Repair manual
Audi S8 D2 facelift 2 Repair Manual
Step-by-step repair and maintenance instructions for the Audi S8 D2 facelift 2 (2002–2003): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
- A/C refrigerant system (R-134a), safety measures
- A/C refrigerant system, general repair guidelines
- Commercial designation
- Color
- Airborne properties
- Solubility of refrigerant oil
- Effects on the environment
- Toxicity
- Temperature/pressure relationship
- Effects on plastics
- Effects on metal
- Critical temperature/critical pressure
- Water solubility
- Flammability
- Refrigerant containers
- Leak detection
- A/C refrigerant oil (PAG), properties
- Refrigerant system with restrictor and accumulator
- A/C compressor
- A/C condenser
- Evaporator
- Accumulator
- Restrictor
- O-rings
- Hoses and lines
- A/C refrigerant system (R-134a), valves and switches
- Pressure relief valve
- Function
- A/C refrigerant high pressure switches -F23- and -F118
- Function of -F23
- Function of -F118
- Valve connections for pressure switches
- Connections for quick coupling adapter on refrigerant circuit
- High pressure service connection with Schrader valve
- A/C refrigerant system (R-134a), pressure & temperature relationships
- Refrigerant circuit with restrictor and accumulator
- Contact corrosion!
- A/C system refrigerant system, servicing
- Switch -F23
- Switch -F118
- Removing and installing
- A/C pressure switch -F129-, functions
- Switching pressures (in bar)
- Testing
- O-rings for refrigerant system
- A/C compressor from mounting bracket, removing and installing
- Nippondenso compressor
- Removing and installing clutch plate bolt
- Pulling off clutch disc
- Installing magnetic coil
- Checking and adjusting gap
- Automatic Climate Control components in engine compartment, servicing
- Sensor for air quality -G238-, function
- Test requirements
- Preparation
- Sensor for air quality -G238-, removing and installing
- Air flow flap motor -V71-, removing and installing
- Recirculation flap motor -V113-, removing and installing
- Control module for fresh air blower -J126-, removing and installing
- Pump valve unit, removing and installing
- Pump valve unit, replacing
- Dust and pollen filters, removing and installing
- Automatic Climate Control components in passenger compartment, servicing
- A/C control head -E87-, removing and installing
- Changes to model year 2000 vehicles
- For A/C control head with part numbers beginning with Index "M"
- Checking
- Heater cores, removing and installing
- Special tools and equipment
- Passenger-side heater core, removing and installing
- Version "1" heater core, removing
- Version "2" heater core, removing
- Version "1" heater core, installing
- Cleaning
- Version "2" heater core, installing
- Driver-side heater core, removing and installing
- Flap and vent motors, servicing
- Left center vent motor -V110- and right center vent motor -V111-, removing and installing
- Center vent adjusting motor -V102-, removing and installing
- Defroster flap motor -V107-, removing and installing
- Left footwell flap motor -V108- and rear footwell vent motor -V112-, removing and installing
- Temperature regulator flap motor -V68- and right footwell flap motor -V109-, removing and installing
- Instrument panel interior temperature sensor -G56-, removing and installing
- Center air outlet in instrument panel, removing and installing
- Making special tool
- Side window air outlet in right (left) of instrument panel, removing and installing
- Climate Control Components in passenger compartment, updates from m.y. 2000
- Air distribution, schematic diagram
- Preparatory work
- Automatic Climate Control System heating performance and operation of pump valve unit, testing
- A/C refrigerant system (R-134a), components
- A/C condenser, removing and installing
- Restrictor, removing and installing
- A/C refrigerant lines from Nippondenso compressor, removing and installing
- A/C compressor, removing and installing
- A/C evaporator, removing and installing
- Removing
- Removing version "2" evaporator
- Installing
- Air conditioner housing, removing and installing
- Air conditioner housing, disassembling and assembling
- Screen, fresh air blower, evaporator and covers in plenum, removing and installing
- Disassembling And Assembling Cover With Recirculating Air Flap
- Disassembling And Assembling Intake Shaft
- Air conditioner housing (lower) and air distribution housing, disassembling and assembling
- Air distribution housing, disassembling and assembling
- A/C refrigerant system (R-134a), leak testing
- A/C refrigerant system (R-134a), testing with pressure gauges
- Measuring pressure and temperature in a "switched-on" refrigerant system
- Measuring pressure and temperature in a closed container or "switched-off" refrigerant system
- A/C refrigerant system (R-134a), checking pressures
- Preparation work
- If A/C refrigerant system base pressure is less than specified on chart, system is low on refrigerant
- If A/C refrigerant system pressure corresponds to or is higher than base pressure specified on chart
- Pressure in refrigerant circuit corresponds to chart or is higher
- Refrigerant R-134a
