Contents Wiring diagrams Section: Procedures All sections

Maintenance Procedures: Other Audi A8 D3 facelift

Procedures 88 illustrations ~8756 words

Oil change service

For information regarding oil change service, refer to ServiceNet; Maintenance Schedules for appropriate model year. Also for oil type and usage, refer to ServiceNet; Additional information; Fluid Capacity Charts for appropriate Model and Year

Contact corrosion

Contact corrosion can occur if improper fastening elements (bolts, nuts, washers, etc.) are used.

For this reason, only fastening elements with a special surface coating are installed. These elements can be recognized by their green color.

In addition, rubber, plastic parts and adhesive are made of non-conductive material.

If there are doubts as to whether parts can be reused, install new parts.

WARNINGOnly using original Audi A8 parts! Accessories must be approved by Audi AG! Damage due to contact corrosion is not covered by warranty!

All switches, all electrical components, all displays and other operating elements: Checking function

  1. Check following
  1. Lighting, headlamps, fog lights, turn signals, hazard warning flashers, taillights, rear fog lights, backup lights, brake lights, parking lights
  2. Interior and reading lights (automatic shutoff on interior lights), illuminated storage compartment, illuminated ashtray, luggage compartment lighting, illuminated ignition
  3. Warning buzzer for lights and/or radio left on
  4. All switches in console
  1. MMI function (radio, navigation, etc.)
  2. Driver Information System (DIS)
  3. Instrument unit with all displays, meters and lights
  4. Two-tone horn
  1. Windshield/headlamp wipers, headlamp cleaning system
  2. Cigarette lighter
  3. Electrical exterior mirrors (heated, adjustable, foldable)
  4. Electric windows
  1. Electric tilt/slide sunroof
  2. Sun shade
  3. Central locking, remote control operation, comfort closing
  4. Electrical seat, headrest, steering wheel and seatbelt height adjustment
  1. Heated seats and rear seat bench, heated steering wheel

Final drive (automatic transmission): Check oil level, add oil if necessary

Automatic Transmission --> - 39 - FINAL DRIVE, DIFFERENTIAL , 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE or 39 - FINAL DRIVE, DIFFERENTIAL , 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE

Continuously Variable Transmission (CVT) --> - 39 - FINAL DRIVE, DIFFERENTIAL , 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE or 39 - FINAL DRIVE, DIFFERENTIAL , 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE

Scheme 27

Scheme 27: Center cap
  1. The removal hook - A - for removing the center cap is located in the vehicles tool kit.

Wheel bolts

The adapter to loosen/tighten the anti-theft wheel bolts is located with the vehicle tool kit.

Note. Be sure to tighten wheel bolts in diagonal sequence to the following specified torque

Tightening torqueNm
Wheel bolts120
  1. Place adapter with vehicle tool kit after completing work.

Battery manager: Deactivate transport mode

Transport mode is for maintaining a vehicles startability (battery charge). Transport mode limits discharging of battery. If transport mode is activated, many functions are not available or have limited function, for example, CD changer is deactivated, radio is deactivated, etc.

Deactivate transport mode using guided fault finding or guided functions.

  1. Follow these steps in sequential order.

Scheme 28

Scheme 28
  1. Connect VAS 5051/5052
  2. Guided Fault Finding or Guided Functions
  3. Go to - function/component selection
  4. Service work
  1. Energy manager, activate/deactivate transport mode
  2. Now follow guided program

Battery with magic eye

  1. Switch ignition off and remove ignition key.

Scheme 29

Scheme 29
  1. Remove right luggage compartment side trim cover - arrows -.

Scheme 30

Scheme 30
  1. Remove cover - 1 - over battery.

Note. Ignore item - 2 -.

Scheme 31

Scheme 31
  1. The magic eye - arrow - gives information about electrolyte level and battery charge.
  2. Three color displays are possible
Color displayBattery level
GreenBattery is sufficiently charged
BlackNo charge or charge too low
Colorless or yellowElectrolyte has reached critical level, battery must be replaced! --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Note. If the battery was recharged, that is, if it was charged while driving, air bubbles can form under the magic eye. These cause an incorrect magic eye color display. If batteries are equipped with plugs for production reasons, these are covered with plastic film.

  1. Before performing visual check, carefully and lightly knock magic eye with handle of a screwdriver.
  1. This removes air bubbles.
  1. Read "magic eye" color display.

Battery sealing plugs

  1. On batteries with visible min and max markings, electrolyte level only needs to be checked visually.
  2. Electrolyte level must be between min. and max. markings.
  3. On batteries where the outer min. and max. markings are difficult to see or the visibility of the electrolyte level cannot be guaranteed due to the opaque battery housing, the sealing plugs must be removed. Then it is possible to check electrolyte level by a visual inspection of the battery interior.
  4. The electrolyte level must meet the inner electrolyte level marking (plastic bar). This corresponds to the outer max. mark.

Note. If electrolyte level is too low, battery loses capacity (loses performance) because the cell plates dry out. If the cell plates are not covered by electrolyte, the plates and plate bridges start to corrode causing the function of the battery to diminish. After a while the battery does no longer function. The battery becomes useless.

WARNINGIf the electrolyte level is below them in. marking, the battery must be replaced! --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Battery, disconnecting and connecting

WARNINGActivate Telematics control module Service Mode before disconnecting battery.

Vehicle Diagnostic, Testing and Information System VAS 5051; Guided Fault Finding; Adaptation; Telephone/Telematics

  1. Switch ignition off and remove ignition key.
  1. Remove right luggage compartment side trim cover - arrows -.
  1. Remove covers - 1 - and - 2 - over battery.

Scheme 32

Scheme 32
  1. Clamp ground wire - 2 - and positive wire - 4 - to battery.

Connect battery

  1. First connect positive wire pole shoe - 4 - by hand to battery positive pole "+" and tighten nut.
  2. Connect ground wire pole shoe - 2 - by hand to battery negative pole "-" and tighten nut.

If the battery is reconnected, the following measures must be performed

  1. Deactivate Telematics control module service mode --> «91 - COMMUNICATION»(ref-289229-S35863497532008062700000)
  2. Activate electric window regulator 1-touch up/down feature Owners Manual.
  3. Turn ignition key in ignition lock left as far as stop one time

If the battery was replaced, the Energy Management Control Module J644 must be recorded. Select "Guided Fault Finding" function to do this.

Note. After reconnecting voltage supply, the ABS warning light may go out after driving a few meters.

Tightening torque

ComponentNm
Battery connection to battery terminal6

Battery level, read out with Guided Fault Finding

  1. Follow these steps in sequential order.
  1. Connect VAS 5051/5052
  2. Guided functions
  3. Select brand and model
  4. Service work
  1. A-battery, checking at delivery inspection
  2. Follow the instructions.

Note. If tester display shows charge or replace battery, see --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Tires, checking

Note. For reasons of safety only tires of same type and tread pattern should be fitted on a vehicle! On All Wheel Drive vehicle tires of the same type and tread pattern must be used. Otherwise the center differential may be damaged.

Checking tire wear pattern

  1. The wear pattern of the front wheels can be used to assess whether a check of the track and camber is necessary
  1. Feathered edges of the treads may indicate faulty toe adjustment.
  2. One-sided tread wear is mainly attributed to incorrect camber.

Note. When wear of this nature is noticed determine cause by performing alignment checks (repair measure).

