Repair manual
Wiring diagrams
Audi A8 D2 Repair Manual
Step-by-step repair and maintenance instructions for the Audi A8 D2 (1994–1999): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
68sections
778articles
ENManual language
- A/C refrigerant system (R-134a), safety measures
- A/C refrigerant system, general repair guidelines
- Commercial designation
- Color
- Airborne properties
- Solubility of refrigerant oil
- Effects on the environment
- Toxicity
- Temperature/pressure relationship
- Effects on plastics
- Effects on metal
- Critical temperature/critical pressure
- Water solubility
- Flammability
- Refrigerant containers
- Leak detection
- A/C refrigerant oil (PAG), properties
- Refrigerant system with restrictor and accumulator
- A/C compressor
- A/C condenser
- Evaporator
- Accumulator
- Restrictor
- O-rings
- Hoses and lines
- A/C refrigerant system (R-134a), valves and switches
- Pressure relief valve
- Function
- A/C refrigerant high pressure switches -F23- and -F118
- Function of -F23
- Function of -F118
- Valve connections for pressure switches
- Connections for quick coupling adapter on refrigerant circuit
- High pressure service connection with Schrader valve
- A/C refrigerant system (R-134a), pressure & temperature relationships
- Refrigerant circuit with restrictor and accumulator
- Contact corrosion!
- A/C system refrigerant system, servicing
- Switch -F23
- Switch -F118
- Removing and installing
- A/C pressure switch -F129-, functions
- Switching pressures (in bar)
- Testing
- O-rings for refrigerant system
- A/C compressor from mounting bracket, removing and installing
- Nippondenso compressor
- Removing and installing clutch plate bolt
- Pulling off clutch disc
- Installing magnetic coil
- Checking and adjusting gap
- Automatic Climate Control components in engine compartment, servicing
- Sensor for air quality -G238-, function
- Test requirements
- Preparation
- Sensor for air quality -G238-, removing and installing
- Air flow flap motor -V71-, removing and installing
- Recirculation flap motor -V113-, removing and installing
- Control module for fresh air blower -J126-, removing and installing
- Pump valve unit, removing and installing
- Pump valve unit, replacing
- Dust and pollen filters, removing and installing
- Automatic Climate Control components in passenger compartment, servicing
- A/C control head -E87-, removing and installing
- Changes to model year 2000 vehicles
- For A/C control head with part numbers beginning with Index "M"
- Checking
- Heater cores, removing and installing
- Special tools and equipment
- Passenger-side heater core, removing and installing
- Version "1" heater core, removing
- Version "2" heater core, removing
- Version "1" heater core, installing
- Cleaning
- Version "2" heater core, installing
- Driver-side heater core, removing and installing
- Flap and vent motors, servicing
- Left center vent motor -V110- and right center vent motor -V111-, removing and installing
- Center vent adjusting motor -V102-, removing and installing
- Defroster flap motor -V107-, removing and installing
- Left footwell flap motor -V108- and rear footwell vent motor -V112-, removing and installing
- Temperature regulator flap motor -V68- and right footwell flap motor -V109-, removing and installing
- Instrument panel interior temperature sensor -G56-, removing and installing
- Center air outlet in instrument panel, removing and installing
- Making special tool
- Side window air outlet in right (left) of instrument panel, removing and installing
- Climate Control Components in passenger compartment, updates from m.y. 2000
- Air distribution, schematic diagram
- Preparatory work
- Automatic Climate Control System heating performance and operation of pump valve unit, testing
- A/C refrigerant system (R-134a), components
- A/C condenser, removing and installing
- Restrictor, removing and installing
- A/C refrigerant lines from Nippondenso compressor, removing and installing
- A/C compressor, removing and installing
- A/C evaporator, removing and installing
