Maintenance: Other Audi A8 D2 facelift

Contact corrosion!

With the extensive use of aluminum construction, corrosion caused by contact between dissimilar metals may result if the wrong fastening components (screws, bolts, nuts, washers, rivets, plugs, grommets, adhesives, etc.) are installed.

For this reason, the manufacturer only installs fastening components that have a special surface coating, recognized by its greenish color, and only uses rubber parts, plastic parts and adhesives that are electrically non-conductive.

These parts, compatible for use with aluminum, are also available as replacement parts.

use only Genuine Parts!

If there is any doubt about whether the old parts are suitable for re-use, always install new replacement parts.

All accessories must be approved by Audi of America, Inc.

Damage from contact corrosion caused by improper assembly with unsuitable parts is NOT covered under warranty!

Windshield washer system, servicing

1. Check aim of nozzles, and adjust if necessary with special tool VAG3125.

Nozzle aiming dimensions

1. a- = 250 mm (9.8 in.)
2. b- = 280 mm (11.0 in.)
3. c- = 180 mm (7.1 in.)
4. d- = 500 mm (19.7 in.)

Tolerance: 20 mm (0.8 in.)

Note. If the spray jet is uneven or cannot be adjusted to the specified settings, replace the nozzle.

Filling windshield washer/headlight cleaner reservoir

1. Fill reservoir to top. Always add windshield cleaner to water and add anti-freezing agent in winter.

Headlight cleaning system nozzles

The spray nozzles of the headlight cleaning system are factory set and therefore do not need to be adjusted.

Windshield wiper blade park position, checking and adjusting

1. Position wiper blades on markings on windshield and tighten arms.
2. Operate single wipe cycle.
3. Align wiper arms and tighten mounting nuts. Tightening torque: 16 Nm (12 ft.lb.)

Reasons for windshield wipers to skip

1. Windshield scratched
2. Wiper blade rubber insert loose or torn
3. Wiper arms or blades loose or bent
4. Wiper blade rubber insert waxed or deformed

If none of above listed causes for skipping or jerking apply, check and if necessary adjust the contact angle of the wiper blades.

Checking wiper blade contact angle

1. Move wiper arms to park position.
2. Remove wiper blade.
3. Insert wiper arm -2- in 3358 B windshield wiper adjuster and tighten with set screw -3-.
4. Compare measured angle with specified value in table.

Adjusting windshield wiper arms

1. Move wiper arms to park position.
2. Remove wiper blade.
3. Insert wiper arm -2- in 3358 B windshield wiper adjuster and tighten with set screw -3-.
4. Apply open end wrench -1- to adjustment tool and bend wiper arm -2- according to specified value -arrows-.
5. Specified value, see «CHECKING WIPER BLADE CONTACT ANGLE»(ref-196906-S14998982892005101000000) .
6. Loosen set screw -3- and release wiper arm -2- from adjustment tool.
7. Insert wiper arm -2- again in 3358 B windshield wiper adjuster tool and tighten again with set screw -3-.
8. Compare measured angle with specified value in «CHECKING WIPER BLADE CONTACT ANGLE»(ref-196906-S14998982892005101000000) .
9. If necessary, repeat bending the arm and check again until specified value is reached.
10. Remove adjustment tool and install wiper blade.

Clock, setting

Two push-buttons for setting the clock are located on the bottom left of the instrument cluster.

1. Press both buttons at same time and hold until display flashes.
2. Press left-hand button to set hours.
3. Press right-hand button to set minutes.

If a button is pressed and held for some time, the display will change faster.

The display stops flashing and the time setting is completed about 15 seconds after the buttons are released.

Radio anti-theft coding, activating

A code is programmed into each radio with anti-theft coding. The coding is not activated before the radio leaves the factory. The coding is first activated by entering the code as follows

1. Switch radio on.
2. Press FM and DX buttons at same time and hold until "CODE" appears in digital frequency display.
3. Release buttons. "1000" is automatically displayed shortly afterward
4. Press station buttons -1- through -4- to enter code number indicated on radio card. Enter first digit of code by pressing button -1-, second digit by pressing button -2-, etc. Each place of code number can be assigned a digit from 0 to 9 It is possible to program a code number with up to 4 digits
5. Once code number is entered, again press FM and DX buttons at same time and hold until "SAFE" is displayed.
6. Release buttons. A frequency is automatically displayed shortly afterward

The radio is now ready for use and the anti-theft coding has been activated.

