INSTALLING Audi S5 I

INSTALLING

Note. After completely removing gas-filled strut, ensure correct position when installing: Tube of gas-filled strut must be engaged on body side

Press gas-filled strut onto ball stud and engage.

Scheme 60

Clamp gas-filled strut in a vise in area -x- = 50 mm (2 in.).

Note. Cover area of sawn portion with a rag to absorb oil spraying out.

Cut through the gas-filled strut cylinder within the first third of the overall cylinder length using the piston rod end of the cylinder as a reference point.

Scheme 61

1. Gasket for plenum chamber To remove, pull back from the body flange at the sides. When installing, slide it into the sealing profile with pre-tension beginning at the sides. Press seal onto opposite side in stages. Slide seal into sealing profile on opposite side. Compress the excess length along the plenum chamber bulkhead.
2. Right sealing profile To remove, unclip from the body and remove it sideways under the fender flange. When installing, the clips on the foam piece must engage in the body.
3. Plenum chamber - bulkhead Slide the plenum chamber seal on at the sides.
4. Left sealing profile To remove, unclip from the body and remove it sideways under the fender flange. When installing, the clips on the foam piece must engage in the body.

Scheme 62

1. Rear lid latch Removing and installing «HOOD RELEASE CABLE»(/audi/s5/i-2007-2011/remont/exterior-body-panels/#hood-lids-coupe) To adjust the hood, slide up or down.
2. Hood cable Removing -- Disconnect the release cable at the coupling «HOOD RELEASE CABLE»(/audi/s5/i-2007-2011/remont/exterior-body-panels/#hood-lids-coupe) . -- Disengage the release cable from the bracket -7-. -- Pull the release cable through to the engine compartment. Installing: in reverse order
3. Cable coupling -- Slide the coupling clamp sideways onto the bracket -8- on the lock carrier. -- Disconnect the release cable here before removing the lock carrier and release lever.
4. Hood lock rear cable Release cable to the operating lever in the vehicle interior.
5. Grommet Ensure correct seating when installing.
6. Hood release lever Disengage the release cable «HOOD RELEASE CABLE»(/audi/s5/i-2007-2011/remont/exterior-body-panels/#hood-lids-coupe) .
7. Lid lock release lever Operating lever cover, removing. Refer to «HOOD RELEASE CABLE»(/audi/s5/i-2007-2011/remont/exterior-body-panels/#hood-lids-coupe) .
8. Lock Carrier
9. Electric wire Pull the electrical wire and the lid lock cable through the lock carrier as shown.
10. Clips Slide the clamp with the electrical wire onto the tab in the lock carrier.

Cable coupling

Scheme 63

1. Rear cable Cable to the operating lever When removing, pull back out of the coupling.
2. Cable coupling To release, remove the clamp from the lock carrier and pull the cable back slightly out of the clamp. Fold the coupling up and lift the front cable with the nipple out of the coupling.
3. Clips Slide sideways onto the lock carrier after installing the cable.
4. Front cable Cable to the hood lock

Attaching Control Cable In Lid Lock

Scheme 64

1. Front release cable Insert the cable nipple in the operating lever in the hood lock.
2. Release cable for right-hand drive
3. Rear lid latch Engage the release cable guide in the lower part of the hood lock.
4. Lock Carrier
5. Clips Slide the clamp with the electrical wire onto the tab in the lock carrier.

Release Cable, Engaging in Hood Lock

Scheme 65

Insert the release cable nipple -2- in the operating lever -arrow- in the hood lock -3-.

Engage the release cable with guide -1- in the hood lock from below.

Operating Lever Cover, Removing

Scheme 66

1. Lower >>A-pillar<< trim
2. Operating lever cover Before removal, first disengage cable in coupling in engine compartment «HOOD RELEASE CABLE»(/audi/s5/i-2007-2011/remont/exterior-body-panels/#hood-lids-coupe) . Pry the clip out of the operating lever. Remove the cover sideways from the operating lever.
3. Hood release lever
4. Clip Press in completely, it must engage.

Operating Lever, Removing

Scheme 67

1. Release cable Clip the cable bracket into the mounting bracket as shown in the magnified section of the illustration.
2. Operating lever mounting bracket Operating lever cover removed Lower >>A-pillar<< trim removed Remove screws -3- and disengage control cable -1-.
3. Screws 2 Nm
4. Clip
5. A-pillar

Release Cable, Routing in Interior

Scheme 68

Route the release cable -1- along the >>A-pillar<< as illustrated.

Press the grommet -2- onto the >>A-pillar<< from the interior.

Release Cable, Routing in Engine Compartment

Scheme 69

Route the release cable -2- as shown in the illustration in the engine compartment along the fender -3-, beginning from the vehicle interior and working out.

Slide the coupling -4- onto the lock carrier. Refer to HOOD RELEASE CABLE .