Check tread depth

  1. Minimum depth: 1.6 mm

Note. This value may vary for individual countries due to different legislative regulations.

Scheme 33

Scheme 33
  1. The minimum tread depth is reached when the tires have worn down level with the 1.6 mm high tread wear indicators - arrows - positioned at intervals around the tire.
  2. If the tread depth is approaching the legal minimum permissible depth, the customer must be informed.

Scheme 34

Scheme 34: Tire pressure, adjusting

Tire pressure values for summer tires are on the sticker on the inside of the fuel tank lid.

Note. Observe that the inflation pressure specifications on the sticker refer to the air pressure of cold tires. Do not reduce increased pressures on warm tires. When using winter tires, the tire pressure must be increased about 0.2 bar.

Spare wheel

  1. Spare wheel with standard tire

Keep the highest pressure intended for the vehicle

  1. Mini spare tire

Pressure is on side of tire

Note. On vehicles with steel rims and wheel covers, check tire pressure valve extensions for damage and contamination that can cause leaks. Replace, if necessary.

Scheme 35

Scheme 35: Tire repair kit: Checking

On vehicles with a tire repair kit, check durability date - arrow -.

Note. If expiration date has passed, replace bottle.

Brake pads: Thickness, checking

Front disc brake pads

WARNINGAt a pad thickness of 11 mm (including backing plate) the brake pads have reached their wear limit and must be replaced (repair measure). Inform the customer.

Note. To check lining thickness, you must remove front wheels.

Scheme 36

Scheme 36
  1. Before removing, mark the placement of the wheels to each brake disc and reinstall wheels in same position after checking.
WARNINGThe following values listed in the table apply to ceramic front brakes. The pads must always be replaced when pad thickness is 9.5 mm (including backing plate). (Repair measures) Please inform the customer.
CISC ceramic front brakes
Brake caliperBrembo M6 Al
Production relevant no. (PR No.)1LW
Brake disc vented385 mm
Brake disc, thickness36 mm
Brake disc, wear limitThe minimum dimension and minimum weight for the brake disc are stamped into the brake disc socket to indicate the wear limit.
Brake caliper, 6 piston monoblockEvery 2 x 32/ 36/ 38 mm
Pad thickness, not including backing plate20.4 mm
Minimum pad thickness with backing plate and damping plate9.5 mm

Rear disc brake pads

WARNINGAt a pad thickness of 8 mm (including backing plate) the brake pads have reached their wear limit and must be replaced (repair measure). Inform the customer.

Note. To check lining thickness, you must remove rear wheels.

  1. Before removing, mark the placement of the wheels to each brake disc and reinstall wheels in same position after checking.
WARNINGThe following values listed in the table apply to ceramic rear brakes. The pads must always be replaced when pad thickness is 3 mm (without backing plate). (Repair measures) Please inform the customer.
Rear brakes
Production relevant no. (PR No.)1KE1KW
Lucas brake caliperEPB (16)EPB (17)
Brake disc ventedMm280310
Brake disc, thicknessMm2222
Brake disc, wear limitMm2020
Brake caliper, pistonMm4343
Pad thickness, not including backing plateMm1212
Wear limit with backing plateMm33

To install front or rear wheels, observe notes for wheel bolts --> Wheel bolts: Tighten to correct torque setting .

Digital TV Tuner: Assign remote control key fob

Digital TV Tuner

Vehicle level, adjusting

The vehicle level is adjusted in the MMI.

  1. Switch ignition on.
  2. Press "CAR" function key. Main menu "adaptive air suspension" appears.
  3. Using control knob, select "automatic" level.

More details about vehicle level: MMI operating instructions

Check vehicle key function

  1. Separate keys so that the function of each key can be checked individually.
  2. Mechanically lock and unlock vehicle with keys on drivers door.
  3. Insert keys in ignition and start engine one after the other.
  4. If engine switches off by itself after about 3 seconds and "save" appears in the odometer display, the key has not been programmed to the immobilizer.
  1. Repair measures: Guided Fault Finding (Programming vehicle keys).
  2. Note number of checked and delivered vehicle keys in delivery protocol.

Front axle joints: Seal boots, checking play and attachment

Note. Perform this test with vehicle on lift (wheels hanging freely).

Tie rod ends

  1. Check play by moving tie rods and wheels.
  1. You should not feel or see any play.
  1. Check all around ball joint boots - arrow - for damage and correct seating. Use a mirror, if necessary.
  1. Ball joint boots can usually be recognized by leaking lubrication.

Scheme 37

Scheme 37
  1. Make sure lock nut - 1 - is tightened to 40 Nm.

All control arms

Scheme 38

Scheme 38
  1. Check all around ball joint boots - arrows - for damage and correct seating. Use a mirror, if necessary.
  1. Ball joint boots can usually be recognized by leaking lubrication.
  2. You should not feel or see any play.

Control arm

Scheme 39

Scheme 39
  1. With unloaded wheels, check relative movement of wheel bearing housing to control arm.
  2. By raising and lowers the wheels several times by hand - arrow - the relative movement between wheel bearing housing and control arm can be observed.
  3. If relative movement when lifting or lowering gives evidence of play that can be felt or seen, control arm must be replaced.

Drive shaft boot

  1. Check all around interior and exterior drive shaft boot for damage and correct seating. Turn wheel, if necessary.
  1. By turning the front wheels, tears can be found in their early stages.
  2. Drive shaft boot damage can usually be recognized by leaking lubrication.

Telephone/Telematics control module, initializing

The initialization must be done the first time it is operated before delivering to the customer.

During initialization, there is a data exchange between the Telematics control module and the service center.

Before initialization, the activation fax response must be received and the SIM card must be released.

Requirements

  1. Sufficient reception
  2. Reception from at least 4 GPS satellites
  3. No 2nd mobile phone card in the cradle.
  1. Switch receiver on.

The "Service mode" display appears.

  1. Press the menu button until the "Security code" display appears.
  2. Enter security code (always "12345" ) using the number field and confirm entry with OK button.

Note. The security code should be saved.

  1. Now enter Telematics center number: "49 172 227 022 0"

and confirm entry with OK button.

  1. Enter Telematics provider number: "2002"

and confirm entry with OK button.

The initialization now takes place (approx. 3 to 6 minutes).

Then the "New vehicle - receive data" display appears.

  1. Confirm display with OK button.

The "Receive Telematics data" display appears.

  1. Confirm display with OK button.

Then the transmission vehicle data can be compared with the entries in the activation fax.

  1. Press the arrow buttons to scroll through this menu. The first menu level is reached by pressing the Back button.

The initialization is complete.

A/C system: Check function, set temperature to 72 F (22 C)

  1. Check all climate control functions: Owners manual

Scheme 40

Scheme 40
  1. Check whether 72 ° F (22 ° C ) is set in both display fields - 1 -.
  2. Set temperature as follows, if necessary
  3. Press buttons - 2 - for automatic operation.
  4. Set temperature to 22 ° C by pressing and turning buttons - 3 -.

Cooling system: Check freeze protection, add coolant, if necessary

Note. All new engines are filled with coolant additive G 12 Plus according to TL VW 774 F (purple color). G 12 Plus can be mixed with the previous coolant additives G 11 and G 12 (red). Ensure that the system is replenished only with G12 Plus (due to its positive properties). G 12 Plus is suitable as a filled-for-life filling for cast iron and all-aluminum engines and gives optimum protection against freezing, corrosion damage, scaling and over-heating. G 12 Plus increases the boiling point to 275 ° F (135 ° C) and ensures for a better heat dissipation. The coolant portion of the mixture must amount to at least 40% (freeze protection to -13 ° F [-25 ° C]) and should not exceed 60% (freeze protection to -40 ° F [-40 ° C]). Otherwise the freeze protection will be reduced and the cooling efficiency will be worsened.