- Removing
- Removing version "2" evaporator
- Installing
- Air conditioner housing, removing and installing
- Air conditioner housing, disassembling and assembling
- Screen, fresh air blower, evaporator and covers in plenum, removing and installing
- Disassembling And Assembling Cover With Recirculating Air Flap
- Disassembling And Assembling Intake Shaft
- Air conditioner housing (lower) and air distribution housing, disassembling and assembling
- Air distribution housing, disassembling and assembling
- A/C refrigerant system (R-134a), leak testing
- A/C refrigerant system (R-134a), testing with pressure gauges
- Measuring pressure and temperature in a "switched-on" refrigerant system
- Measuring pressure and temperature in a closed container or "switched-off" refrigerant system
- A/C refrigerant system (R-134a), checking pressures
- Preparation work
- If A/C refrigerant system base pressure is less than specified on chart, system is low on refrigerant
- If A/C refrigerant system pressure corresponds to or is higher than base pressure specified on chart
- Pressure in refrigerant circuit corresponds to chart or is higher
- Refrigerant R-134a
- Refrigerant (PAG) oil
- A/C refrigerant system (R-134a), discharging
- Discharging
- A/C refrigerant system (R-134a), evacuating & recharging
- Evacuating & recharging
- A/C refrigerant system (R-134a), flushing with compressed air and nitrogen
- A/C does not cool (cooling has stopped completely)
- Insufficient cooling during all driving or engine speed (RPM)
- A/C compressor noisy
- A/C compressor noisy immediately after switching A/C ON and/or when driving around corners or braking "refrigerant shock" -refrigerant system Overcharged
- With an otherwise properly operating A/C system, water sprays out of instrument panel vents
- A/C refrigerant system (R-134a), replacing components
- DESCRIPTION & OPERATION
- BLEEDING PROCEDURES
- Without Electronic Stability Program
- With Electronic Stability Program
- BRAKELIGHT SWITCH
- PARKING BRAKE
- POWER BOOSTER PUSH ROD
- BRAKE PAD INDICATOR LIGHT
- REMOVAL & INSTALLATION
- CALIPER (FRONT)
- HP2 Steel Caliper Bracket Retrofit
- FRONT PADS (FN3)
- Removal (FN3)
- Installation (FN3)
- FRONT PADS (HP2, ALUMINUM CALIPER)
- FRONT PADS (HP2, STEEL CALIPER
- Removal (HP2, Steel Caliper)
- Installation (HP2, Steel Caliper)
- FRONT PADS(BREMBO)
- Removal (Brembo)
- Installation (Brembo)
- Removal
- Installation
- PARKING BRAKE CABLES
- PARKING BRAKE LEVER
- REAR PADS
- Disassembly & Reassembly
- FRONT CALIPER (HP2, ALUMINUM CALIPER)
- FRONT CALIPER (HP2, STEEL CALIPER)
- FRONT CALIPER (BREMBO)
- Cleaning & Inspection
- MASTER CYLINDER
- VACUUM POWER BOOSTERS
- TORQUE SPECIFICATIONS
- DISC BRAKE SPECIFICATIONS
- Safety precautions
- Rules of cleanliness
- Technical data
- Component locations, overview
- Intake air system with Mass Air Flow (MAF) sensor
- Fuel rail and fuel injectors
- Dual-stage intake manifold with intake manifold change-over valve
- VAG1598/19 test box, connecting
- Engine Control Module (ECM) (without metal anti-theft housing), replacing
- After installation of new ECM
- Engine Control Module (ECM) (with metal anti-theft housing), replacing
- Installing Engine Control Module (ECM)
- Engine idle speed and CO content, checking
- Requirements
- Fuel pressure regulator and residual fuel pressure, checking
- Preparation
- Checking fuel injector leakage
- Checking fuel injection volume
- Installing
- Fuel pump relay, checking
- Checking function of fuel pump relay -J17
- Oxygen Sensor (O2S) control, checking
- Checking
- Heated Oxygen Sensor (HO2S) signal wiring and wiring connections, checking
- Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) signal wiring and wiring connections, checking
- Oxygen Sensor (O2S) heating, checking
- Heated Oxygen Sensor (HO2S) aging, checking
- Test conditions
- If specified values are not displayed
- Heated Oxygen Sensor (HO2S), removing and installing
- IAC function, checking
- Checking idle air control signal from ECM
- Closed Throttle Position (CTP) switch, checking