Scheme 70

1. Left stop Hood side
2. Rear lid A second person is needed during removal and installation to support and hold the rear lid. Removing -- Remove the rear lid trim panel. Refer to «Interior Trim»(/audi/s5/i-2007-2011/remont/exteriorinterior-trim/#interior-trim-coupe). -- Disconnect the electrical wires and remove from the lid. -- On the hood side, only loosen the rear nut and remove both side nuts. Refer to «LID HINGE»(/audi/s5/i-2007-2011/remont/exterior-body-panels/#hood-lids-coupe). -- Remove the rear lid. Installing: in reverse order Adjusting: -- Adjust the front height and the position of the hood lengthwise using the hood hinge. -- Adjust the rear height on the rear lid lock with the end plate. -- Align the hood so it is centered according to the gap dimensions (Scheme 53). -- Adjusting buffer stops Rear Lid Seal, Removing and Installing, refer to «HOOD SEAL»(/audi/s5/i-2007-2011/remont/exterior-body-panels/#hood-lids-coupe).
3. Right stop Hood side
4. Cover Placed on the lid lock.
5. Rear lid lock To remove, remove combi-bolts and disengage cable.
6. Cover for lid lock Remove the lid trim before removing. When installing, the cover must engage securely in the lid lock.
7. Nuts 21 Nm
8. Stop Body side
9. Stop
10. Adjusting buffer
11. Striker Adjusting: -- Tighten combi-bolts, see item 7 by hand (it must still be possible to slide striker). -- Carefully close the rear lid so that it is flush with the side panels. -- Carefully open lid and tighten bolts. Item -7- 7.
12. Nuts 21 Nm

Scheme 71

Close the rear lid.

Note. If the lid is adjusted correctly, the stop buffers -2- must lightly contact the body when the lid is closed.

The stop buffers can be loosened or tightened as needed to be flush.

The buffers -3- must engage audibly when pressing them in and the hood trim -1- must be installed.

Check the gap dimensions. (Scheme 53)

Scheme 72

1. Hood
2. Hood hinge Removing -- On the lid side, only loosen the rear nut and remove both side nuts. -- Remove the nuts over the rear shelf and the hinge. Installing: -- Insert the hinge under the rear shelf and secure it lightly using the nuts. -- Position the lid on the hinge and secure it using the nuts. -- Engage the spring and the gas-filled strut. -- Close the lid carefully. -- Align the lid sideways and lengthwise.
3. Nuts 21 Nm

Lid lock spring

Scheme 73

1. Lid dampening mechanism
2. Hood hinge
3. Ball stud 21 Nm
4. Gas strut Only installed on the left side of the vehicle.
5. Spring

Spring engaging points

Scheme 74

1. Spring Engaging: -- With the lid closed, engage the spring first on the hinge side and then on the body side. -- On the left side of the vehicle, the spring eyes must face down on the retaining pins, as shown in the magnified section of the illustration. -- Up on the right side. Body engaging points: -- On the right side, engage the sprint at point -a-. -- On the left side, engage the spring at point -d- after installing the lid hinge end stop.
2. Retaining screws Note the different directions for engaging the spring on the left and right. The spring eye faces down on the left side and up on the right side.

Lid Hinge Cable Guide, Removing

Scheme 75

1. Hood
2. Hood hinge
3. Cable guide Unclip the retaining tabs -arrows- and remove the cable guide from the lid hinge.
4. Electric wire
5. Rear lid trim Removing, refer to «Removal and Installation»(/audi/s5/i-2007-2011/remont/exteriorinterior-trim/#interior-trim-coupe)
6. Intermediate piece Can only be removed after removing the lid trim. Unclip from the lid.

Spring Cover, Removing

Scheme 76

Disengage the sides of the cover from the spring and remove it back from the retaining pins.

Gas-Filled Strut, Disengaging

Lift the retaining springs -arrow- on the gas-filled strut -1- slightly using a small screwdriver and remove it from the ball stud -2-.

Lid hinge end stop

Scheme 77

To remove, press the retainer on the clip to the side.

Clip the end stop -2- under the rear shelf -1- in the direction of the arrow.

The retainer on the clip must engage audibly.

Gas-Filled Strut, Releasing Gas

Clamp gas-filled strut in a vise in area -x- = 50 mm (2 in.).

Note. Cover area of sawn portion with a rag to absorb oil spraying out.

Cut through the gas-filled strut cylinder within the first third of the overall cylinder length using the piston rod end of the cylinder as a reference point.

Scheme 78

1. Cover Before removing, remove the lid trim from the lid lock.
2. Nut 21 Nm
3. Cover for lid lock When installing, cover must engage audibly in lid lock.
4. Rear lid latch Before removal, remove lid lock cover. Remove the rear lid trim. Refer to «Removal and Installation»(/audi/s5/i-2007-2011/remont/exteriorinterior-trim/#interior-trim-coupe) Disconnect electrical connector. If necessary, disengage the emergency release cable. Remove nuts and remove lid lock. Remove the lid lock with the clip from the centering hole.
5. Centering hole
6. Centering clip To install, first press the lid lock with the clip into the centering hole.

Rear lid lock emergency release

Scheme 79

1. Lid trim Removed. Refer to «Removal and Installation»(/audi/s5/i-2007-2011/remont/exteriorinterior-trim/#interior-trim-coupe)
2. Cover Unclip
3. Hood
4. Release cable Unclip the cover before removing. First unclip from the cable bracket on the lid lock and then disengage from the operating lever.
5. Rear lid latch
6. Emergency release operating lever When installing, first engage the release cable on the operating lever and then press it into the cable bracket.

Scheme 80

1. Rear lid
2. Lid seal To remove, remove seal from body flange. When installing, align the seal with the joint -arrow- toward the center of the vehicle. Beginning at the seam, press the seal all around onto the body flange.
3. Body flange