  1. The freeze protection must be ensured to approximately -13 ° F (-25 ° C).

Checking freeze protection and adding coolant additive if necessary

Special tools, testers and auxiliary items required

Scheme 41

Scheme 41
  1. Refractometer T10007

Note. Read the bright/dark boundary to obtain an accurate reading for the following tests. Place a drop of water on the glass to improve the readability of the bright/dark boundary. The bright/dark boundary can be clearly recognized on the "WATERLINE".

  1. Check the concentration of the coolant additive using refractometer T10007 (operating instructions).

Scheme 42

Scheme 42

The scale - 1 - of the refractometer is designed for coolant additives G 12; G12 Plus and G11.

Scale - 2 - refers only to coolant additive G 13. (previously L80)

Note. The freeze protection must be ensured to approximately -13 ° F [-25 ° C]. If for climatic reasons greater freeze protection is required, the amount of G 12 Plus can be increased, but only up to 60% (freeze protection to about -40 ° F [-40 ° C]), otherwise freeze protection and cooling effectiveness will be reduced.

  1. If freeze protection is insufficient, drain off required quantity shown in freeze protection table and add coolant additive G 12 Plus.

Note. Observe waste disposal regulations!

Freeze protection to ° C
Actual valueSpecified value6-cylinder engines8-cylinder engines12-cylinder engines
0255.05.05.0
356.06.06.0
5254.54.54.5
355.55.55.5
10253,53,53,5
354.54.54.5
15252.52.52.5
353,53,53,5
20251.51.51.5
352.52.52.5
25351.51.51.5
30351.01.01.0
35400.50.50.5
  1. Check coolant additive concentration after test drive again.

Checking coolant level and adding coolant if necessary

  1. Check coolant level in expansion tank with engine cold.
  1. Delivery inspection: Coolant level above the "MIN marking" - arrow -.

Scheme 43

Scheme 43
  1. Inspection service: Coolant level above the "MIN marking" - arrow -.
  1. If coolant is too low, add required amount according to mixture ratio.

Note. Determine cause of fluid loss which cannot be attributed to normal use and rectify (repair measure).

Mixture ratio

Freeze protection toCoolant additive G 12 Plus / TL VW 774 FWater
25 ° CApprox. 40%Approx. 60 %
35 ° CApprox. 50 %Approx. 50 %
40 ° FApprox. 60 %Approx. 40%

Note. Coolant additive G 12 Plus conforming to TL VW 774 F prevents freeze and corrosion damage, scaling, and raises the boiling point. For these reasons, the cooling system must be filled with radiator freeze and corrosion protection fluid all year round. Especially in countries with tropical climates or when vehicle is driven under heavy load, the coolant improves the engine reliability by its increased boiling point. The coolant concentration must not be reduced by adding water, even during the warmer season. The coolant additive ratio must be at least 40%.

Ribbed belt, W12 (6.0 MPI) and 10-cylinder gasoline engines (5.2 FSI), checking

Check guide rollers and tensioner rollers and replace if necessary.

Scheme 44

Scheme 44: Ribbed belt, W12 (6.0 MPI) and 10-cylinder gasoline engines (5.2 FSI), checking

Check ribbed belt - 1 - for

  1. Sub-surface cracks (cracks, core ruptures, cross sectional breaks)
  2. Layer separation (top layer, cord strands)
  3. Base break-up
  4. Fraying of cord strands
  1. Flank wear (material wear, frayed flanks, flank brittleness -glassy flanks-, surface cracks)
  2. Traces of oil and grease

Note. Replace the belt if any damage is found. This will avoid possible break-downs or operating problems. The replacement of a ribbed belt is a repair measure

Ribbed belt, removing and installing

>

  1. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289203-S16488527182008062700000) , 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ
  2. 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK , 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM
  3. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289204-S09096153412008062700000) , 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM
  4. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289206-S19139229562008062700000) , 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB

Instrument cluster: Adapt language version

  1. Follow these steps in sequential order.
  1. Connect VAS 5051/5052
  2. Guided Fault Finding or Guided Functions
  3. Go to - function/component selection
  4. Service work
  1. Language adaptation
  2. Now follow guided program

8-cyl. gasoline engines

  1. Remove noise insulation --> «Noise insulation, removing»(ref-289228-S26392535092008062700000)
  2. Remove strut tower cover --> «Strut tower cover: removing»(ref-289228-S13207260922008062700000) .

Scheme 45

Scheme 45
  1. Remove hose - arrow - to secondary air injection pump at bottom of air filter housing.

Scheme 46

Scheme 46
  1. Remove clips - 1 -.
  2. Remove bolt - 2 -.
  3. Remove cover - arrows - upward from air filter housing.

Scheme 47

Scheme 47
  1. Remove air guide hose - 2 - on air filter housing.
  2. Disconnect electrical connector - 1 -.
  3. Remove bolts - arrows - and remove air filter housing.

Scheme 48

Scheme 48

Note. On 4.2L engines, the vacuum hose on the service cover - arrow - must be removed.

Scheme 49

Scheme 49
  1. Remove bolts - arrows - from upper part of air filter.
  2. Remove old filter insert and clean air filter housing.

* Follow notes * See footnote

Note. If the air filter element is heavily soiled or soaked, dirt particles or moisture can reach the Mass Air Flow Sensor G70 and cause an incorrect air flow reading. This causes lack of performance because a lower injection amount is calculated. Always use an original air filter element. Use a lubricant (silicone-free) when installing intake hose. Secure all hose connections with hose clamps that match current standard production.

  1. Check drain hose in bottom side of air filter or dirt and adhesion (clean, if necessary).
  2. Clean air filter housing (upper and lower parts) of salt residue, dirt or leaves (clean with vacuum, if necessary).
  3. Check mass air flow sensor and intake hose (clean air side) for salt residue, dirt and leaves.
  4. Check intake canal up to filter insert for soiling.
  1. When installing air filter element, ensure it is centered in mount on bottom of air filter.
  2. Carefully and gently place upper part of air filter on lower part. When doing so, ensure upper part of air filter is not crooked on air filter element. Pay attention to the seal lip on the air filter element (air leak).
  3. Finally, screw upper part of air filter onto lower part.

10-cyl. gasoline engines (5.2 FSI)

Right air filter insert, removing and installing

Scheme 50

Scheme 50: 10-cyl. gasoline engines (5.2 FSI)
  1. Remove air guide hose between Mass Air Flow (MAF) Sensor G70 and Throttle Valve Control Module J338 by loosening hose clamps - arrows -.
  2. Lay aside air guide hose with connected vacuum lines - 1 and 2 -.
  3. Remove electrical connector from Mass Air Flow (MAF) Sensor G70.

Scheme 51

Scheme 51
  1. Remove bolts - arrows -.
  2. Remove upper part of air filter housing.

Scheme 52

Scheme 52
  1. Remove air filter insert.

Note. Ensure no dirt enters air filter housing or mass air flow (MAF) sensor.

Installing

Installation is done in reverse sequence while observing the following.

