head, valve gear 90
1 Safety precautions90
2 Timing chain cover91
Audi A8 2018 ➤
6-cylinder direct injection engine (30 ltr 4-valve TFSI EA839) – Edition 072019
Contents i
3 Chain drive92
31 Exploded view – camshaft timing chains92
32 Exploded view – drive chain for oil pump92
33 Removing camshaft timing chain from camshafts92
34 Removing and installing camshaft timing chain 93
4 Cylinder head 94
41 Exploded view – cylinder head 94
42 Exploded view – camshaft housing94
43 Removing and installing cylinder head 94
44 Removing and installing camshaft housing 94
45 Checking compression 95
5 Valve gear96
51 Exploded view – valve gear 96
52 Measuring axial clearance of camshaft 96
53 Measuring radial clearance of camshaft 96
54 Removing and installing camshaft96
55 Removing and installing cam actuators 96
56 Removing and installing camshaft control valve 1 N20597
57 Removing and installing valve stem oil seals 97
17 – Lubrication 98
1 Safety precautions98
2 Sump/oil pump 99
21 Exploded view – sump/oil pump 99
22 Engine oil99
23 Removing and installing sump (bottom section) 99
24 Removing and installing sump (top section) 99
25 Removing and installing oil baffle plate 99
26 Removing and installing oil pump99
27 Removing and installing oil level and oil temperature sender G266 99
3 Engine oil cooler 100
31 Exploded view – engine oil cooler100
32 Removing and installing engine oil cooler100
33 Removing and installing spray nozzle valve 100
4 Crankcase breather 101
5 Oil filter/oil pressure switches 102
51 Exploded view – oil filter 102
52 Exploded view – oil pressure switches/oil pressure control 102
53 Removing and installing oil filter housing102
54 Removing and installing oil pressure switch F22103
55 Removing and installing oil temperature sender G8 103
56 Removing and installing oil pressure sender G10103
57 Checking oil pressure 103
58 Removing and installing valve for oil pressure control N428 104
19 – Cooling 105
1 Safety precautions105
2 Cooling system/coolant 106
21 Connection diagram – coolant hoses 106
22 Checking cooling system for leaks113
23 Draining and filling cooling system117
3 Coolant pump/thermostat assembly 133
31 Exploded view – coolant pump/thermostat133
32 Exploded view – electric coolant pump 133
Audi A8 2018 ➤
6-cylinder direct injection engine (30 ltr 4-valve TFSI EA839) – Edition 072019
ii Contents
33 Exploded view – coolant temperature senders 136
34 Exploded view – coolant valves 140
35 Removing and installing electric coolant pump 142
36 Removing and installing coolant pump 152
37 Removing and installing map-controlled engine cooling system thermostat F265 152
38 Removing and installing coolant temperature sender G62 152
39 Removing and installing engine outlet coolant temperature sender G82152
310 Removing and installing radiator outlet coolant temperature sender G83 152
311 Removing and installing temperature sender for engine temperature regulation G694153
312 Removing and installing coolant temperature sender for high-voltage system 154
313 Removing and installing coolant valves 163
4 Coolant pipes 171
41 Exploded view – coolant pipes 171
42 Removing and installing coolant pipes 176
5 Radiator/radiator fans 197
51 Exploded view – radiator/radiator fans 197
52 Exploded view – radiator cowl and radiator fans 201
53 Removing and installing radiator201
54 Removing and installing radiator cowl 204
55 Removing and installing radiator fan V7205
56 Removing and installing radiator for high-voltage coolant circuit206
21 – Turbocharging/supercharging 209
1 Safety precautions209
2 Turbochargers 210
21 Exploded view – turbocharger 210
22 Removing and installing turbocharger 210
23 Renewing vacuum unit for turbocharger211
24 Removing and installing temperature sender for engine cover panel G765 211
3 Charge air system212
31 Exploded view – charge air system212
32 Exploded view – hose connections for charge air system213
33 Removing and installing air pipe213
34 Removing and installing charge air cooler214
35 Removing and installing charge pressure sender G31 215
36 Removing and installing overrun air recirculation valve 216
37 Checking charge air system for leaks 216
24 – Mixture preparation – injection 218
1 Safety precautions218
2 Injection system 219
21 Overview of fitting locations – injection system 219
22 Checking fuel system for leaks 229
3 Vacuum system 230
4 Air cleaner231
41 Exploded view – air cleaner housing 231
42 Removing and installing air cleaner housing 232
5 Intake manifold 233
51 Exploded view – intake manifold 233
52 Removing and installing intake manifold233
53 Removing and installing throttle valve module J338 234
6 Injectors 235
7 Senders and sensors 236
71 Exploded view – pressure differential sender, vehicles with particulate filter 236
Audi A8 2018 ➤
6-cylinder direct injection engine (30 ltr 4-valve TFSI EA839) – Edition 072019
Contents iii
72 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
G71 236
73 Removing and installing fuel pressure sender G247 236
74 Removing and installing fuel pressure sender for low pressure G410 236
75 Removing and installing pressure differential sender for particulate filter G1037 – vehicles
with particulate filter 237
8 High-pressure pump 238
81 Exploded view – high-pressure pump 238
82 Removing and installing high-pressure pump 238
83 Removing and installing high-pressure pipe 238
9 Lambda probe 240
91 Exploded view – Lambda probe 240
92 Removing and installing Lambda probe 240
10 Engine control unit241
101 Exploded view – engine control unit 241
102 Removing and installing engine/motor control unit J623241
26 – Exhaust system243
1 Safety precautions243
2 Exhaust pipes/silencers 244
21 Exploded view – silencers244
22 Removing and installing front silencers 247
23 Separating exhaust pipes/silencers 248
24 Removing and installing silencers249
25 Stress-free alignment of exhaust system252
26 Checking exhaust system for leaks 253
3 Emission control system 254
31 Exploded view – emission control system254
32 Removing and installing catalytic converter 257
33 Removing and installing particulate filter258
34 Removing and installing exhaust flap control unit J883260
4 Exhaust gas temperature control261
41 Removing and installing exhaust gas temperature sender 3 G495 – vehicles with particulate
filter261
28 – Ignition system 262
1 Safety precautions262
2 Ignition system 263
21 Exploded view – ignition system 263
22 Removing and installing ignition coils with output stages263
23 Removing and installing knock sensor 1 G61 265
24 Removing and installing Hall senders 265
25 Removing and installing engine speed sender G28 266
93 – Electric drive systems 267
1 Safety precautions267
2 High-voltage components268
21 Overview of fitting locations – high-voltage components268
3 Warning labels 271
31 Checking warning labels271
4 High-voltage battery unit275
41 Exploded view – high-voltage battery 275
42 Inspection and classification of hybrid battery unit AX1278
43 Removing and installing hybrid battery unit AX1280
44 Checking for high-voltage battery leaks 288
Audi A8 2018 ➤
6-cylinder direct injection engine (30 ltr 4-valve TFSI EA839) – Edition 072019
iv Contents
45 Removing and installing battery regulation control unit J840 291
46 Removing and installing switching unit for high-voltage battery SX6 292
5 High-voltage battery components295
51 Exploded view – components of hybrid battery unit AX1295
52 Overview of fitting locations – battery modules 298
53 Performing leak test on cooling system for hybrid battery unit AX1 299
54 Determining mean cell voltage 301
55 Charging and discharging battery modules 302