Service Reminder Indicator (SRI), adapting displays

After the ignition is switched on (engine not started), the next service due is displayed (flashed) for a few seconds in place of the trip recorder reading.

If the due date for a service has been reached, one of the following flashing displays also appears for a few seconds after the engine is started

SERVICE REMINDER INDICATOR DISPLAY

A service which is due is displayed 1000 km (620 mi.) or 10 days before the predetermined mileage or date is actually reached.

During the Pre-Delivery Inspection (PDI) or each Inspection service the SRI should be adapted to the distance and time intervals specified until the next required service (i.e. from the date and mileage that the present service is being carried out) using the VAG1551 Scan Tool.

The SRI is adapted by selecting the adaptation channels individually and entering the corresponding adaptation values.

Scheme 30

Scheme 31

The following displays are adapted depending on the service carried out.

Instrument cluster display, adapting language version

Before the vehicle is delivered to the customer, it is possible to select one of the following languages for the display of the instrument cluster combination processor

1. German
2. English
3. French
4. Italian

The instrument cluster is adapted to show the displays in German when the car leaves the factory. Perform the following steps in order to adapt the language version

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

1. Connect VAG1551 Scan Tool, see «CONNECTING VAG1551 SCAN TOOL, ADAPTING SRI DISPLAYS»(ref-196906-S39247068532005101000000) .
2. Switch ignition on.
3. Press button -1- to select "Rapid data transfer" operating mode 1.
4. Press buttons -1- and -7- to insert "Instrument Cluster" address word 17.
5. Advance through program sequence using --> button.
6. Press buttons -1- and -0- to select "Adaptation" function 10.
7. Press -Q- button to confirm input.
8. Press buttons -0- and -4- to select channel 04.
9. Press -Q- button to confirm input. Indicated on display
10. Advance through program sequence using --> button. Indicated on display
11. Input the specified value according to table below. LANGUAGE ADAPTATION VALUE Language version Adaptation value German 00001 English 00002 French 00003 Italian 00004 NOTE: Enter "0" for each of the first four digits. If an incorrect entry is made, the "Adaptation" function is ended and must be initiated again.
12. Press -Q- button to confirm input. The newly entered value (example: 2) is indicated on the display.
13. Press -Q- button to confirm input. Indicated on display
14. Press -Q- button to confirm. Indicated on display
15. Press => button to end coding. Indicated on display. Adaptation of channel 04 is ended.

Requirements

1. Tires inflated to correct pressures
2. Lenses clean and free of damage
3. Reflectors in proper condition
4. Springs settled (load vehicle with one person or 75 kg/165 lbs. in driver's seat and roll several meters/yards)

Adjusting headlight aim

Main headlight (right)

1. Height adjustment
2. Lateral adjustment

1. Adjust light using suitable screwdriver.

The positions of the two adjusting wheels are reversed on the left-hand headlight.

Scheme 38

Service

Align vehicle headlamps using the VAS5107 (Hella Universal Beamsetter IV) and the following procedure

Additional instructions and diagrams => Instruction Manual for the Hella Beamsetter Series IV

1. Position vehicle on a flat floor surface that meets the following (ISO 10640) specifications: 0.5mm or less slant from front wheel to back wheel of the Beamsetter -A-. 1 mm or less slant per meter for the length of the vehicle -B-.
2. Clean headlight lenses.
3. Adjust vehicle tire pressure to specifications. Have a second technician sit in the driver's seat while aligning the headlights.
4. Bounce front and rear of vehicle up and down several times to settle vehicle suspension.

Aligning fog lamp

1. Switch fog lamps ON.
2. Align Beamsetter box with fog lamp (make sure it is between 30 and 70cm from the fog lamp lens).
3. Set Beamsetter scaled wheel to 1.4%.