For proper mass air flow sensor function, it is important to observe the following notes and perform the procedure exactly.

Note. If the air filter insert is heavily soiled or soaked, dirt particles or moisture can reach the Mass Air Flow Sensor and cause an incorrect air flow reading. This causes lack of performance because a lower injection amount is calculated. Always use an original air filter insert. The air filter housing must be clean. Secure all hose connections with hose clamps that match current standard production.

  1. When cleaning air filter housing with compressed air, observe the following: To avoid malfunctions, cover critical air carrying components such as Mass Air Flow (MAF) sensor, air duct, etc. with a clean cloth.
  2. Observe waste disposal regulations!

Scheme 53

Scheme 53
  1. Blow out water drain (small hole in lower part of air filter housing - 1 - ) with compressed air.
  2. Clean air filter housing (upper and lower parts) of salt residue, dirt or leaves (clean with vacuum, if necessary).
  3. Check mass air flow sensor and air guide hose (clean air side) for salt residue, dirt and leaves.
  4. Check air duct from lock carrier to air filter housing for dirt and leaves.
  1. When installing air filter insert, ensure it is centered in mount on bottom part of air filter housing.
  2. Carefully place upper part of air filter housing on lower part without much force (pay attention to sealing lips and air duct - 2 - - "air leaks" ).

Scheme 54

Scheme 54
  1. When positioning upper part of air filter housing on electrical connectors - 1 - , ensure they are not pinched in the housing.
  2. Ensure air guide hose is seated securely between Mass Air Flow (MAF) Sensor G70 and Throttle Valve Control Module J338.

Left air filter insert, removing and installing

Removing

Scheme 55

Scheme 55
  1. Remove air guide hose between Mass Air Flow (MAF) Sensor 2 G246 and Mass Air Flow (MAF) Sensor 2 J544 by loosening hose clamps - 1 and 2 -.
  2. Remove electrical connector from Mass Air Flow (MAF) Sensor 2 G246.

Scheme 56

Scheme 56
  1. Remove bolts - arrows -.
  2. Remove upper part of air filter housing.
  3. Remove air filter insert.

Note. Ensure no dirt enters air filter housing or mass air flow (MAF) sensor.

Installing

Installation is done in reverse sequence while observing the following.

For proper mass air flow sensor function, it is important to observe the following notes and perform the procedure exactly.

Note. If the air filter insert is heavily soiled or soaked, dirt particles or moisture can reach the Mass Air Flow Sensor and cause an incorrect air flow reading. This causes lack of performance because a lower injection amount is calculated. Always use an original air filter insert. The air filter housing must be clean. Secure all hose connections with hose clamps that match current standard production.

  1. When cleaning air filter housing with compressed air, observe the following: To avoid malfunctions, cover critical air carrying components such as Mass Air Flow (MAF) sensor, air duct, etc. with a clean cloth.
  2. Observe waste disposal regulations!
  1. Blow out water drain (small hole in lower part of air filter housing - 1 - ) with compressed air.

Note. The illustration shows the right lower part of the air filter housing. Left side is same.

  1. Clean air filter housing (upper and lower parts) of salt residue, dirt or leaves (clean with vacuum, if necessary).
  2. Check mass air flow sensor and air guide hose (clean air side) for salt residue, dirt and leaves.
  3. Check air duct from lock carrier to air filter housing for dirt and leaves.
  4. When installing air filter insert, ensure it is centered in mount on bottom part of air filter housing.
  1. Carefully place upper part of air filter housing on lower part without much force (pay attention to sealing lips and air duct - "air leaks" ).
  2. Ensure air guide hose is seated securely between Mass Air Flow (MAF) Sensor 2 G246 and Throttle Valve Control Module J544.

W12 gasoline engine

Left engine bank

  1. Loosen hose clamp - 1 -.
  2. Remove hose connector - 2 - from intake hose.

Scheme 57

Scheme 57
  1. Remove intake hose from intake manifold.

Scheme 58

Scheme 58
  1. Loosen 5 bolts on air filter cover.
  2. Remove air filter cover upward and disconnect mass air flow (MAF) sensor - 1 -.
  3. Remove old filter insert and clean air filter housing.
  4. Assembly is reverse of removal.

Right engine bank

Scheme 59

Scheme 59
  1. Loosen hose clamp - 1 -.
  2. Remove intake hose - 2 - from intake manifold and press it to side.
  3. Release connector consoles - 3 - and - 4 -. Remove upward.
  1. Loosen 5 bolts on air filter cover.
  2. Remove air filter cover upward and disconnect mass air flow (MAF) sensor - 1 -.
  3. Remove old filter insert and clean air filter housing.
  4. Assembly is reverse of removal.

* Follow notes * See footnote

Engine cover, removing

8 Cylinder engine

Removing

Scheme 60

Scheme 60: Engine cover, removing
  1. Remove engine cover panel with both hands first at points - 1 - and then at points - 2 -. Make sure you remove the engine cover panel slowly and evenly.

Installing

  1. To avoid damage, do not hit engine cover with fist or a tool.
  2. Position engine cover on engine (be careful of oil filler tube and oil dipstick).
  3. Push engine cover first with both hands into position - 3 - in rubber grommets and then with both hands into position - 4 -.

Note. To avoid causing damage, do not bang the engine cover panel down with your fist or a tool.

12 cylinder engine

Removing

Scheme 61

Scheme 61
  1. Carefully pull engine cover at rear and middle upward and off - arrows 1
  2. Then, pull engine cover forward and off of intake manifold - arrows 2 -.

Installing

  1. Installation is reverse of removal

Note. To avoid causing damage, do not bang the engine cover panel down with your fist or a tool.

V8 5-valve gasoline engines

  1. Remove noise insulation --> «Noise insulation, removing»(ref-289228-S26392535092008062700000) .
  2. Open oil drain plug on oil pan.

Scheme 62

Scheme 62
  1. Open oil drain plug - arrow - on filter housing.

Note. Oil filter is located below air filter.

  1. Remove air filter --> «Air cleaner: Clean air filter housing and replace filter»(ref-289228-S36253890822008062700000) .

Scheme 63

Scheme 63
  1. Press heat shield - 1 - in direction of vehicle frame.
  2. Remove oil filter cover - arrow -.
  3. Clean sealing surfaces oil filter cover and at oil filter housing.

Scheme 64

Scheme 64
  1. Replace the oil filter element - 1 -.

Note. Observe waste disposal regulations!

  1. Install new O-ring - 2 - and lubricate lightly.
  2. Engage new oil filter insert in oil filter cover.
  3. Install oil filter cover - 3 -.
  4. Bend heat shield back into original position.
  1. Install oil drain plug on oil pan and filter housing with new sealing rings.
  2. Fill up with engine oil, specifications --> «Engine oil: Fill»(ref-289228-S36225123552008062700000) .
Tightening torqueNm
Oil filter cover25
Oil drain plug to oil filter housing10
Oil drain plug on oil pan50

Scheme 65

Scheme 65: 8-cyl. gasoline engines (4.2 FSI)
  1. Remove engine cover

Scheme 66

Scheme 66
  1. Remove oil filter cover with a socket wrench SW 24 - arrow -.

Scheme 67

Scheme 67
  1. Clean sealing surfaces oil filter cover and at oil filter housing.
  2. Replace O-rings - 2 - and - 4 - and filter component - 3 -.