- Intake Manifold Tuning (IMT) valve function, checking
- Function, checking
- Checking voltage supply
- Electrical check
- Test requirement
- Checking actuation
- Motronic ECM power supply relay, checking
- Throttle Position (TP) sensor, checking and adjusting
- Checking function
- Adjusting
- Mass Air Flow (MAF) sensor, checking
- Checking MAF sensor -G70
- Checking MAF sensor signal wiring
- Engine Speed (RPM) sensor, checking
- Engine Coolant Temperature (ECT) sensor, checking
- Intake Air Temperature (IAT) sensor, checking
- Air conditioning signals, checking
- Rear window defogger signal, checking
- Engine Speed (RPM) signal, checking
- Vehicle Speed Sensor (VSS) signal, checking
- Requirement
- Automatic transmission selector lever position signal, checking
- CAN-bus data exchange between Motronic ECM and automatic transmission TCM, checking
- CAN-bus data exchange between Motronic ECM and ABS control module, checking
- Traction control (ASR) signal, checking
- Fuel level status, checking
- Malfunction Indicator Lamp (MIL) function, checking
- Function
- Available functions
- Malfunction Indicator Lamp (MIL), function
- Functional testing
- Requirements
- Check Diagnostic Trouble Code (DTC) Memory, (scan tool function 02)
- Diagnostic Trouble Code (DTC) table
- Erasing DTC memory
- Output Diagnostic Test Mode (DTM), (scan tool function 03)
- Actuating sequence
- Procedure
- Basic Setting, (scan tool function 04)
- Basic setting
- Engine Control Module (ECM) coding, checking
- Readiness code, checking (m.y. 1997)
- Readiness code, checking (m.y. 1998)
- Readiness code, generating (m.y. 1997)
- Step 1: Check DTC memory
- Step 2: Erase DTC Memory
- Step 3: Heated Oxygen Sensor (HO2S) and Heated Oxygen Sensor (HO2S) 2 (bank 1 and bank 2), readiness
- Readiness code, generating (m.y. 1998)
- Safety precautions
- Transmission controls
- Malfunction recognition by the TCM
- TCM backup functions
- Mechanical backup with non-active control module
- Malfunction Indicator Lamp (MIL), function
- MIL functional check
- Conditions for recognition of a driving cycle (Dcy)
- On Board Diagnostic (OBD), functions
- Electrical and electronic components, locations
- Removing and installing Transmission Control Module (TCM) -J217
- Installing
- VAG 1551 Scan Tool (ST), connecting and selecting function
- Test requirements
- VAG 1551 Scan Tool (ST), overview of available functions
- Code Control Module (scan tool function 07)
- Diagnostic Trouble Code (DTC) table
- Output Diagnostic Test Mode (DTM) (function 03)
- Requirement
- Read Measuring Value Block (function 08)
- Electrical testing
- Testing
- Multi-pin connector (88-pin connector) of TCM -J217- (socket numbers on VAG 1598/20)
- Overview of test steps (of 88-pin connector)
- Disconnecting connector
- Wiring harness between Transmission Control Module (TCM) and transmission, checking
- Transmission diagram for all-wheel drive
- Shift element positions
- Transmission controls
- Malfunction recognition by the TCM
- TCM backup functions
- Mechanical backup with non-active control module
- Malfunction Indicator Lamp (MIL), function
- MIL functional check
- Conditions for recognition of a driving cycle (Dcy)
- On Board Diagnostic (OBD II), functions
- Electrical and electronic components, locations
- Installing
- VAG 1551, connecting and selecting function
- Test requirements
- OBD II functions
- DTC table
- CAN-Bus wire data exchange
- Output Diagnostic Test Mode (DTM) (function 03), conducting
- Requirement
- After successful check of DTC memory
- Control module, coding (function 07)
- Requirements
- Measuring value block, reading (function 08)
- Electrical testing
- Testing
- Overview of test steps (of 88-pin connector)
- Wiring harness between Transmission Control Module (TCM) and transmission, checking
- Shift element positions
- General
- Function
- VAG1551 Scan Tool (ST), connecting and entering address word
- Selecting functions
- Requirements
- End Output
- Bus
- CAN
- The DTC table indicates the bus must be checked
- Is there is a malfunction?