Adjust fog lamp so the top of the beam pattern aligns with the centerline of the target grid on the beam pattern screen.

Scheme 39

Door locks and lock buttons

1. Open and close driver and front passenger doors.
2. Lock buttons must move up when opening and down when closing each door
3. Press lock buttons down on front passenger and rear doors and close doors.

Doors must be locked

It must not be possible to press the lock button down on the driver door while the door is open.

Child safety locks (rear doors)

1. Move lever on door lock down in direction of arrow (refer to marking on door lock).

Door lever on inside must be inoperative while lock button is in unlocked position

Note. If the door locks do not operate freely, they must be removed, cleaned and greased.

Interior monitoring system, checking

The ultrasonic monitoring system must be checked as follows

1. Cover all ultrasonic sensors with masking tape.
2. Open side window to be checked approx. 10 cm (4 in.).
3. Lock vehicle and arm anti-theft alarm and interior monitoring.
4. Wait for 30 seconds until warning light blinks in slow intervals (once every 2 seconds).
5. Reach through window opening and remove tape from sensor. If interior monitor is working properly, alarm will sound
6. Unlock vehicle to stop alarm.
7. Check all other sensors, one after another.
8. Always apply tape to previously checked sensor.

Scheme 40

1. Lubricate front and rear door check straps with G 000 150 grease, only at points shown (arrows).

Battery electrolyte level, checking

1. Check electrolyte level. Electrolyte level must be between MIN and MAX markings If levels are low
2. Top up cells to MAX marking with distilled water.

1. Vehicle parked for at least two hours without any electrical load on battery (no engine starts, no charging or discharging)
2. Battery installed
3. Ignition switched off

Cooling system, checking and correcting antifreeze protection and coolant level

1. Check concentration of antifreeze. NOTE: Coolant must be protected against freezing down to approx. -25° C (-13° F). In regions with an arctic climate, protection must be assured down to approx. -35° C (-31° F). If greater protection is necessary for climatic reasons, the concentration of anti-freeze/anti-corrosion additive may be increased up to 60%, for protection down to approx. -40° C (-40° F). Using a concentration above 60% will decrease protection against freezing and impair cooling efficiency of the coolant. Vehicles produced up to 06.96 have used the coolant additive G11-A8C (color: green). For vehicles produced from 07.96, only the coolant additive G12-A8D TL 774D (color: red) is used, which does not normally need to be replaced. If the protection is insufficient
2. Drain volume specified in correction table and replace with anti-freeze/anti-corrosion additive. For coolant specifications, see appropriate Cooling System, Mechanical article.

Anti-freeze protection correction

ANTI-FREEZE PROTECTION CORRECTION

1. After road test, check antifreeze concentration. When engine is cold
2. Check coolant level at expansion tank. PDI: coolant level up to MAX marking Inspection Service: coolant level between MIN and MAX markings If the coolant level is insufficient
3. Add missing volume with coolant mixed to ratio specified below.

Mixing ratios

COOLANT MIXING RATIOS

Note. To avoid frost and corrosion damage, and to increase the boiling point of the coolant, the cooling system must be filled year-round with a mixture of anti-freezelanti-corrosion concentrate and water. The concentration of antifreeze must not be reduced by topping up with water during warm seasons or in warm regions. The coolant additive concentration must be at least 40%. The higher boiling point of the coolant contributes to operational safety when the engine is working under heavy loads, particularly in regions with tropical climates.

Coolant, replacing

Note. Recommended mixing ratio: 50:50 Capacity: approx. 9 liters (9.5 qts.) Always drain coolant into a clean container.