Note. By removing the filter element, a valve is opened that allows the oil in the filter housing to flow automatically back into the crankcase. Observe installation position of tab on oil filter. Observe waste disposal regulations!

  1. Insert new oil filter in filter housing
  2. Install new O-ring - 2 - and lubricate lightly.
  3. Install oil filter cover - 1 -.
  4. Remove noise insulation --> «Noise insulation, removing»(ref-289228-S26392535092008062700000)
  1. Open oil drain plug on oil pan or extract engine oil.
  2. Install oil drain plug.

Note. Install oil drain plug with new gasket. Check for cleanliness.

Tightening torqueNm
Oil filter cover25
Oil drain plug on oil pan25
  1. Fill motor oil --> «Engine oil: Fill»(ref-289228-S36225123552008062700000) .

10-cyl. gasoline engine (5.2 FSI)

  1. Remove noise insulation --> «Noise insulation, removing»(ref-289228-S26392535092008062700000)
  2. Open oil drain plug and drain engine oil.
  3. Install oil drain plug with new gasket.

Scheme 68

Scheme 68
  1. Remove rear engine cover - 2 - - arrows -.

Scheme 69

Scheme 69
  1. Remove EVAP valve from bracket and lay aside.
  1. Loosen cover - 1 - AF 32.
  2. Remove filter component - 3 -.
  3. Replace O-rings - 2 - and - 4 - and filter component - 3 -.

Note. By removing the filter element, a valve is opened that allows the oil in the filter housing to flow automatically back into the crankcase. Observe installation position of tab on oil filter. Observe waste disposal regulations!

  1. Insert new oil filter in filter housing
  2. Install new O-ring - 2 - and lubricate lightly.
  3. Install oil filter cover - 1 -.

Note. Install oil drain plug with new gasket. Check for cleanliness.

Tightening torqueNm
Oil filter cover25
Oil drain plug25
  1. Fill motor oil --> «Engine oil: Fill»(ref-289228-S36225123552008062700000) .
  1. Remove noise insulation --> «Noise insulation, removing»(ref-289228-S26392535092008062700000)
  2. Open oil drain plug and drain engine oil.
  3. Install oil drain plug with new gasket.
  1. Loosen cover - 3 - AF 32.
  2. Remove filter component - 1 -.
  3. Replace O-ring - 2 - and filter element - 1 -.
  4. Fill with engine oil, specifications --> «Engine oil: Fill»(ref-289228-S36225123552008062700000)

Note. Observe waste disposal regulations! Do not extract engine oil!

Tightening torqueNm
Oil filter cover25
Oil drain plug50

Engine oil: Fill

Note. Please follow specified engine oil capacity and oil standards in the ELSA maintenance table.

  1. Check engine oil level --> «Engine: Oil level, checking»(ref-289228-S15549726642008062700000) .

Engine: Oil level, checking

Note. Oil temperature at least 140 ° F (60 ° C). Vehicle must be in level position. After stopping engine, wait a few minutes to allow oil to flow back into oil pan.

  1. Pull out oil dipstick and wipe with clean rag. Replace dipstick and push down to stop.
  2. Pull out dipstick again and read oil level.

Scheme 70

Scheme 70

Markings on dipstick

Note. Oil level must not exceed - a - mark on dipstick.

Navigation: Eject button, unlocking

  1. Follow these steps in sequential order.
  1. Connect VAS 5051/5052
  2. Guided functions
  3. Go to - function/component selection
  4. Service work
  1. J401 - Navigation, Eject button, locking/unlocking
  2. Now follow guided program

Headlamp washer system: Check spray jet setting.

Headlamp cleaner spray jets are set at the factory and do not need to be adjusted.

Scheme 71

Scheme 71: Strut tower cover: removing
  1. Remove both spreader clips - 1 - and remove bolt - 2 -.
  2. Remove cover from retainers.

Scheme 72

Scheme 72: Special tools and equipment needed
  1. Windshield washer aiming tool T10127 equipped with replacement tip 3125/5A

Note. Never use a needle or a similar object, since it may damage the water hoses in the spray nozzle!

Windshield spray jet setting

  1. Mark four points on windshield using water-soluble pen.

Scheme 73

Scheme 73

Adjusting dimension

  1. Dimension - a - = 400 mm
  2. Dimension - b - = 250 mm
  3. Dimension - c - = 300 mm
  4. Dimension - d - = 500 mm
  1. Locate individual spray jet points using adjustment tool.

Note. The adjustment dimensions give values for a driving vehicle, that is, when parked, the spray pattern will shift slightly.

Windshield wiper blades: Park position and checking for damage

Front windshield wiper blade park position

  1. Switch windshield wipers on and off and allow to run to end position.
  2. Switch ignition off.

Scheme 74

Scheme 74
  1. Check whether wiper blades rest again front window in indicated position.
Dimension - aDimension - b
10 mm27 mm

Note. Dimensions indicate distance of wiper blades to plenum chamber cowl panel grille on lower window edge.

  1. If necessary, unscrew wiper arm, align and tighten nuts.
  2. Activate mist wipe and check adjustment.
Tightening torqueNm
Wiper arm to wiper shaft21

Wiper blade, replacing

Removing

  1. Lift wiper arm off of windshield.

Scheme 75

Scheme 75
  1. Slide retaining clip - 2 - in direction of - arrow - from wiper arm - 3 -.
  2. Remove wiper blade - 1 - down off wiper arm.

Installing

Scheme 76

Scheme 76
  1. Insert wiper arm joint in guide on wiper blade - arrow 1 -. Ensure joint sits completely in guide.
  2. Lock wiper blade by slide on retaining clip - arrow 2 -.

Sunroof: Check function, clean guide rails and spray on grease spray

  1. Check sunroof for leaks.
  2. Clean guide rails.
  3. Spray guide rails.
  1. Lubricant: "G 052 778 A2"
  1. Check sunroof function.

Tank filling table

Fuel level according to fuel gauge8-cylinder engine additional weight in kg
1/465
1/245
3/425
Full0

Example: 8-cylinder engines

If the fuel tank is half full, place a weight of 45 kg in the luggage compartment.

Note. For additional weight use containers filled with water. A container filled with 5 liters of water weighs approx. 5kg.

Vehicle must be rolled for several meters or the front and rear suspension must be bounced several times so that the springs settle.

  1. Vehicle and headlamp adjuster must be on a level surface operating instructions for headlamp adjuster.
  2. Vehicle and headlamp adjuster must be aligned.

Ensure headlamp adjuster is about 30 cm in front of headlamp.

  1. Inclination measure must be set.

Scheme 77

Scheme 77

Inclination measurements are stamped in "%" at top of headlamp. The headlamps must be adjusted according to these measurements. Percentage information is based on a projection distance of 10 meters. For example, with an inclination measurement of 1.0% (on vehicles with headlamp range adjuster), this converts to 10 cm.

Ellipsoid headlamps, adjusting

Vehicle level, adjusting --> Vehicle level, adjusting

  1. Observe testing and adjusting conditions.

Scheme 78

Scheme 78

Adjusting screws on left headlamp.

Allocation on right side is a reversed image.

  1. To adjust height, turn adjustment screws - 1 - and - 2 - with same number of revolutions.
  2. To adjust laterally, turn only adjustment screw - 1 -.