56 Removing and installing battery modules303
6 Power and control electronics for electric drive 310
61 Overview of fitting locations – power and control electronics for electric drive 310
62 Removing and installing power and control electronics for electric drive312
63 Removing and installing bracket for power and control electronics for electric drive JX1
317
7 Electric drive motor319
71 Exploded view – electric drive motor 319
72 Removing and installing three-phase current drive VX54321
73 Removing and installing centring sleeve321
74 Removing and installing drive motor temperature sender G712322
75 Removing and installing drive motor rotor position sender 1 G713 323
76 Removing and installing torsion damper324
77 Removing and installing actuator for disengagement clutch V606 326
78 Removing and installing coolant connection 327
79 Transporting three-phase current drive 328
710 Checking free movement of disengagement clutch 329
8 High-voltage wiring331
81 Overview of fitting locations – high-voltage wires331
82 Removing and installing high-voltage wiring harness for hybrid battery unit AX1336
83 Removing and installing high-voltage wiring harness for drive motor 339
84 Removing and installing high-voltage wire for electrical air conditioner compressor 343
85 Removing and installing high-voltage wire for high-voltage heater (PTC)346
9 De-energising high-voltage system 351
10 Re-energising high-voltage system 354
11 Potential equalisation lines355
111 General notes – potential equalisation lines 355
112 Overview of fitting locations – potential equalisation lines355
113 Removing and installing potential equalisation lines 356
12 Charging socket 361
121 Exploded view – charging socket361
122 e-tron charging system 362
123 Diagnosis of e-tron charging system 362
124 Removing and installing high-voltage battery charging socket 1 UX4 364
125 Removing and installing module for battery charge selector buttons EX32 365
13 Charging unit for high-voltage battery 367
131 Exploded view – charging unit for high-voltage battery 367
132 Removing and installing charging unit 1 for high-voltage battery AX4 367
133 Removing and installing bracket for charging unit 1 for high-voltage battery AX4 374
14 Engine sound generation375
141 Overview of fitting locations – engine sound generation 375
142 Removing and installing engine sound generator control unit J943 375
143 Removing and installing actuator 1 for engine sound generator R257 377
144 Removing and installing fan for engine sound generator control unit V719 378
List of Workshop Manual Repair Groups
R e p a i r Gr o u p
00 – Technical data
10 – Removing and installing engine
13 – Crankshaft group
15 – Cylinder head, valve gear
17 – Lubrication
19 – Cooling
21 – Turbocharging/supercharging
23 – Mixture preparation – injection
26 – Exhaust system
28 – Glow plug system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed
Service
All rights reserved
No reproduction without prior agreement from publisher
Copyright © 2019 Audi AG, Ingolstadt D4B80593910
Contents
00 – Technical data 1
1 Identification 1
11 Engine number/engine data 1
2 Safety precautions2
21 Safety precautions when working on the fuel system 2
22 Safety precautions when working on vehicles with start/stop system 2
23 Safety precautions when using testers and measuring instruments during a road test 3
24 Safety precautions when working on the cooling system3
25 Safety precautions when working on the exhaust system3
26 Safety precautions when working on the SCR system 4
27 Safety precautions when working on the glow plug system 5
3 Repair instructions6
31 Identification plates6
32 Use of impact wrenches 6
33 Rules for cleanliness 7
34 General notes 7
35 General repair instructions9
36 Foreign particles in engine10
37 Contact corrosion10
38 Routing and attachment of pipes, hoses and wiring 10
39 Installing radiators and condensers 11
310 Performing adaptions after renewing a component 11
10 – Removing and installing engine12
1 Removing and installing engine 12
2 Assembly mountings 13
3 Engine cover panel14
31 Removing and installing engine cover panel 14
13 – Crankshaft group15
1 Cylinder block (pulley end)15
11 Exploded view – cylinder block (pulley end) 15
12 Exploded view – sealing flange (pulley end) 17
13 Removing and installing poly V-belt 19
14 Removing and installing tensioner for poly V-belt20
15 Removing and installing vibration damper20
16 Removing and installing bracket for ancillaries 22
17 Removing and installing engine support24
18 Renewing crankshaft oil seal (pulley end)24
19 Removing and installing sealing flange (pulley end) 26
2 Cylinder block (gearbox end) 29
21 Exploded view – cylinder block (gearbox end) 29
22 Removing and installing drive plate 30
23 Renewing crankshaft oil seal (gearbox end) 32
3 Crankshaft35
31 Exploded view – crankshaft 35
32 Crankshaft dimensions 36
33 Allocation of main bearing shells37
34 Measuring axial clearance of crankshaft37
35 Measuring radial clearance of crankshaft38
36 Removing and installing sender wheel 38
37 Checking sender wheel 39
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen I) – Edition 042019
Contents i
4 Balance shaft 41
41 Exploded view – balance shaft 41
42 Removing and installing balance shaft 41
43 Renewing roller bearing 48
5 Pistons and conrods 50
51 Exploded view – pistons and conrods 50
52 Removing and installing pistons 52
53 Measuring piston projection at TDC 53
54 Checking pistons and cylinder bores 56
55 Checking radial clearance of conrod bearings 57
15 – Cylinder head, valve gear 58
1 Timing chain cover58
11 Exploded view – timing chain cover 58
12 Removing and installing timing chain cover 61
2 Chain drive70
21 Exploded view – camshaft timing chains70
22 Exploded view – drive chain for high-pressure pump 72
23 Exploded view – drive chain for oil pump73
24 Exploded view – intermediate drive 74
25 Removing camshaft timing chain from camshafts74
26 Removing and installing camshaft timing chain 85
27 Removing and installing drive chain for high-pressure pump 94
28 Installing intermediate drive 96
3 Cylinder head 103
31 Exploded view – cylinder head 103
32 Exploded view – cylinder head cover 105
33 Removing and installing cylinder head 107
34 Removing and installing cylinder head cover 114
35 Removing and installing seals for injectors 119
36 Checking compression 120
4 Valve gear122
41 Exploded view – valve gear 122
42 Measuring axial clearance of camshaft 128
43 Measuring radial clearance of camshaft 129
44 Removing and installing camshaft130
45 Removing and installing valve stem oil seals 143
5 Inlet and exhaust valves 150
51 Machining valve seats 150
52 Checking valve guides 150
53 Checking valves 151
54 Valve dimensions151
17 – Lubrication 152
1 Sump/oil pump 152
11 Exploded view – sump/oil pump 152
12 Engine oil156
13 Removing and installing sump (bottom section) 156
14 Removing and installing sump (top section) 158
15 Removing and installing oil pump161
16 Removing and installing oil level and oil temperature sender G266 163
2 Engine oil cooler 164
21 Exploded view – engine oil cooler164
22 Removing and installing engine oil cooler165
23 Removing and installing temperature regulator for engine oil cooler 166
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen I) – Edition 042019
ii Contents
3 Oil filter/oil pressure switches 169
31 Exploded view – oil filter 169
32 Removing and installing oil pressure sender G10170
33 Checking oil pressure 170
34 Removing and installing oil filter housing171
35 Removing and installing valve for oil pressure control N428 172