- While checking the bus lines, differentiate between the following two situations
- Three or more control modules are communicating across a "two-line bus system"
- Example 1
- Example 2
- Example 3
- Reconnecting battery, procedures
- Basic setting for the up and down power windows function
- Setting the clock
- Adaptation of throttle valve control module
- Application notes
- Road test
- If there is a complaint, a pin-pointed troubleshooting must be carried out
- Test requirements
- Technical publications required
- Function of Bosch ABS 5.0 Series
- Electronic brake force distribution
- Table of warning light functions
- Function of On Board Diagnostic (OBD)
- Technical data of On Board Diagnostic (OBD)
- Check control module version
- Check DTC memory
- Encode control module
- Read measured value block
- Test table, Display group 1
- Test table, Display group 3
- Electrical testing
- Function of Bosch ABS 5.3 Series
- Two communications systems are in use
- Output Diagnostic Test Mode (DTM)
- Test table, Display group 2
- Note on DTC table
- Electronic Stabilization Program (ESP)
- Safety measures and troubleshooting basics
- Test drive
- Test conditions
- Technical information required
- ESP function
- EBD
- ESP
- Examples
- Hydraulic pump for traction control -V156- and the sensor for brake pressure -G201
- Steering Angle Sensor -G85
- Airbag spiral spring/return spring with slip ring -F138
- Sender for rotation rate -G202
- Sensor for transverse acceleration -G200
- The parking brake switch
- The ABS solenoid valve relay -J106- and the ABS return flow pump relay -J105
- ABS/ESP Control Module CAN Bus
- Indicator light functions, overview
- On Board Diagnostic (OBD), specific functions
- On Board Diagnostic (OBD), technical data
- Control module versions (scan tool function 01), checking
- DTC table
- Basic setting (scan tool function 04)
- Login procedure (scan tool function 11)
- Display group 1: Zeroing the steering angle sensor -G85
- Display group 2: Activating hydraulic pump for traction control -V156
- Display group 3: Activating ESP driving test
- Output Diagnostic Test Mode (DTM) (scan tool function 03)
- Code Control Module (scan tool function 07)
- Measuring Value Block (scan tool function 08), reading
- Test table: display group 1 (001)
- Electrical test table
- Safety precautions
- On Board Diagnostic (OBD) functions
- DTC table for tire pressure monitoring
- Performing coding
- Code: 20129
- Adaptation
- Tire pressure monitoring system, operating for the first time
- V.A.G 1551 scan tool, connecting
- General information
- Conditions
- Control module identification (example)
- Check DTC Memory (function 02)
- Erase DTC Memory (function 05)
- End output (function 06)
- Diagnostic Trouble Code (DTC) table
- Output Diagnostic Test Mode (function 03)
- Code Control Module (function 07) for central locking
- Coding table for vehicles up to 06.97
- Coding table for vehicles from 07.97
- Read Measuring Value Block (function 08)
- Vehicle key for radio remote control, programming/erasing
- Work step of adapting new radio-controlled keys
- Work procedure for re-adapting existing radio-controlled keys
- Work sequence for erasing memory positions
- Function
- Interior monitoring system, functional test
- Interior monitoring system diagnostic
- Diagnostic table
- Corrective action
- Sensor Check
- Replace control module
- Check wiring
- Removing
- Installing
- Assignment of connector at control module
- Assignment of connector at sensor
- Momentary contact deactivation switch, checking
- On Board Diagnostic (OBD) of interior monitoring system, initiating
- Equipment version without side curtain airbag system
- Equipment version with side curtain airbag system
- Output Diagnostic Test Mode (DTM) (function 03) (vehicles without side curtain airbag)
- Special tools, testers and auxiliary items required
- Test sequence
- Output Diagnostic Test Mode (DTM) (function 03) (vehicles with side curtain airbag)
- Code Control Module (function 07) (vehicles without side curtain airbag)
- Code Control Module (function 07) (vehicles with side curtain airbag)
- Adaptation (function 10)
- General information
- Technical data
- System changes from m.y. 1998
- System changes from m.y. 2000 (with revised driver's information display)
- Requirements
- Diagnostic Trouble Code (DTC) Memory, checking (function 02)
- If a DTC was recognized
- Diagnostic Trouble Code (DTC) table
- Changes to model year 2000 and up vehicles
- Output Diagnostic Test Mode (DTM) (function 03)
- Initiating output DTM
- Output Diagnostic Test Mode (DTM) Idle speed control test, initiating
- Basic Setting (function 04)
- End Output (function 06)
- Code Control Module (function 07)
- Coding variants
- Example for A/C control head -E87- up to index "H"
- Example for A/C control head -E87- from index "J"
- Coding A/C control head -E87- (up to index "H")
- Coding A/C control head -E87-, beginning at index "J"
- Coding A/C control head -E87-, model year 2000 and up
- Read Measuring Value Block (function 08)
- Read Measuring Value Block, initiating
- Overview of display group numbers which can be selected
- Display group 001 - A/C compressor cut-off conditions, voltage for A/C clutch -N25-, voltage to terminal 15 and requirement for recirculating air mode/sensor for air quality -G238
- Display group 006-Temperature regulator flap motor -V68
- Display group 012-ACF flap motor -V114
- Display group 013-Left center air vent switch -F183- and right center vent switch -F184-, center vent position sensor -G142- and calculated ambient temperature for outside air temp
- Display group 014-Outside air temperature sensor -G17- and fresh air intake duct temperature sensor -G89-, left vent temperature sensor -G150- and right vent temperature sensor -G1
- Display group 015-Instrument panel interior temperature sensor -G56-, calculated coolant temperature and sunlight photo sensor -G107
- Display group 001: Instantaneous occurring compressor shut off conditions, voltage for A/C clutch, -N25-, Voltage to terminal "15" and requirement recirculation mode/sensor for air
- Display group 021: Idle RPM increase, activating fan for coolant and activating washer system
- Display group 022: Allocation ignition key and signal for "time ignition off"
- Tools required
- Connecting VAG1598/19 test box to connector of A/C control head -E87
- Test step 9 - Signal for washer/wiper system
- Electrical test changes for model year 2000 and up vehicles
- Bus
- Example
- Can-Bus malfunction "Faulty databus drive," checking
- Malfunction is indicated only by A/C control head -E87
- In another control module a malfunction is indicated
- Can-Bus notes
- Required measuring and test items
- Test requirements
- Windshield defroster, disconnecting
- Solar sunroof, checking
- Checking function of solar sunroof
- Data Link Connector (DLC), checking wiring connections
- Instrument cluster technical features
- Display "DEF" in trip recorder
- Notes on exchanging the instrument cluster
- Safety precautions for road testing with use of test equipment
- Information needed
- Test requirements
- OBD functions
- Output Diagnostic Test Mode (DTM) (scan tool function 03)
- In function "Output Diagnostic Test Mode" all sensors of the instrument cluster that are coded are activated.