Headlamps, adjusting (gas-discharge lamps)

  1. Observe testing and adjusting conditions.

Oil quality, adapting

  1. Follow these steps in sequential order.
  1. Connect VAS 5051/5052
  2. Guided Fault Finding or Guided Functions
  3. Go to - function/component selection
  4. Service work
  1. Combination Processor, changing oil quality
  2. Now follow guided program

Note. It is necessary to change oil quality if changed between inspection. Inspection Service = Oil quality 1 WIV = Wartungsintervall - Verlangerung (Maintenance Interval Extension) Please follow guided program function description

Maximum values, adapting

  1. Follow these steps in sequential order.
  1. Connect VAS 5051/5052
  2. Guided Fault Finding or Guided Functions
  3. Go to - function/component selection
  4. Service work
  1. Combination Processor, adjusting maximum WIV value
  2. Now follow guided program

Fixed interval maximum values

Minimum mileage in Km15000
Maximum mileage in Km15000
Maximum time interval in days365

Note. WIV = Wartungsintervall - Verlangerung (Maintenance Interval Extension) Please follow guided program function description

Telematics: Emergency battery, replacing

Note. Emergency battery should be replaced very 4 years on vehicles with Telematics.

WARNINGActivate Telematics control module Service Mode before disconnecting battery.

Vehicle Diagnostic, Testing and Information System VAS 5051; Guided Fault Finding; Adaptation; Telephone/Telematics

The Telematics control module is located under the drivers seat.

Removing

  1. Position drivers seat all the way back.
  2. Move floor covering back. --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000)

Scheme 79

Scheme 79
  1. Release electronic box cover and open box - arrows -.

The control module is only wedged into the electronics box.

Scheme 80

Scheme 80
  1. Pry transceiver - 1 - in direction of - arrow - out of electronics box - 2 -.

Scheme 81

Scheme 81
  1. Remove bolt - 1 - on battery compartment cover - 2 - and open battery compartment.

Scheme 82

Scheme 82
  1. Remove emergency battery - 3 - and disconnect connector - 2 -.

Installing

  1. Perform installation in reverse order of removal.

If the battery is reconnected, the following measures must be performed

  1. Deactivate Telematics control module service mode Vehicle Diagnosis, Testing and Information System VAS 5051; Guided Fault Finding; Adaptation; Telephone/Telematics.
  2. Activate electric window regulator 1-touch up/down feature Owners Manual.
  3. Turn ignition key in ignition lock left as far as stop one time

Note. After reconnecting voltage supply, the ABS warning light may go out after driving a few meters.

Scheme 83

Scheme 83: Door arrester and lock cylinder: Lubricate
  1. Lubricate door arrester only on lubrication places indicated - arrows -.
  1. Lubricant: "G 052 778 A2"
  1. Lubricate lock cylinder.
  1. Lubricant: "G 052 778 A2"

Transport mode, deactivating

Deactivate air suspension transport mode using guided fault finding or guided functions.

  1. Follow these steps in sequential order.
  1. Connect VAS 5051/5052
  2. Guided Fault Finding or Guided Functions
  3. Go to - function/component selection
  4. Service work
  1. Activate or deactivate air suspension transport mode
  2. Now follow guided program

Note. Car body may lower. The error 00219 Transport level active (yellow indicator light in instrument cluster lights up) is automatically deleted. Air suspension transport mode is for loading vehicles, for example (on train, ship, truck, airplane, etc.).

Scheme 84

Scheme 84: Plenum chamber cover: removing
  1. Remove plenum chamber cover gasket - 1 -.
  2. Remove plenum chamber cover - 2 - and - 3 -.

Scheme 85

Scheme 85: Plenum chamber water drain, checking and cleaning
  1. Check whether there is dirt in areas - A - and - B - in the plenum chamber.

Note. Clean drains and area under air conditioning unit of heavy dirt, e.g. with a standard flexible gripping device. Fine deposits and mud can be removed, for example, with a thin water hose or a pressure cup spray gun V.A.G 1538 and a flexible nylon tube V.A.G 1538/2.

Winter tires from factory

On vehicles that were delivered from factory with winter tires, check for correct pressure during delivery inspection.

The excessive speed warning sticker should be placed in drivers field of vision.

Timing belt: replacing (V8 gasoline engines)

8-cylinder Engine -->

  1. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289203-S16488527182008062700000) , 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ
  2. 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK , 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM

Note. The timing belt replacement should be documented in the service book.

Clock, setting

Radio clock

Note. The clock can function as a radio-controlled quartz clock as well as a normal quartz clock.

If an acceptable radio clock signal is received, clock automatically switches to "radio-controlled quartz clock" operating mode. The radio clock reception symbol (radio tower radiating waves) appears in display. If the clock does not receive a valid signal, it automatically switches to "quartz clock" mode after 3 days and radio clock reception symbol goes out.

Setting the quartz clock is described in the MMI owners manual.

Scheme 86

Scheme 86: Necessary special tools
  1. Spark plug wrench 3122 B

Scheme 87

Scheme 87
  1. Ignition Coil Puller T40039
  2. Ignition Coil Puller T10166
WARNINGPlace Ignition Coil Puller T40039 on top rib - arrow - of ignition coil and pull this from spark plug. Placing on bottom rib can cause damage.

Note. Plug designation --> 28 - IGNITION/GLOW PLUG SYSTEM , 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BVJ 28 IGNITION/GLOW PLUG SYSTEM , 4.2 LITER V8 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): BFM 28 - IGNITION/GLOW PLUG SYSTEM , 5.2 LITER 10-CYL. 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BSM 28 IGNITION SYSTEM , 6.0 LITER 12-CYL. 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BSB Observe waste disposal regulations!

V8 gasoline engines

  1. Switch ignition off.

Right cylinder bank

  1. Remove air filter --> «Air cleaner: Clean air filter housing and replace filter»(ref-289228-S36253890822008062700000) .

Scheme 88

Scheme 88
  1. Remove both bolts - 1 -.
  2. Push connector - 2 - toward ignition coil, press on catch with hand and remove connector.
  3. Remove ignition coils - 3 - from spark plugs with Ignition Coil Puller T40039.
  4. Remove spark plugs using spark plug wrench 3122B.
  1. Install new spark plugs.
Tightening torqueNm
Spark plugs in cylinder head30

Note. Push ignition coils by hand into intended resources in cylinder head cover.

Left cylinder bank

Scheme 89

Scheme 89
  1. Remove both bolts - 1 -.
  2. Push connector - 2 - toward ignition coil, press on catch with hand and remove connector.
  3. Remove ignition coils - 3 - from spark plugs with Ignition Coil Puller T40039.
  4. Remove spark plugs using spark plug wrench 3122B.
  1. Install new spark plugs.
Tightening torqueNm
Spark plugs in cylinder head30

Note. Push ignition coils by hand into intended resources in cylinder head cover.

V10 gasoline engines

  1. Remove rear engine cover - 2 -.

Removing cylinder bank 1 (right)

  1. Remove air guide hose between Mass Air Flow (MAF) Sensor G70 and Throttle Valve Control Module J338 by loosening hose clamps - arrows -.
  2. Lay aside air guide hose with connected vacuum lines - 1 and 2 -.
  3. Remove electrical connector from Mass Air Flow (MAF) Sensor G70.
  1. Remove bolts - arrows -.
  2. Remove upper part of air filter housing.

Scheme 90

Scheme 90
  1. Remove bolts - 1 - and - 2 -.

Scheme 91

Scheme 91
  1. Pull ignition coils about 30 mm out of spark plug shaft with Puller T40039.
  2. Release electrical connectors and remove them evenly from ignition coils.
  3. Remove spark plugs using spark plug wrench 3122B.
  4. Install new spark plugs.