Scheme 41

1. Carefully open cap on expansion tank (to release pressure), then close cap again.
2. Remove noise insulation panel. See «NOISE INSULATION PANEL, REMOVING AND INSTALLING»(ref-196906-S40004704632005101000000) .
3. Remove air grille from left region of front bumper.
4. Place VW 1306 drain pan (or equivalent) beneath car.
5. Attach auxiliary hose to drain tap on bottom left of radiator. Hose inner diameter: approx. 12 mm (1/2 in.)
6. Route other end of hose into drain pan.
7. Open coolant drain plug through hole for air intake grille.
8. Open drain plug on left of engine below knock sensor.
9. Open drain plug on oil cooler housing behind oil filter.
10. Disconnect return line from radiator to expansion tank at radiator.
11. Hold line connection at radiator closed with finger.
12. Blow compressed air into disconnected return line until no more coolant flows out from any drain opening.

Filling system with coolant

1. Close drain plugs at left of engine block, at oil cooler housing and at bottom left of radiator.
2. Attach return line to radiator.
3. Remove cap from expansion tank, install VAG1274/1 adapter and extend with 42 mm diameter auxiliary hose 100 mm long (1.65 x 3.94 in.).
4. Open bleeder screws at feed and return lines of heating system. see scheme 52
5. Pour in coolant until it flows out at bleeder screws.
6. Close bleeder screws.
7. Install cap on expansion tank.
8. Disconnect two-pin connector for pump unit.
9. Switch climate control to LO setting.
10. Start engine and maintain engine speed at approx. 2000 RPM for approx. 3 minutes.
11. Check level in expansion tank; top up to MAX if necessary. WARNING: The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth, and open carefully to relieve system pressure slowly.
12. Reconnect two-pin connector.
13. Switch climate control to HI setting.
14. Set blower to lowest speed.
15. Start engine and maintain engine speed at 2000-3000 RPM for approx. 10 minutes.
16. Switch ignition off.
17. Switch ignition on. With climate control in HI setting, electric pump of system must NOT make any noises. Otherwise there is air in heating system and bleeding process must be repeated. If no noises can be heard
18. Switch ignition off, check coolant level in expansion tank and top up if necessary.

Dust and pollen filters, replacing

The dust and pollen filters are located on the underside of the hood.

1. Turn clamping pins -A- and remove filter.
2. Replace filter element.

Spark plugs, replacing

1. Remove air intake pipe between air cleaner housing and throttle body.
2. Remove engine cover.
3. Remove ignition coils.

Tightening torque for spark plugs: 30 Nm (22 ft.lb.)

Scheme 42

Brake pad thickness, checking

Note. If the thickness of the pad (including the backing plate) is 7 mm (0.28 in.), the brake pads have reached their wear limit and should be replaced.

Front brake pads

1. Clean insides of wheels.
2. Determine thickness of outer and inner pads by inspecting visually. Outer pad: with aid of light shone through opening in disc wheel Inner pad: with aid of light and mirror Dimension -a- equals pad thickness including backing plate Wear limit: 7 mm (0.28 in.)

Rear brake pads

1. Remove rear wheels. NOTE: Mark the position of each wheel relative to the brake disc and install the wheel in the same position after the inspection.
2. Determine thickness of outer and inner pads. Dimension -a- equals pad thickness including backing plate Wear limit: 7 mm (0.28 in.)
3. Thoroughly clean all dirt from wheels.
4. Install wheels and tighten wheel bolts. Tightening torque: 120 Nm (89 ft.lb.)

Tie rod ends, checking

Note. The inspection must be performed with the vehicle raised (wheels clear of the ground).

1. Check for play by moving tie rods and wheels. Specification: no play
2. Ensure proper and secure attachment.
3. Check dust boots for signs of damage and for correct installation.

Tire condition and wear pattern (including spare), checking

Pre-Delivery Inspection

1. Check tire tread pattern and side walls for signs of damage; remove any foreign bodies such as nails or splinters.

Tire tread depth (including spare), checking

1. Check tread depth. Minimum tread depth: 1.6 mm (0.063 in.)

Note. The minimum tread depth may differ in certain countries because of different legal requirements.

If the tread depth is close to the minimum legal allowable depth, i.e. if the 1.6 mm (0.063 in.) wear indicators spaced around the tire circumference no longer have any tread pattern, the customer must be informed.

Tire pressures (including spare), checking

Tire pressures are indicated on a label inside the fuel filler lid.