36 Removing and installing oil temperature sender 2 G664173
19 – Cooling 174
1 Cooling system/coolant 174
11 Connection diagram – coolant hoses 174
12 Checking cooling system for leaks174
13 Draining and filling cooling system177
2 Coolant pump/thermostat assembly 183
21 Exploded view – coolant pump 183
22 Exploded view – electric coolant pump 184
23 Exploded view – thermostat 185
24 Exploded view – coolant temperature senders 187
25 Removing and installing electric coolant pump 187
26 Removing and installing coolant pump 187
27 Removing and installing thermostat housing 189
28 Removing and installing map-controlled engine cooling system thermostat F265 190
29 Removing and installing coolant temperature sender G62 191
210 Removing and installing temperature sender for engine temperature regulation G694192
211 Removing and installing coolant temperature sender 2 G802 193
212 Removing and installing coolant valves 194
3 Coolant pipes 196
4 Radiator/radiator fans 197
21 – Turbocharging/supercharging 198
1 Turbocharger 198
11 Exploded view – turbocharger 198
12 Removing and installing turbocharger 201
2 Charge air system206
21 Exploded view – charge air system206
22 Exploded view – hose connections for charge air system206
23 Removing and installing charge air cooler207
24 Removing and installing charge pressure sender G31 207
25 Checking charge air system for leaks 207
23 – Mixture preparation – injection 210
1 Injection system 210
11 Overview – fuel system 210
12 Overview of fitting locations – injection system 210
13 Filling and bleeding fuel system 210
14 Checking fuel system for leaks 211
2 Vacuum system 212
21 Connection diagram – vacuum system 212
22 Checking vacuum system212
3 Air cleaner213
4 Intake manifold 214
41 Exploded view – intake manifold 214
42 Removing and installing intake manifold (top section) 217
43 Removing and installing intake manifold (bottom section)219
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen I) – Edition 042019
Contents iii
44 Removing and installing intake manifold flap motor V157220
45 Removing and installing throttle valve module J338 222
5 Injectors/high-pressure reservoir (rail) 224
51 Exploded view – injectors224
52 Checking injectors228
53 Performing adaption of correction values for injectors 228
54 Checking for injectors sticking open 229
55 Checking return flow rate of injectors with engine running232
56 Checking return flow rate of injectors at starter cranking speed236
57 Checking pressure retention valve in fuel return line 238
58 Removing and installing injectors239
59 Removing and installing high-pressure pipes 244
510 Removing and installing high-pressure reservoir (rail) 246
6 Senders and sensors 251
61 Removing and installing intake air temperature sender G42 251
62 Removing and installing air mass meter G70 251
63 Removing and installing fuel temperature sender G81 251
64 Removing and installing fuel pressure sender G247 254
65 Removing and installing fuel pressure sender for low pressure G410 256
66 Checking fuel pressure regulating valve N276 256
67 Removing and installing fuel pressure regulating valve N276 257
68 Removing and installing pressure differential sender G505 258
7 High-pressure pump 259
71 Exploded view – high-pressure pump 259
72 Removing and installing high-pressure pump 261
8 Lambda probe 265
81 Exploded view – Lambda probe 265
82 Removing and installing Lambda probe 266
83 Removing and installing NOx senders 267
84 Removing and installing particulate sensor G784267
9 Engine control unit268
26 – Exhaust system269
1 Exhaust pipes/silencers 269
11 Exploded view – silencers269
12 Removing and installing front exhaust pipe 269
13 Separating exhaust pipes/silencers 269
14 Removing and installing silencers269
15 Stress-free alignment of exhaust system269
16 Checking exhaust system for leaks 269
2 Emission control system 270
3 SCR (selective catalytic reduction) system 271
31 Exploded view – reducing agent tank 271
32 Exploded view – reducing agent supply line 271
33 Draining reducing agent tank 273
34 Removing and installing reducing agent tank 273
35 Removing and installing injector for reducing agent N474 273
36 Removing and installing control unit for reducing agent metering system J880275
4 Exhaust gas temperature control276
41 Exploded view – exhaust gas temperature control276
42 Removing and installing exhaust gas temperature sender 1 G235 278
43 Removing and installing exhaust gas temperature sender 2 G448 279
44 Removing and installing exhaust gas temperature sender 3 G495 280
45 Removing and installing exhaust gas temperature sender 4 G648 282
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen I) – Edition 042019
iv Contents
46 Removing and installing exhaust gas temperature sender 5 G815 284
47 Removing and installing catalytic converter temperature sensor 1 G20284
5 Exhaust gas recirculation286
51 Exploded view – exhaust gas recirculation system286
52 Removing and installing exhaust gas recirculation cooler291
53 Removing and installing exhaust gas recirculation temperature sensor G98 296
54 Installing repair kit for exhaust gas recirculation cooler 297
6 Exhaust manifold300
61 Exploded view – exhaust manifold300
62 Removing and installing exhaust manifold301
28 – Glow plug system302
1 Glow plug system302
11 Exploded view – glow plug system302
12 Removing and installing glow plug303
13 Removing and installing Hall sender G40306
14 Removing and installing engine speed sender G28 306
R e p a i r Gr o u p
00 – Technical data
20 – Fuel supply system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed
Service
All rights reserved
No reproduction without prior agreement from publisher
Copyright © 2018 Audi AG, Ingolstadt D4B8077F6CD
Contents
00 – Technical data 1
1 Safety precautions1
11 Safety precautions when working on the high-voltage system 1
12 Safety precautions when working in the vicinity of high-voltage components 2
13 Safety precautions when working on the fuel system 2
14 Safety precautions when working on vehicles with start/stop system 3
15 Safety precautions when using testers and measuring instruments during a road test 3
16 Safety precautions when working on the SCR system 3
2 Repair instructions5
21 Rules for cleanliness 5
22 Test conditions 5
23 Contact corrosion5
24 Routing and attachment of pipes, hoses and wiring 6
20 – Fuel supply system 7
1 Fuel tank 7
11 Exploded view – fuel tank7
12 Draining fuel tank14
13 Removing and installing fuel tank22
14 Removing and installing misfuelling prevention device 38
15 Deactivating misfuelling prevention device 41
2 Fuel delivery unit/fuel gauge senders 42
21 Exploded view – fuel delivery unit/fuel gauge senders 42
22 Removing and installing fuel delivery unit/fuel gauge senders 45
23 Bleeding fuel line for metering pump 54
24 Removing and installing fuel gauge sender G 55
3 Plug-in connectors57
31 Disconnecting plug-in connectors57
4 Fuel filter 61
41 Exploded view – fuel filter61
42 Exploded view – water separator62
43 Removing and installing water separator63
5 Activated charcoal filter system 65
51 Connection diagram – activated charcoal filter system 65
52 Exploded view – activated charcoal filter system68
53 Removing and installing activated charcoal filter72
54 Removing and installing fuel tank leak detection module GX3673
55 Removing and installing control unit for fuel tank leak detection J909 74
56 Checking fuel system for leaks – vehicles with fuel tank leak detection module GX36 74
57 Operation of fuel tank leak detection – vehicles with fuel tank leak detection module GX36