Removing cylinder bank 2 (left)

  1. Remove air guide hose between Mass Air Flow (MAF) Sensor G246 and Throttle Valve Control Module J544 by loosening hose clamps - arrows -.
  2. Remove electrical connector from Mass Air Flow (MAF) Sensor 2 G246.
  1. Remove bolts - arrows -.
  2. Remove upper part of air filter housing.

Scheme 92

Scheme 92
  1. Remove bolts - 1 - and - 3 -.
  1. Pull ignition coils about 30 mm out of spark plug shaft with Puller T40039.
  2. Release electrical connectors and remove them evenly from ignition coils.
  3. Remove spark plugs using spark plug wrench 3122B.
  4. Install new spark plugs.

Installing ignition coils

  1. Loosely place all ignition coils in spark plug shaft.
  2. Align ignition coils to connectors and place all connectors evenly on ignition coils.
  3. Press ignition coils evenly by hand onto spark plugs (do not use a hammer under any circumstances).

Tightening torque

ComponentNm
Electrical wiring guide for ignition coils to cylinder head cover5

Left cylinder bank

Scheme 93

Scheme 93: W12 gasoline engine
  1. Remove cover behind intake manifold - arrows -.

Scheme 94

Scheme 94
  1. Remove left cover in engine compartment - arrows -.

Scheme 95

Scheme 95
  1. Remove left air guide hose - arrows -.

Scheme 96

Scheme 96
  1. Remove vacuum hose - arrow - to brake booster on left side part of intake manifold.

Scheme 97

Scheme 97
  1. Disconnect electrical connector - 4 -.

Note. When loosening bolt - 1 - , secure threaded plate against falling off.

  1. Remove bolts - 1 through 3 - and remove left side part of intake manifold.

Right side

Scheme 98

Scheme 98
  1. Remove right cover in engine compartment - arrows -.

Scheme 99

Scheme 99
  1. Remove right air guide hose - arrows -.
  2. Remove oil filler tube cap.

Scheme 100

Scheme 100
  1. Disconnect electrical connector - 1 -.

Note. When loosening bolt - 4 - , secure threaded plate against falling off.

  1. Remove bolts - 2 through 4 - and remove right side part of intake manifold.

Scheme 101

Scheme 101
  1. Disconnect electrical connectors - 1 - on ignition coils - 2 -.

Scheme 102

Scheme 102
  1. Remove ignition coils from spark plugs with Puller T10166.
  2. Remove spark plugs using spark plug wrench 3122 B.

Installing

Installation is done in reverse sequence while observing the following

Note. Replace seals. Push ignition coils by hand into intended resources in cylinder head cover.

Torques

ComponentNm
Side part of intake manifold to top part22 * See footnote
Connector bracket to side part of intake manifold8
Spark plugs in cylinder head30

*No tolerance, maintain exact tightening torque.

Headlights: Aiming using Hella Universal Beamsetter IV

Service

Align vehicle headlamps using the VAS 5107 (Hella Universal Beamsetter IV) and the following procedure

Additional instructions and diagrams article for the Hella Beamsetter Series IV

"Automatic" drive mode set on MMI MMI operating instructions

Scheme 103

Scheme 103: Headlights: Aiming using Hella Universal Beamsetter IV
  1. Position vehicle on a flat floor surface that meets the following (ISO 10640) specifications
  1. 0.5mm or less slant from front wheel to back wheel of the Beamsetter - A -.
  2. 1mm or less slant per meter for the length of the vehicle - B -.
  1. Clean headlight lenses.
  2. Adjust vehicle tire pressure to specifications.

Have a second technician sit in the drivers seat while aligning the headlights.

  1. Bounce front and rear of vehicle up and down several times to settle vehicle suspension.

Setting low beam alignment of drivers side headlight

  1. Move Beamsetter into position in front of the vehicle so it is aligned with the vehicle and Beamsetter box is 30 to 70cm (12 to 28 in.) from the drivers side headlight.
  2. Switch headlights ON in low beam position.
  3. Align Beamsetter box so it is centered on the headlight (align vertically then horizontally).

Note. Use the arrows on the Beamsetter box as a guide. You may want to use a straight edge or tape measure, because alignment must be within 3cm (1.2 in.) of the center of the headlight.

  1. Without moving the Beamsetter, slide Broad-band sight toward center of vehicle (Broad-band sight can also be moved up and down for a better position).

Use Broad-band sight to make final alignment of Beamsetter box to vehicle by

  1. Loosening hand-wheel that locks column in place.
  2. Sighting down through the slit in the Broad-band sight and rotating Beamsetter box and column until two similar points on vehicle are aligned.

Note. Try using corners of the headlight housings or two screws that are the same height and as far apart as possible on the vehicle.

  1. Carefully tighten hand wheel without changing Beamsetter position.
  2. Set inclination to 1.0%.
  3. Set Beamsetter " "Scaled wheel" to the proper low beam inclination "%."
  4. Adjust height (vertical) alignment first. Turn headlight height adjuster screw to align the upper edge of the flat portion of the beam with the center horizontal line of the grid on the Beamsetter pattern screen.

Note. VOL is the correct beam pattern for both right and left headlights.

Scheme 104

Scheme 104
  1. Adjust lateral (horizontal) alignment of drivers side headlight so that the peak (highest point) of the headlight beam pattern aligns with the right edge of the target box of the grid on the pattern screen (it should match the VOL pattern shown on the Beamsetter box).

Note. If the height alignment changed, readjust.

Checking drivers side headlight high beam alignment

  1. Switch headlights ON in high beam position.
  2. Realign Beamsetter box with the high beam headlight if necessary

Scheme 105

Scheme 105
  1. Set Beamsetter "Scaled wheel" to 0%.
  2. Cover low beam lamp (use hand or small piece of cardboard) and check that the "hot spot" of high beam pattern is centered on the square target box of the pattern screen.

Note. High beam pattern is built into the reflector design and cannot be adjusted separately.

If high beam pattern is way out of adjustment

  1. Inspect for reflector damage.
  2. Replace reflector if needed.

Note. Always align headlight in the low beam position.

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).

Scheme 106

Scheme 106
  1. 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.

Passengers side headlight, alignment

  1. Move Beamsetter to the passenger side of the vehicle and follow the same procedures to align the Beamsetter box to the headlamp.
  2. Align headlight low beam, check high beam and align fog lamp.

Note. Make sure to reset the Beamsetter "Scaled wheel" to the proper setting each time you change from low beam to high beam or to fog lamp.

  1. Ensure that headlights and vehicle body are clean and free of fingerprints.

Vehicle, lifting

Vehicle lift mode

Note. Before lifting vehicle with vehicle jack or lift, vehicle lifting mode must be activated so that the automatic air suspension regulating process does not make lifting with vehicle jack or lift more difficult. Vehicle lifting mode automatically switches off when vehicle speed exceeds 15 km/h. When vehicle lifting mode is activated, the indicator light in the instrument cluster comes on.

Switching on

  1. Switch ignition on.
  2. Press "CAR" function key. Main menu "adaptive air suspension" appears.
  3. Press "SETUP" function key. "adaptive air suspension" menu appears.
  4. Turn control knob to desire mode and select "ON".