1. Pressure values listed apply to cold tires
2. When using winter tires, respective pressures must be increased by 0.2 bar (3 psi)
3. For the spare tire, maintain the highest inflation pressure specified for the vehicle

Engine oil level, checking

1. After switching ignition off, wait at least 3 minutes to allow oil to flow back into sump.
2. Withdraw dipstick, wipe off with clean cloth and insert dipstick fully.
3. Withdraw dipstick again and note oil level indicated.

Marking ranges on dipstick

1. Oil MUST NOT be added
2. Oil may be added. After adding oil, level may then be in range -a
3. Oil MUST be added. After adding oil, it is sufficient if level is then somewhere in range -b- (knurled area)

Pre-Delivery Inspection (PDI)

At the PDI the brake fluid level must be at the MAX marking.

Procedure

Use new brake fluid with part number B 000 700 A (corresponds to US standard FMVSS 116 DOT 4)

Note. Part numbers are for reference only! Check with parts department for correct part number. Only use new brake fluid conforming to US standard FMVSS 116 DOT 4 Genuine VW/Audi brake fluid conforms to this specification.

Note the following

For this reason the brake fluid pressure at the VAS5234 Brake filler and bleeder unit must be adjusted down to 1 bar. See instruction manual for VAS5234.

Observe instruction manual for VAS5234!

1. Remove brake fluid reservoir cap.
2. Insert suction hose from VAS5234 to extract as much brake fluid as possible from brake fluid reservoir.
3. Install VAG1869/2 brake pedal depressor between driver's seat and brake pedal and apply tension. WARNING: Do not reuse used / extracted brake fluid!
4. Install VAS5234/1 adapter to brake fluid reservoir.
5. Connect filler hose from VAS5234 to VAS5234/1 adapter.

Vehicles with manual transmission

1. Pull cover cap off clutch slave cylinder bleed screw.
2. Connect collecting bottle bleeder hose -A- to bleeder screw of clutch slave cylinder -arrow-, open bleeder screw and allow approximately 0.1 liter to flow out. Close bleeder screw and install cover cap.
3. Operate clutch pedal several times.

Continued for all vehicles

1. Connect collecting bottle bleeder hose -1- to rear right bleeder screw, open bleeder screw and allow the appropriate quantity to flow out (see «BRAKE FLUID QUANTITY»(ref-196906-S01321386332005101000000) ), then close bleeder screw.
2. Repeat procedure on rear left bleeder screw.
3. Connect collecting bottle bleeder hose -1- to front right bleeder screw, open bleeder screw and allow the corresponding quantity to flow out (see «BRAKE FLUID QUANTITY»(ref-196906-S01321386332005101000000) ), then close bleeder screw.
4. Repeat procedure on front left bleeder screw.
5. Install cover caps on brake caliper bleeder screws.
6. Move filler lever on VAS5234 to position -B- (see operating instructions).
7. Take filler hose off VAS5234/1 adapter.
8. Remove adapter from brake fluid reservoir.
9. Check brake fluid level and top off if necessary.
10. Reinstall brake fluid reservoir cover -1-.
11. Remove brake pedal depressor VAG1869/2.
12. Check pedal pressure and brake pedal free play. Free play: max 1/3 of pedal travel.

BRAKE FLUID QUANTITY

Total quantity: 2 liters (2.1 quarts) (not including amount extracted from brake fluid reservoir).

Transportation safety blocks, removing

Some vehicles are suppled with brightly colored safety blocks installed in the front suspension struts. These vehicles are identified by means of a special tag hung over the mirror.

1. Release pressure on coil springs (e.g. by lifting vehicle using vehicle lift). NOTE: It is not necessary to remove the wheels.
2. Pull down overload spring -2-.
3. Remove safety blocks -1- (two blocks in each strut).
4. Push overload spring -2- upwards and clip into spring retainer.

Engine

1. Check output, acceleration, hot starting and idling characteristics.
2. Check for misfiring.

Automatic transmission

1. Check selector lever position, shift lock/ignition key lock, shifting characteristics, and transmission range selector lever display in instrument cluster.