81
58 Operation of activated charcoal filter system – vehicles with high-voltage system81
6 Accelerator mechanism 82
61 Exploded view – accelerator pedal module82
62 Removing and installing accelerator pedal module GX284
7 Fuel pump86
71 Checking fuel system pressurisation pump G6 86
72 Removing and installing suction-jet pump97
73 Removing and installing fuel pump control unit J538 97
Copyright by AUDI AG
List of Workshop Manual Repair Groups
R e p a i r Gr o u p
00 – Technical data
32 – Torque converter
37 – Controls, housing
38 – Gears, control
39 – Final drive – front differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed
Service
All rights reserved
No reproduction without prior agreement from publisher
Copyright © 2018 Audi AG, Ingolstadt D4B80796534
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
Contents
00 – Technical data 1
1 Identification 1
11 Gearbox identification 1
2 Safety precautions2
21 Safety precautions when working on vehicle 2
22 Safety precautions when working on vehicles with start/stop system 3
23 Safety precautions when using testers and measuring instruments during a road test 3
24 Safety precautions when working on subframe 3
25 Safety precautions when tow-starting and towing3
3 Repair instructions4
31 Rules for cleanliness 4
32 General notes 4
33 General repair instructions5
34 Contact corrosion7
35 Routing and attaching lines and wiring 7
4 Technical data 8
41 Capacities8
42 Oil distribution 9
43 Allocation of gearbox to engine 9
44 Clutch logic9
5 Transmission layout 11
32 – Torque converter12
1 Torque converter12
37 – Controls, housing13
1 Selector mechanism 13
11 Exploded view – selector mechanism 13
12 Exploded view – manual release mechanism for parking lock 14
13 Checking selector mechanism 15
14 Manual release from position P 19
15 Removing and installing selector lever handle 20
16 Removing and installing selector mechanism 21
17 Removing and installing manual release cable for parking lock 22
18 Renewing seal for parking lock shaft 25
2 Removing and installing gearbox28
21 Removing gearbox28
22 Installing gearbox48
23 Tightening torques for gearbox 53
3 Assembly mountings 55
31 Exploded view – assembly mountings 55
32 Removing and installing tunnel cross member 56
4 Transporting gearbox 62
5 Securing to engine and gearbox support63
6 ATF circuit64
61 Exploded view – ATF circuit 64
62 Removing and installing ATF cooler 66
63 Removing and installing ATF lines67
7 ATF70
71 Checking ATF level 70
72 Draining and filling ATF 73
Audi A8 2018 ➤
8-speed automatic gearbox 0D5 – Edition 042018
Contents i
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
38 – Gears, control 77
1 ATF system 77
11 Removing and installing oil pan 77
2 Mechatronic unit 81
39 – Final drive – front differential 82
1 Final drive82
11 Exploded view – final drive82
12 Removing and installing O-ring on cover for front final drive 84
2 Gear oil 86
21 Checking gear oil level 86
22 Draining and filling gear oil89
3 Oil seals 95
31 Overview of fitting locations – oil seals 95
32 Renewing oil seal (left-side) 95
33 Renewing oil seal (right-side) 98
4 Differential100
41 Removing and installing flange shaft (left-side) 100
42 Removing and installing flange shaft (right-side)103
5 Centre differential106
6 Transfer box 107
7 Gearbox control system 108
71 Overview of fitting locations – gearbox control system 108
Workshop Manual
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ ,
Audi A4 China 2016 ➤ ,
Audi A4 allroad quattro 2016 ➤ ,
Audi A5 2016 ➤ , Audi A6 2019 ➤ ,
Audi A6 China 2019 ➤ ,
Audi A7 Sportback 2018 ➤ ,
Audi A8 2018 ➤ , Audi Q5 2017 ➤ ,
Audi Q5 China 2019 ➤ , Audi Q7 2016 ➤ ,
Audi Q8 2018 ➤
Rear final drive 0D2, 0D3, 0DB, 0B0, 0BX, 0DG, 0G2,
09R
Edition 092018
Service
Service Department Technical Information
List of Workshop Manual Repair Groups
R e p a i r Gr o u p
00 – Technical data
39 – Final drive – rear differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed
Service
All rights reserved
No reproduction without prior agreement from publisher
Copyright © 2018 Audi AG, Ingolstadt D4B80529C8E
Contents
00 – Technical data 1
1 Identification 1
11 Identification of final drive1
12 Identification of four-wheel drive coupling 0CJ or 0CX 5
2 Technical data 7
21 Allocation of gearbox to engine 7
22 Capacities13
3 Transmission layout 16
31 Transmission layout – vehicles without four-wheel drive coupling16
32 Transmission layout – vehicles with four-wheel drive coupling »quattro ultra« 17
4 Safety precautions18
41 Safety precautions when working on vehicle 18
42 Safety precautions when working on vehicles with start/stop system 19
43 Safety precautions when working on high-voltage system19
44 Safety precautions when working in the vicinity of high-voltage components 20
5 Repair instructions21
51 General repair instructions21
52 Safety precautions and testing – rear final drive 0D3 “quattro sport” and 0BX “quattro sport”
21
53 Safety precautions and testing – four-wheel drive coupling 0CJ or 0CX24
54 Special tools 24
55 Components 24
56 Contact corrosion26
6 Electrical components 28
61 Overview of fitting locations – electrical components 28
39 – Final drive – rear differential 30
1 Propshaft30
11 Exploded view – propshaft30
12 Removing and installing propshaft32
13 Renewing protective boot47
2 Final drive50
21 Exploded view – final drive50
22 Removing and installing final drive55
23 Dismantling and assembling final drive 86
24 Hydraulic control unit, 0D3 “quattro sport” and 0BX “quattro sport” 94
25 Checking torque distribution – 0D3 “quattro sport” and 0BX “quattro sport” 103
3 Gear oil 104
31 Overview of fitting locations – drain and inspection plugs104
32 Checking gear oil level 107
33 Draining and filling gear oil109
4 ATF119
41 Checking ATF level 119
42 Draining and filling ATF 119
5 Oil seals 124
51 Overview of fitting locations – oil seals 124
52 Renewing oil seal (left-side) 131
53 Renewing oil seal (right-side) 138
54 Renewing input shaft oil seal 151
55 Renewing protective ring on flange shaft175
56 Renewing protective ring on propshaft flange 181
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A4 China 2016 ➤ , Audi A4 a
Rear final drive 0D2, 0D3, 0DB, 0B0, 0BX, 0DG, 0G2, 09R – Edition 092018
Contents i
6 Assembly mountings 184
61 Removing and installing bonded rubber bush 184
7 Four-wheel drive coupling186
71 Exploded view – four-wheel drive coupling186
72 Removing and installing four-wheel drive coupling 187
73 Additional work required if four-wheel drive coupling was renewed 190
74 Checking oil level191
75 Draining and filling fluid for four-wheel drive coupling 191
76 Removing and installing control unit 194
77 Additional work for “quattro ultra” vehicles196
78 Checking setting torque of four-wheel drive coupling 197
79 Renewing oil seal for four-wheel drive coupling output shaft 199
710 Renewing oil seal for four-wheel drive coupling input shaft 201
8 Gearbox control system 203
81 Overview of fitting locations – gearbox control system 203
82 Removing and installing all-wheel drive control unit J492 – vehicles with “quattro ultra”206
83 Removing and installing differential lock control unit J187 – vehicles with “quattro sport”
206
84 Additional work required after renewing differential lock control unit J187 208
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A4 China 2016 ➤ , Audi A4 a
Rear final drive 0D2, 0D3, 0DB, 0B0, 0BX, 0DG, 0G2, 09R – Edition 092018
ii
Workshop Manual
Audi A8 2018 ➤
Brake system
Edition 042018
Service
Service Department Technical Information