Switching off

  1. Switch ignition on.
  2. Press "CAR" function key. Main menu "adaptive air suspension" appears.
  3. Press "SETUP" function key. "adaptive air suspension" menu appears.
  4. Turn control knob to "Vehicle lifting mode" and select "OFF" to switch of vehicle lifting mode.
WARNINGBefore driving on to a hoist ensure there is sufficient clearance between low lying vehicle components and hoist. Before driving a vehicle onto a lifting platform it must be ensured that the vehicle weight does not exceed the permissible lifting capacity of the platform. Vehicle may only be lifted at points indicated in illustration in order to avoid damaging vehicle floor pan and to prevent vehicle from tipping. Never start engine and engage a gear with vehicle lifted so long as even one wheel has contact with the floor. There is a risk of an accident if this is not observed! If work is to be performed under vehicle it must be supported by suitable stands.

Floor jack

Always use a suitable rubber or wooden block between the jack and the vehicle.

A floor jack must be attached only at the mounting points depicted in the illustration.

Do not lift the vehicle at the engine oil pan, transmission, or on front or rear axles as serious damage may result.

Workshop hoist

Before driving on to a lifting platform ensure there is sufficient clearance between low lying vehicle components and lifting platform.

Lifting points for lifting platform and floor jack

Scheme 107

Scheme 107

Front and rear

On oval rubber discs on vehicle floor.

Suspension blocks, installing

If pressure is lost in the air suspension shock absorbers, the vehicle does not have sufficient ground clearance.

The vehicle must not be moved in this condition.

To drive onto a car transporter or a lift, for example, suspension blocks must be installed.

This increases the ground clearance.

WARNINGThe vehicle is not in driveable condition when suspensions blocks are installed. The vehicle can only be moved. When moving steering wheel from center position, do not turn more than one left or right. After completing suspension block installation, inspect areas around front suspension strut mounts for possible body damage and repair if necessary. The upper rear control arms on the front axle must be replaced before the vehicle can be driven again.

Special tools and equipment needed

Scheme 108

Scheme 108
  1. Suspension block set T10156

Suspension blocks for the front axle are different and are marked accordingly

Front axle suspension blocks, inserting

  1. Turn wheels to straight ahead position.
  2. Raise vehicle using a vehicle jack.
WARNINGSecure vehicle against falling down.

Scheme 109

Scheme 109
  1. Insert suspension blocks - A - between wheel housing - 1 - and upper rear control arm - 2 -.
  2. Lower vehicle.

Rear axle suspension struts, inserting

  1. Raise vehicle using a vehicle jack.
  2. Remove wheel.
WARNINGSecure vehicle against falling down.

Scheme 110

Scheme 110
  1. For example, by placing removed wheel below.

Scheme 111

Scheme 111
  1. Insert suspension block - A - between long member - 1 - and upper transverse link - 2 -.
  2. Re-install wheel.
  3. Lower vehicle.

Wheel bolt tightening torque --> Wheel bolts: Tighten to correct torque setting

  1. Install wheels --> «44 - WHEELS, TIRES AND WHEEL ALIGNMENT»(ref-289219-S22679788402008062700000)

Tow starting/towing Some engines listed below are for European models and are not applicable to the North American market.

Note. If air suspension shock absorbers in one axle lose pressure completely, the vehicle does not have enough ground clearance. The vehicle must not be moved in this condition. To drive onto a car transporter or a lift, for example, suspension blocks must be installed.

Note. Remove towing eye after use and return to vehicle tool kit storage compartment. Towing eye must always be in vehicle. For the 2008 Audi A8, The towing eye/loop can be located either in the vehicle tool kit or the spare wheel well storage compartment.

Front towing eye

  1. Attach tow rope or bar only at following eyes

Scheme 112

Scheme 112
  1. Remove cover from below.
  2. Remove towing eye from vehicle tool kit or the spare wheel well storage compartment.

Scheme 113

Scheme 113
  1. Screw in towing eye - arrow - until stop and tighten eye with wheel bolt wrench.

Rear towing eye

Scheme 114

Scheme 114
  1. Remove cover from above.

Note. The tow-rope should be able to stretch to reduce the risk of damage to both vehicles. It is advisable to use synthetic fiber ropes or ropes of similar elastic material only. However, it is safer to use a tow-bar! Avoid excessive towing effort and do not jerk. During towing operations on unsurfaced roads there is always a danger that the attachment points will be overstressed and damaged. Vehicle towing should only be done if it is not possible to start the engine with the starting assist cable.

If the vehicle must ever tow or be towed, observe the following

  1. Regulations concerning towing must be observed.
  2. Both drivers must be familiar with the specifics of towing procedures. Inexperienced drivers should not attempt to tow start or tow.
  3. When using a tow rope the driver of the towing vehicle must engage the clutch very gently when moving off and changing gear.
  4. The driver of the vehicle being towed must ensure that the tow rope is always taut.
  1. The emergency lights must be switched on both vehicles - unless local regulations differ.
  2. The ignition must be switched on, so that the steering wheel is not locked and the turn signals, horn, windshield wipers, and windshield washer system can be operated.
  3. Since the brake booster only works with the engine running, the brake pedal must be stepped on with substantially more force when the engine is switched off.
  4. With the engine switched off, the power steering also does not work, increasing the amount of steering effort.
  1. Without lubricants in the manual transmission and/or automatic transmissions the car may only be towed with raised drive wheels.

When towing vehicles with manual transmission, observe the following

  1. Before tow starting, push in clutch pedal and hold, and select gear 2 or 3.
  2. Switch ignition on.
  3. When both vehicles are moving, release clutch pedal.
  4. As soon as engine starts, depress clutch and move gear stick into neutral to avoid running into the towing vehicle.

Note. Vehicles with catalytic converter (gasoline engine only) must not be started when the catalytic converter is at operating temperature and pulling the vehicle over a longer distance of more than 50 m. Otherwise unburned fuel may pass into the catalytic converter and cause damage. Tow starting vehicles with an automatic transmission is for technical reasons not possible.

When towing vehicles with front wheel drive and automatic transmission, observe the following

  1. Selector lever must be in the "N" position.
  2. Do not tow vehicle faster than 50 km/h (30 mph).
  3. Do not tow further than 50 km (30 miles).

For longer distances, the front end of the vehicle must be raised.

Reason: When the engine is not running the transmission oil pump is not working and the transmission is not adequately lubricated for high speeds or long distances.

Using a breakdown vehicle, the vehicle may only be towed suspended at the front.

Reason: If given a rear suspended tow, the drive shafts turn backward. This would cause the planetary gears in the automatic transmission to achieve such high RPM that the transmission would be heavily damaged within a very short time.

When towing vehicles with all wheel drive and manual transmission, also observe the following

  1. Do not tow vehicle faster than 50 km/h (30 mph).
  2. Do not tow further than 50 km (30 miles).

Using a breakdown vehicle the vehicle may be towed suspended at front or rear.

Note. If normal towing of the vehicle is not possible, the vehicle must be transported with a special transporter or trailer. This is also valid for distances greater than 50 km (30 miles).

When towing vehicles with all wheel drive and automatic transmission, also observe the following

  1. Selector lever must be in the "N" position.
  2. Do not tow vehicle faster than 50 km/h (30 mph).
  3. Do not tow further than 50 km (30 miles).

The vehicle must not be towed by a tow truck with front or rear axle raised.

Note. If normal towing of the vehicle is not possible, the vehicle must be transported with a special transporter or trailer.