Foot brake, parking brake

1. Check operation of foot brakes, parking brake and ABS.
2. Check for pulling to one side during braking.
3. Check for rubbing and squeaking.

Sunroof

1. Check operation.

Cruise control system

1. Check operation.

Radio

1. Check reception and GALA operation.
2. Check for interference.

On-board computer, auto-check system

1. Check operation.

Steering wheel

1. Check that wheel is centered when driving straight ahead.

Handling

1. Check for pulling to side when driving straight ahead (on flat road).

Imbalance

1. Check for vibrations from wheels, axle shafts, and drive shaft.

Noises

1. Check for wind noises, squeaks and rattles.

Wheel bearings

1. Check for noises.

Within 48 Hours after arrival at Dealer

Important!

If any defects on the exterior have been identified (scratches, dings, dents and other types of body damage)

1. Contact your Service Manager and arrange to repair defects immediately.

Note. After removal of RAPGARD(R), some vehicles may exhibit temporary paint discoloration or paint swelling (caused by trapped moisture under the RAPGARD(R)).

1. This temporary swelling is caused by the paint finish absorbing moisture trapped under the RAPGARD(R) film.
2. This swelling will disappear with exposure to the sun or heat lamps within 2 - 3 hours. Severe Paint swelling may require 2 - 3 days to recover.

DO NOT buff or refinish paint for this condition!

After inspecting and removing RAPGARD(R), washing vehicle, inspecting and repairing any defects in paint surfaces, moldings and glass

1. Protect the vehicle paint surface by applying 3M Perfect It(tm) Paste Wax (3M Part No. 39526) or equivalent.

RAPGARD(R) Disposal

RAPGARD(R) can be disposed as normal paper waste. If unsure about proper disposal procedures in your area, check local regulations.

For all Models arriving at your dealership with transportation wiper blades

Transportation wiper blades are shorter than original equipment wiper blades and colored blue or yellow.

To ensure customer satisfaction, leave transportation wiper blades on vehicle until time of retail vehicle delivery.

Transportation wiper blades, removing

Transportation blades can easily be removed as follows

1. Grasp blade as shown and rotate in direction of arrow (toward windshield).
2. Rotate blade in opposite direction (black arrow) then, carefully slide blade off wiper arm.

Note. Wiper arm/blade alignment has been preset at the factory, then checked and adjusted (if necessary) during the PDI.

DO NOT twist or bend the wiper arm. If wiper arm/blade alignment is incorrect, chattering and/or streaking will occur.

If arm has been bent

See WINDSHIELD WIPER AND WASHER SYSTEM .

1. Install original equipment wiper blades (located in trunk) at the time of retail vehicle delivery.

Note. Wiper blade with air deflector (arrow) must be installed on driver's side with deflector on bottom of wiper blade. Passenger's side wiper blade may be curved, install with curved ends of blade pointing up.

Engine code and engine number

Location: on left-hand side of cylinder block directly above hydraulic pump

Note. The engine code is also given on the vehicle data plates in the owner's Maitenance booklet and in the spare wheel well.

Scheme 43

Vehicle, lifting

Vehicle lift

1. Make sure there is sufficient clearance between lowest parts of vehicle and vehicle lift before driving onto lift.

Workshop trolley jack

1. If a trolley jack is used it must also only lift at the points shown in the illustration.

Positioning points for vehicle lift and workshop trolley jack

Front and rear locations: oval rubber blocks on car floor

Scheme 44

Towing

The towing eye provided in the vehicle tool kit must be installed in a threaded socket in the front or rear of the vehicle to enable it to be towed. The sockets are located below the bumpers on the right side of the vehicle.

To access the front towing eye socket

1. Remove screw from air inlet grille and remove grille.

To access the rear towing eye socket

1. Pry cover out of bumper using screwdriver.

After removing the relevant trim cover, the towing eye can be installed tightly.

1. After use, remove towing eye and place in vehicle tool kit storage compartment.

The towing eye must always be carried in the car.