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
List of Workshop Manual Repair Groups
R e p a i r Gr o u p
00 – Technical data
45 – Anti-lock brake system
46 – Brakes – mechanism
47 – Brakes – hydraulics
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed
Service
All rights reserved
No reproduction without prior agreement from publisher
Copyright © 2018 Audi AG, Ingolstadt D4B807959FB
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
Contents
00 – Technical data 1
1 Identification 1
11 PR number and type of brake system 1
2 Safety precautions2
21 Safety precautions when working on vehicles with start/stop system 2
22 Safety precautions when using testers and measuring instruments during a road test 2
3 Repair notes 3
31 Rules for cleanliness 3
32 General repair instructions3
33 Contact corrosion3
4 Technical data 4
41 Technical data for brakes4
5 Brake test5
51 General notes 5
52 Testing vehicles with four-wheel drive 5
53 Testing parking brake 5
45 – Anti-lock brake system 7
1 General notes 7
11 Notes for repair work on the ABS7
2 Overview of fitting locations 8
21 Overview of fitting locations – ABS/ESP 8
3 Control unit and hydraulic unit 10
31 Exploded view – control unit and hydraulic unit 10
32 Removing and installing ABS control unit J104 / ABS hydraulic unit N5512
33 Separating control unit from hydraulic unit15
34 Attaching control unit to hydraulic unit 16
4 Sensors 18
41 Exploded view – front wheel speed sensor18
42 Exploded view – rear wheel speed sensor19
43 Removing and installing brake pedal position sender G100 19
44 Removing and installing front wheel speed sensor G45 / G47 21
45 Removing and installing rear wheel speed sensor G44 / G46 21
46 – Brakes – mechanism 23
1 Front brakes 23
11 Exploded view – front brakes 23
12 Removing and installing brake pads 26
13 Removing and installing brake caliper 30
14 Renewing brake caliper 33
15 Removing and installing brake disc 37
16 Removing and installing splash plate 38
17 Removing and installing pad wear indicator wire39
2 Rear brakes 41
21 Exploded view – rear brakes 41
22 Removing and installing brake pads 44
23 Removing and installing brake caliper 48
24 Renewing brake caliper 50
25 Removing and installing brake carrier 53
26 Removing and installing brake disc 54
27 Removing and installing splash plate 56
28 Removing and installing pad wear indicator wire57
Audi A8 2018 ➤
Brake system – Edition 042018
Contents i
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
3 Parking brake 58
31 Exploded view – parking brake 58
32 Removing and installing parking brake motor V282 / V283 59
33 Releasing parking brake manually60
4 Brake pedal 62
41 Exploded view – brake pedal 62
42 Removing and installing mounting bracket63
43 Separating brake pedal from brake servo64
44 Connecting brake pedal to brake servo 65
45 Removing and installing brake pedal 65
47 – Brakes – hydraulics 67
1 Front brake caliper67
11 Exploded view – front brake caliper 67
12 Removing and installing protective cap 67
2 Rear brake caliper70
21 Exploded view – rear brake caliper70
22 Removing and installing brake caliper piston 70
3 Brake servo / brake master cylinder 74
31 Exploded view – brake servo / brake master cylinder 74
32 Note on activation pin for brake pedal position sender G100 76
33 Removing and installing brake servo 76
34 Removing and installing brake master cylinder 80
35 Removing and installing brake fluid reservoir 83
36 Removing and installing brake fluid level warning contact F34 86
4 Vacuum system 87
41 Exploded view – vacuum pump 87
42 Checking non-return valve91
43 Removing and installing non-return valve91
44 Removing and installing vacuum pump 94
45 Removing and installing brake servo pressure sensor 97
46 Checking vacuum system98
5 Hydraulic system103
51 General notes on brake fluid 103
52 Bleeding hydraulic system104
53 Leak test 110
Audi A8 2018 ➤
Brake system – Edition 042018
iiWorkshop Manual
Audi A8 2018 ➤
Heating, air conditioning
Edition 052019
Service
Service Department Technical Information
List of Workshop Manual Repair Groups
R e p a i r Gr o u p
00 – Technical data
80 – Heating
87 – Air conditioning system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed
Service
All rights reserved
No reproduction without prior agreement from publisher
Copyright © 2019 Audi AG, Ingolstadt D4B807A7492
Contents
00 – Technical data 1
1 Safety measures1
11 Safety precautions when working on air conditioners 1
12 Safety precautions when handling refrigerants 1
13 Safety precautions when working on vehicles with high-voltage system2
14 Safety precautions when working in the vicinity of high-voltage components 2
15 Safety precautions when working on vehicles with start/stop system 3
16 Safety precautions when using testers and measuring instruments during a road test 3
17 Safety precautions when working on the cooling system4
18 Safety precautions when working on vehicles with auxiliary/supplementary heater 4
2 Identification 5
21 Identification of heater and air conditioning unit 5
3 General notes 7
31 Type plates7
32 Notes on odours in vehicles with air conditioner7
4 Repair instructions9
41 Rules for cleanliness 9
42 General notes 9
43 General repair instructions10
44 Contact corrosion10
45 Routing and attaching lines and wiring 10
46 Installing radiators and condensers 11
47 Checking heating output 11
48 Checking cooling output 11
49 Checking air conditioning system functions – vehicles with high-voltage system12
410 Working on refrigerant circuit 12
411 Paintwork repairs on vehicles with air conditioning system 13
412 Refrigerant circuit seals 14
413 Notes on high-voltage components and potential equalisation lines 16
414 Use of impact wrenches 17
415 Identification plates17
5 Technical data 18
51 Refrigerant capacities 18
52 Approved refrigerant oils and refrigerant oil capacities 19
53 Oil distribution 25
80 – Heating 26
1 Overview of fitting locations – heater 26
87 – Air conditioning system27
1 Overview of fitting locations – air conditioner 27
11 Overview of fitting locations – components not located in passenger compartment 27
12 Overview of fitting locations – components in passenger compartment (front) 34
13 Overview of fitting locations – components in passenger compartment (rear) 36
2 Refrigerant circuit38
21 System overview – refrigerant circuit 39
22 Exploded view – condenser 50
23 Exploded view – refrigerant lines51
24 Exploded view – heat exchanger for heat pump operation77
25 Exploded view – heat exchanger for high-voltage battery78
26 Removing and installing heat exchanger for heat pump operation with refrigerant receiver
79
Audi A8 2018 ➤
Heating, air conditioning – Edition 052019
Contents i
27 Removing and installing refrigerant receiver 82
28 Removing and installing heat exchanger for high-voltage battery84
29 Removing and installing high-pressure sender G65 88
210 Removing and installing refrigerant pressure and temperature sender G395 90
211 Removing and installing refrigerant pressure and temperature sender 2 G82692
212 Removing and installing refrigerant pressure and temperature sender, low-pressure side
G1052 96
213 Removing and installing refrigerant pressure and temperature sender, high-pressure side
G1053 96
214 Removing and installing refrigerant shut-off valve V42497
215 Removing and installing refrigerant lines with internal heat exchanger 100
216 Removing and installing refrigerant lines in plenum chamber 106
217 Removing and installing leadthrough for refrigerant lines in plenum chamber 110
218 Removing and installing expansion valve115
219 Removing and installing non-return valves in refrigerant circuit 127