- Diagnostic Trouble Code (DTC) memory, erasing (scan tool function 05)
- Requirements
- End output (scan tool function 06)
- Code Control Module, (scan tool function 07)
- Coding
- Read measuring value block (scan tool function 08)
- Display group 001
- Display group 002
- Adaptation (scan tool function 10)
- Adaptation (function 10)
- Fuel gauge adaptation
- Adaptation fuel consumption indicator
- Adaptation of service indicator for oil change service (distance)
- Adaptation of service indicator for Inspection Service I (distance)
- Adaptation of service indicator for Inspection Service I (time)
- Adaptation of service indicator for Inspection Service II (time)
- Adaptation of Kilometer-/mile display
- Instrument cluster, values to be entered when replacing
- General
- Function
- Safety precautions for road testing with use of measuring and test equipment
- Additional information
- Diagnostic Trouble Code (DTC) table
- Basic setting (scan tool function 04)
- Control module, coding (scan tool function 07)
- Initiate coding
- Test conditions
- DESCRIPTION
- Pneumatic Circuits
- Tailgate/Trunk Lock
- Remote Control System
- Anti-Theft System
- Programming
- CENTRAL LOCKING SYSTEM
- SELECTIVE CLOSE FEATURE
- CONVENIENCE CLOSE/OPEN FEATURE
- POWER LOCKING SWITCH
- COMPONENT LOCATIONS
- CODE CONTROL MODULE (SCAN TOOL FUNCTION 07)
- Control Module Coding Options (Up To 06.97)
- Control Module Coding Options (Up To 07.97)
- Coding Control Module
- READ MEASURING VALUE BLOCK (SCAN TOOL FUNCTION 08)
- FRONT DOOR COMPONENT CARRIER
- REAR DOOR COMPONENT CARRIER
- SELF-DIAGNOSTIC SYSTEM
- RETRIEVING DIAGNOSTIC TROUBLE CODES
- Connecting VAG Scan Tool (ST)
- Initiating Central Locking System On Board Diagnostic (OBD)
- Check DTC Memory (Function 02)
- Carrying Out "Output Diagnostic Test Mode (DTM)" (Function 03)
- End Output (Scan Tool Function 06)
- Erase DTC Memory (Scan Tool Function 05)
- DIAGNOSTIC TROUBLE CODE DEFINITIONS
- REMOVAL & INSTALLATION
- Removal
- Installation
- Removal & Installation (Front)
- Removal & Installation (Rear)
- Removal & Installation (Fuel Filler Flap)
- Removal & Installation (Rear Lid)
- TORQUE SPECIFICATIONS
- APPLICATION
- SERVICE INTERVALS
- CHECKING FLUID LEVEL
- Rear Final Drive
- RECOMMENDED FLUID
- FLUID CAPACITIES
- DRAINING & REFILLING
- 01L Transaxle
- Transfer Case
- ATF LINES & ATF COOLER FLUSHING
- SELECTOR LEVER CONTROLS
- ON-VEHICLE REPAIRS
- DRIVE SHAFT
- Carbon Fiber
- Steel
- LOCKING CABLE
- Checking
- Adjustments
- 1997-99
- 2000-03
- Removal & Installation (Carbon Fiber)
- Removal & Installation (Steel)
- LEFT DRIVE FLANGE
- Removal & Installation
- REAR FINAL DRIVE FLANGE SEALING RINGS
- SELECTOR LEVER CABLE
- TRANSMISSION RANGE SWITCH
- TORQUE SPECIFICATIONS