220 Unfastening and assembling connection points of refrigerant lines – PR numbers KK1/KK3
135
221 Detaching and attaching refrigerant lines – PR numbers KK1/KK3 137
222 Removing and installing refrigerant lines to rear heater and air conditioning unit140
223 Removing and installing condenser/gas cooler 141
224 Detaching and attaching refrigerant lines at condenser 145
225 Removing and installing accumulator – vehicles with R744 148
226 Removing and installing desiccant bag/desiccant cartridge – vehicles with R134a/R1234yf
151
227 Removing and installing evacuating and charging valve (low-pressure and high-pressure
sides) 151
228 Starting up air conditioner after charging refrigerant circuit 154
229 Removing and installing pressure limiting valve (low-pressure side) 158
230 Cleaning air conditioner refrigerant circuit – vehicles with high-voltage system 159
3 Heat pump valve unit 178
31 Exploded view – heat pump valve unit 178
32 Removing and installing heat pump valve unit 179
33 Dismantling and assembling heat pump valve unit 181
34 Removing and installing refrigerant expansion valve 2 N637 183
4 Air conditioner compressor185
41 Exploded view – drive unit for air conditioner compressor185
42 Exploded view – pulley 191
43 Detaching and attaching air conditioner compressor at bracket199
44 Detaching and attaching refrigerant lines at air conditioner compressor201
45 Removing and installing air conditioner compressor 211
46 Preparations for renewing pulley223
47 Removing and installing pulley (without magnetic clutch)224
48 Removing and installing pulley with air conditioning system magnetic clutch N25 228
5 Control motors 234
51 Overview of fitting locations – control motors (front) 235
52 Exploded view – control motors (front) 240
53 Overview of fitting locations – control motors (rear) 244
54 Exploded view – control motors (rear) 246
55 General information and procedure for removing and installing control motors 248
56 Removing and installing fresh air flap control motor V438 , operation 250
57 Removing and installing defroster flap control motor V107 252
58 Removing and installing left footwell flap control motor V108 / control motor for left footwell
temperature flap V411 254
59 Removing and installing right footwell flap control motor V109 / control motor for right footwell
temperature flap V412 256
510 Removing and installing left centre vent control motor V110 258
511 Removing and installing right centre vent control motor V111 259
Audi A8 2018 ➤
Heating, air conditioning – Edition 052019
ii Contents
512 Removing and installing air recirculation flap control motor V113260
513 Removing and installing rear temperature flap control motor V137 / rear left air quantity flap
control motor V239 262
514 Removing and installing left temperature flap control motor V158 263
515 Removing and installing right temperature flap control motor V159 265
516 Removing and installing right B-pillar and footwell shut-off flap control motor V211 266
517 Removing and installing left B-pillar and footwell shut-off flap control motor V212 268
518 Removing and installing left side vent control motor V299 270
519 Removing and installing right side vent control motor V300 272
520 Removing and installing rear left temperature flap control motor V313274
521 Removing and installing rear right temperature flap control motor V314275
522 Removing and installing rear left chest vent control motor V315277
523 Removing and installing rear right chest vent control motor V316 279
524 Removing and installing rear air recirculation flap control motor V421 281
525 Removing and installing rear air distribution flap control motor V427 / rear right air distribution
control motor V594 284
526 Removing and installing rear left air distribution control motor V593 285
527 Removing and installing control motor for left side window defroster flap V409286
528 Removing and installing control motor for right side window defroster flap V410287
529 Removing and installing rear right air quantity flap control motor V240288
530 Removing and installing brackets for control motors on front heater and air conditioning
unit290
6 Front heater and air conditioning unit 299
61 Exploded view – heater and air conditioning unit299
62 Exploded view – air intake box of heater and air conditioning unit304
63 Exploded view – evaporator housing 305
64 Removing and installing evaporator 307
65 Cleaning evaporator 309
66 Checking electric supplementary heater ( auxiliary air heater control unit J604 with auxiliary
air heater element Z35 ) 317
67 Removing and installing auxiliary air heater control unit J604 (with auxiliary air heater element
Z35 ) 319
68 Removing and installing heater and air conditioning unit322
69 Detaching and attaching air intake box at heater and air conditioning unit 328
610 Removing and installing dust and pollen filter 328
611 Removing and installing fresh air blower V2 with fresh air blower control unit J126 330
612 Removing and installing heat exchanger331
613 Removing and installing condensation drain 338
614 Checking condensation drain 339
7 Rear heater and air conditioning unit 340
71 Exploded view – attachments for heater and air conditioning unit and air intake box 340
72 Removing and installing evaporator 344
73 Removing and installing heater and air conditioning unit346
74 Removing and installing rear fresh air blower V80 352
75 Removing and installing rear fresh air blower control unit J391354
76 Removing and installing heat exchanger – vehicles with PR number 9AH354
77 Checking condensation drain hose 358
8 Air duct 359
81 Exploded view – routing of air flow and air distribution in passenger compartment 359
82 Air intake and air outlet openings365
83 Removing and installing air distribution housing (driver side) 372
84 Removing and installing air distribution housing (passenger side) 373
85 Removing and installing footwell vent (driver side) 374
86 Removing and installing footwell vent (front passenger side) 375
87 Removing and installing rear footwell vent376
88 Removing and installing air duct for glove box cooling 376
Audi A8 2018 ➤
Heating, air conditioning – Edition 052019
Contents iii
89 Removing and installing forced ventilation vents in passenger compartment 377
810 Checking forced ventilation vents in passenger compartment 378
811 Removing and installing fresh air intake 379
812 Removing and installing plenum chamber water drain 383
813 Checking plenum chamber water drain 384
814 Cleaning plenum chamber water drain 384
9 Coolant circuit 385
91 Exploded view – high-voltage heater (PTC) Z115385
92 Incorporation of heater and air conditioning unit into engine coolant circuit 386
93 Removing and installing high-voltage heater (PTC) Z115 (with high-voltage heater (PTC)
control unit J848 )390
10 Operating and display unit394
101 Overview – operating and display unit 394
102 Removing and installing operating and display unit 395
11 Further control components 397
111 Removing and installing rear sunlight penetration photosensor G914 397
112 Removing and installing external air quality and air humidity sensor G935 398
113 Removing and installing ambient temperature sensor G17 398
114 Removing and installing front chest vent temperature sensor G385 / G386 399
115 Removing and installing left footwell vent temperature sender G261 400
116 Removing and installing right footwell vent temperature sender G262 400
117 Removing and installing evaporator output temperature sender G263 401
118 Removing and installing rear right chest vent temperature sender G636 / rear left chest vent
temperature sender G635 – vehicles with PR number 9AU 401
119 Removing and installing rear left chest vent temperature sender G635 – vehicles with PR
number 9AH 402
1110 Removing and installing rear right chest vent temperature sender G636 – vehicles with PR
number 9AH 402
1111 Removing and installing vent temperature sender for rear footwell G637 / G638 – vehicles
with PR number 9AH 403
1112 Removing and installing sensor for interior carbon dioxide concentration G929404
1113 Removing and installing dash panel temperature sensor G56 404
1114 Removing and installing rear chest vent temperature sensor G537 405
1115 Removing and installing humidity sender G355405
1116 Removing and installing thermal management control unit J1024 406
12 Air ionisation system 407
121 Overview of fitting locations – air ionisation system 407
122 Exploded view – fragrance diffuser system409
123 Removing and installing control unit for fragrance diffuser system J1101 with blower for
fragrance diffuser system V686 410
124 Removing and installing function unit for fragrance diffuser system GX43 411
125 Removing and installing control motor for fragrance diffuser system V687 412
126 Temperature sensor for fragrance diffuser system G1056 414
127 Removing and installing ioniser control unit J897414
128 Removing and installing driver side ioniser J1105 414
129 Removing and installing passenger side ioniser J1106415
Audi A8 2018 ➤
Heating, air conditioning – Edition 052019
ivWorkshop Manual
Audi A8 2018 ➤
Communication
Edition 062019
Service
Service Department Technical Information
List of Workshop Manual Repair Groups
R e p a i r Gr o u p
91 – Communication
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed
Service
All rights reserved
No reproduction without prior agreement from publisher
Copyright © 2019 Audi AG, Ingolstadt D4B807A7F5E
Contents
91 – Communication1
1 Infotainment system 1
11 Layout – infotainment system 1
12 Overview of fitting locations – infotainment system 7
13 Removing and installing infotainment system display 8
14 Removing and installing control unit 1 for information electronics J79410
15 Removing and installing driver side volume regulator E67 13
16 Removing and installing additional display and operating unit 1 E857 14
17 Removing and installing wireless operating unit 1 E85915
2 Sound system 17
21 Layout – sound system 17
22 Overview of fitting locations – sound system 28
23 Overview of fitting locations – ANC microphones33
24 Removing and installing digital sound package control unit/amplifier 34
25 Removing and installing rear treble loudspeakers37
26 Removing and installing front treble loudspeakers R20 / R22 38
27 Removing and installing rear mid-range loudspeakers 39
28 Removing and installing front mid-range loudspeakers 40
29 Removing and installing rear bass loudspeakers R15 / R17 41
210 Removing and installing front bass loudspeakers R21 / R23 42
211 Removing and installing subwoofer R21144
212 Removing and installing effect loudspeakers 44
213 Removing and installing centre loudspeaker 46
214 Removing and installing ANC microphones 47
3 Aerial systems 48
31 Layout – aerial systems 48
32 Overview of fitting locations – aerial systems 50
33 Removing and installing aerial amplifiers54
34 Removing and installing window aerial suppression filter56
35 Removing and installing traffic data aerial57
36 Removing and installing dedicated short-range communication aerial 58
37 Removing and installing roof aerial 58
38 Removing and installing emergency call module aerials59
39 Removing and installing LTE aerials 60
310 Removing and installing internal vehicle communication aerial R364 61
311 Removing and installing near field communication aerials62
312 Removing and installing bumper aerials62
313 Removing and installing GPS aerial 64
314 Removing and installing digital radio aerial 64
315 Removing and installing satellite tuner aerial R172 64
316 Removing and installing near field communication control unit 65
317 Removing and installing roof aerial control unit JX3 65
4 Radio 66
41 Layout – radio 66
42 Overview of fitting locations – radio 70
43 Removing and installing radio 70
44 Removing and installing digital radio 70
5 DVD/CD changer71
51 Removing and installing DVD changer 71
6 Telephone system74
61 Layout – telephone74
62 Overview of fitting locations – telephone system89
Audi A8 2018 ➤
Communication – Edition 062019
Contents i
63 Exploded view – microphone unit90
64 Removing and installing microphone unit in front roof module R164 91
65 Removing and installing aerial amplifier for mobile telephone 91
66 Removing and installing telephone bracket 92
7 Navigation system96
71 Layout – navigation system96
72 Overview of fitting locations – navigation system98
73 Removing and installing control unit for navigation system 98
8 TV system99
81 Layout – TV system 99
82 Overview of fitting locations – TV system100
83 Removing and installing TV tuner101
84 Removing and installing TV card reader103
9 Reversing camera system104
10 Multi-function steering wheel 105
101 Layout – multi-function steering wheel 105
102 Exploded view – multi-function steering wheel 105
103 Removing and installing multifunction buttons in steering wheel E441 / E440 106
104 Removing and installing tiptronic switches in steering wheel E480 / E479 107
11 Speech dialogue system109
111 Layout – speech dialogue system109
112 Removing and installing speech dialogue system109
12 Connection for external multimedia devices 111
121 Layout – connection for external multimedia devices 111
122 Removing and installing connection for external multimedia devices 112
13 Rear Seat Entertainment system (RSE) 113
131 Overview – Rear Seat Entertainment system 113
132 Overview of fitting locations – Rear Seat Entertainment system113
133 Removing and installing multimedia system display unit Y31 / Y32 115
134 Removing and installing holder for multimedia system display unit R315 / R316116
135 Removing and installing rear information display and operating unit control unit J648 / J649
118
14 Night vision system 119
15 Overhead view camera 120
16 Mobile online services 121
161 Layout – mobile online services 121
162 Overview of fitting locations – mobile online services 124
163 Removing and installing emergency call module control unit and communication unit J949
126
164 Removing and installing emergency battery for telematics A16128
165 Removing and installing loudspeaker for emergency call module R335128
166 Removing and installing interface control unit for telematics J1221 129
167 Removing and installing telephone and telematics control unit J526 129
168 Removing and installing data transmission aerial130
Workshop Manual
Audi A1 2011 ➤ ,
Audi A1 Sportback 2018 ➤ ,
Audi A2 2001 ➤ , Audi A3 2004 ➤ ,
Audi A3 2013 ➤ ,
Audi A3 Limousine China 2014 ➤ ,
Audi A3 Sportback China 2014 ➤ ,
Audi A4 2001 ➤ , Audi A4 2008 ➤ ,
Audi A4 2015 ➤ ,
Audi A4 Cabriolet 2003 ➤ ,
Audi A5 2016 ➤ ,
Audi A5 Cabriolet 2009 ➤ ,
Audi A5 Coupé 2008 ➤ , Audi A6 1998 ➤ ,
Audi A6 2005 ➤ , Audi A6 2011 ➤ ,
Audi A6 2019 ➤ , Audi A6 China 2012 ➤ ,
Audi A7 Sportback 2011 ➤ ,
Audi A7 Sportback 2018 ➤ ,
Audi A8 2003 ➤ , Audi A8 2010 ➤ ,
Audi A8 2018 ➤ , Audi Q2 2016 ➤ ,
Audi Q3 2012 ➤ , Audi Q3 2019 ➤ ,
Audi Q3 China 2013 ➤ ,
Audi Q3 China 2019 ➤ , Audi Q5 2008 ➤ ,
Audi Q5 2017 ➤ , Audi Q5 China 2010 ➤ ,
Audi Q7 2007 ➤ , Audi Q7 2016 ➤ ,
Audi Q8 2018 ➤ , Audi R8 2007 ➤ ,
Audi R8 2015 ➤ , Audi TT 1999 ➤ ,
Audi TT 2007 ➤ , Audi TT 2015 ➤ ,
Audi e-tron 2019 ➤
Electrical system; General information
Edition 082019
Service
Service Department Technical Information
List of Workshop Manual Repair Groups
R e p a i r Gr o u p
27 – Starter, current supply, CCS
92 – Windscreen wash/wipe system
94 – Lights, bulbs, switches – exterior
96 – Lights, bulbs, switches – interior
97 – Wiring
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed
Service
All rights reserved
No reproduction without prior agreement from publisher
Copyright © 2019 Audi AG, Ingolstadt A005AA00420
Contents
27 – Starter, current supply, CCS 1
1 Battery 1
11 Basic information on the battery 1
12 Battery types 1
13 Warnings and safety precautions3
14 Battery terminal screw connection5
2 Checking battery6
21 Test sequence 6
22 Visual inspection8
23 Checking colour indicator of magic eye 9
24 Checking battery using vehicle diagnostic tester10
25 Battery tester with printer VAS 6161 12
26 Battery tester with printer VAS 5097 A 17
27 Current draw test22
28 Checking no-load voltage of battery, stock vehicles 23
3 Charging battery 25
31 Battery charger VAS 5095 A 25
32 Battery charger VAS 590030
33 Battery charger VAS 590342
34 Battery charger VAS 590654
35 Solar panel VAS 6102 A57
36 Totally discharged batteries 58
4 Alternator60
41 Checking alternator 60
42 Bosch alternator up to 2000 – exploded view 61
43 Bosch alternator from 2001 onwards – exploded view 62
44 Removing and installing voltage regulator – Bosch alternator from 2001 onwards 63
45 Bosch alternator from 2007 onwards – exploded view 63
46 Removing and installing voltage regulator – Bosch alternator from 2007 onwards 64
47 Checking carbon brushes – all types of Bosch alternators from 2001 onwards 65
48 Valeo alternator up to 2000 – exploded view 65
49 Valeo alternator from 2001 onwards – exploded view 67
410 Removing and installing voltage regulator – Valeo alternator from 2001 onwards68
411 Checking carbon brushes – Valeo alternator from 2001 onwards68
412 Removing and installing voltage regulator – Valeo alternator from 2007 onwards69
413 Checking carbon brushes – Valeo alternator from 2007 onwards69
414 Hitachi alternator – exploded view70
415 Removing and installing voltage regulator – Hitachi alternator 71
416 Checking carbon brushes – Hitachi alternator 72
417 Removing and installing poly V-belt pulley without free-wheel 73
418 Removing and installing poly V-belt pulley with free-wheel 73
419 Checking poly V-belt pulley with free-wheel 76
92 – Windscreen wash/wipe system77
1 Washer fluid hoses77
11 Disconnecting and connecting washer fluid hose connectors 77
12 Servicing a smooth washer fluid pipe 78
13 Servicing a washer fluid hose with corrugated tube 79
94 – Lights, bulbs, switches – exterior82
1 Safety precautions when handling gas discharge bulbs82
96 – Lights, bulbs, switches – interior84
Audi A1 2011 ➤ , Audi A1 Sportback 2018 ➤ , Audi A2 2001 ➤ , Audi A3 20
Electrical system; General information – Edition 082019
Contents i
1 Immobiliser84
11 General notes 84
12 Defective transponder or loss of key 84
13 Renewing reader coil 84
14 Procedure for renewing lock set 85
2 Towing bracket 86
21 Removing and installing socket for towing bracket – version 1 86
22 Removing and installing socket for towing bracket – version 2 87
23 Removing and installing socket for towing bracket – version 3 89
24 Removing and installing socket for towing bracket – version 4 90
97 – Wiring 93
1 Vehicle diagnostic, testing and information systems 93
11 Connecting vehicle diagnostic tester 93
2 Repairing wiring harnesses and connectors 95
21 General information on repairs to the vehicle electrical system 95
22 Wiring harness repair set98
23 Description of tools100
24 Repairing wiring harnesses 104
25 Repairing fibre optic cables 131
26 Repairing aerial wires 142
27 Repairing connector housings and electrical connectors154
28 Releasing and dismantling connector housings 157
3 Contact surface cleaning set VAS 6410163
31 Using contact surface cleaning set VAS 6410 163
4 ESD (electrostatic discharge) workplace VAS 6613 170
41 Using ESD workplace VAS 6613170
Audi A1 2011 ➤ , Audi A1 Sportback 2018 ➤ , Audi A2 2001 ➤ , Audi A3 20
Electrical system; General information – Edition 082019
ii
General InformationBody Repairs,
General Body Repairs
Edition 042018
Service
Service Department Technical Information
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
R e p a i r Gr o u p
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed
Service
All rights reserved
No reproduction without prior agreement from publisher
Copyright © 2018 Audi AG, Ingolstadt 001KAH00020
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
Contents
1 Safety precautions1
11 Fuel tank and fuel pipes 1
12 Air conditioning system / refrigerant 1
13 Electronic control units 1
14 Battery, power supply 2
15 High-voltage components / electric vehicles 2
16 Natural gas vehicles 2
2 General notes on body repairs 3
21 Original joint 3
22 Galvanised body parts 3
23 Removing remaining material 3
24 New parts3
25 Moulded foam inserts 4
3 Explanation of symbols 5
31 Symbols relating to procedures for separating components 5
32 Symbols relating to welding, brazing and soldering 5
33 Symbols relating to rivets6
34 Symbols relating to preparation 7
35 Symbols relating to corrosion protection8
4 Vehicle body construction features 9
41 Multi-material mix9
42 Body structures 9
5 Assessing damage10
51 General notes 10
52 Checking weld seams and aluminium node castings 10
53 Load paths10
54 Measuring procedures / damage diagnosis 13
55 Overview of materials used 14
56 Passive safety 19
6 Thermal joining techniques 23
61 Resistance spot welding (RP) 23
62 Shielded arc plug welding (SG plug welding) 24
63 SG continuous seams and stitch weld seams 25
64 MIG soldering/brazing 26
65 Aluminium welding27
66 Laser welding 28
67 Laser soldering/brazing 29
68 Replacement joining techniques in repair work (steel) 29
69 Replacement joining techniques in repair work (aluminium) 30
7 Cold joining techniques 31
71 Bonding 31
72 Rivets 33
73 Overview of riveting attachments (pairs of tools)37
74 Overview of rivets and tools 38
75 Overview of rivets used for repair measures 45
76 Flow-drill screws (FDS) 46
77 Clinching 48
8 Separating techniques in body welding; areas of application 49
81 Drilling 49
82 Saw-cutting49
83 Grinding 49
84 Milling 50
General InformationBody Repairs, General Body Repairs – Edition 042018
Contents i
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
85 Separating bonded joints50
86 Pulling out rivets which are only accessible from one side 50
9 Surface repairs 51
91 Dent removal techniques for sheet steel51
92 Dent removal procedures for aluminium panels 52
93 Bonded joints with aluminium 53
94 Processing metal and aluminium filler 53
95 Processing unleaded tin 54
96 Definition of “accurately aligned surface” / handover to paint shop 54
10 Performing straightening work on body structure55
101 Straightening 55
102 Separating cuts 55
103 Body sub-parts and part sections55
11 Corrosion protection 56
111 Corrosion protection for attachments and welded parts 56
112 Cavity sealing 56
12 Plastic repairs 58
121 Repairing dents 58
122 Repairing scratches 59
123 Repairing cracks and tears (up to a length of 100 mm) 60
124 Repairing holes (up to 30 mm diameter)61
125 Plastic repairs (glass fibre materials) 63
13 Glass repairs 66
131 Repairing windscreens 66
14 Thread repairs 68
141 Thread repairs for safety-related components 68
General InformationBody Repairs, General Body Repairs – Edition 042018
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
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