- Refrigerant (PAG) oil
- A/C refrigerant system (R-134a), discharging
- Discharging
- A/C refrigerant system (R-134a), evacuating & recharging
- Evacuating & recharging
- A/C refrigerant system (R-134a), flushing with compressed air and nitrogen
- A/C does not cool (cooling has stopped completely)
- Insufficient cooling during all driving or engine speed (RPM)
- A/C compressor noisy
- A/C compressor noisy immediately after switching A/C ON and/or when driving around corners or braking "refrigerant shock" -refrigerant system Overcharged
- With an otherwise properly operating A/C system, water sprays out of instrument panel vents
- A/C refrigerant system (R-134a), replacing components
- DESCRIPTION & OPERATION
- BLEEDING PROCEDURES
- Without Electronic Stability Program
- With Electronic Stability Program
- BRAKELIGHT SWITCH
- PARKING BRAKE
- POWER BOOSTER PUSH ROD
- BRAKE PAD INDICATOR LIGHT
- REMOVAL & INSTALLATION
- CALIPER (FRONT)
- HP2 Steel Caliper Bracket Retrofit
- FRONT PADS (FN3)
- Removal (FN3)
- Installation (FN3)
- FRONT PADS (HP2, ALUMINUM CALIPER)
- FRONT PADS (HP2, STEEL CALIPER
- Removal (HP2, Steel Caliper)
- Installation (HP2, Steel Caliper)
- FRONT PADS(BREMBO)
- Removal (Brembo)
- Installation (Brembo)
- Removal
- Installation
- PARKING BRAKE CABLES
- PARKING BRAKE LEVER
- REAR PADS
- Disassembly & Reassembly
- FRONT CALIPER (HP2, ALUMINUM CALIPER)
- FRONT CALIPER (HP2, STEEL CALIPER)
- FRONT CALIPER (BREMBO)
- Cleaning & Inspection
- MASTER CYLINDER
- VACUUM POWER BOOSTERS
- TORQUE SPECIFICATIONS
- DISC BRAKE SPECIFICATIONS
- General repair instructions
- Safety precautions when working on the fuel supply system
- Rules for cleanliness
- Position of cross brace
- Position of double hose clamp
- Fuel tank, draining
- Special tools and required equipment
- Work sequence
- Fuel tank with attachments, removing and installing
- Removing
- Installing
- Fuel delivery module and fuel level senders, removing and installing
- Fuel supply system, function
- Fuel pump, electrical testing
- Checking current draw
- Fuel pump delivery volume, checking
- Requirements for test
- Fuel delivery module, removing and installing
- Leak checking
- Fuel level senders, checking
- Fuel level sensors, removing and installing
- Removing and installing Fuel Level Sensor 2 -G169- (left)
- Fuel filler neck with expansion tank, component overview
- Installation position of Ground (GND) connection
- Bleed valve, removing and installing
- Gravity valve, checking
- Fuel filler neck with expansion tank, removing and installing
- Fuel filter, replacing
- EVAP canister, component overview
- EVAP canister, removing and installing
- EVAP system leak detection circuit diagram
- EVAP system leak detection system, function
- EVAP system, automatic leak testing
- EVAP system, leak testing using VAS5051 or VAG1551
- Test requirements
- Checking fuel supply and tank ventilation system for leaks
- Leak Detection Pump (LDP) -V144-, overview
- Special tools and equipment
- Checking internal resistance
- Checking voltage supply
- Test requirement
- Description
- Perform EVAP tester self-test
- Calibrate KLI9210 Tester
- Test LDP -V144- for internal leaks
- Test EVAP System
- Accelerator pedal linkage (vehicles with electronic throttle control), servicing
- Test sequence
- Safety precautions
- Rules for cleanliness
- Technical data (A8 vehicles)
- Technical data (S8 vehicles)
- Component locations, overview
- Wiring and component check with VAG1598/31 test box
- Connecting VAG1598/31 test box
- Motronic Engine Control Module (ECM) -J220- (without metal anti -theft housing), replacing
- Removing Engine Control Module (ECM)
- Installing engine control module
- Motronic Engine Control Module (ECM) -J220- (with metal anti -theft housing), replacing
- Procedure
- Installing Engine Control Module (ECM)
- Motronic Engine Control Module (ECM) Power Supply Relay -J271-, checking
- Checking activation of the ECM power supply relay
- Activating Cruise Control System (CCS)
- Test conditions
- Checking idle speed
- If the idle speed is too high or too low, or if the engine does not idle smoothly, and there are no malfunctions stored in the DTC memory, perform the following tests (marked with
- Relevance of figures in 5-digit readout in Display Group 056
- Requirements
- Removing fuel rail
- Checking fuel injectors for leaks
- Fuel Pump (FP) relay -J17- and relay activation, checking
- Functional test of fuel pump relay
- Testing activation of fuel pump relay
- Checking function
- Reading Display Group 002
- Checking wiring for MAF sensor
- Intake Air Temperature (IAT) sensor -G42-, checking
- Engine Coolant Temperature (ECT) sensor -G62-, checking
- Oxygen sensor control, function
- Significance of 3 digit indication in Display Group 30
- Checking oxygen sensor adaptation and oxygen sensor control
- Evaluation display group 32
- Evaluation display group 33
- Test requirements
- Test sequence for oxygen sensor 1 before catalytic converter bank 1
- Continuation
- Test sequence for oxygen sensor 1 before catalytic converter bank 2
- Component location of connectors for oxygen sensors 2 behind catalytic converter
- Checking oxygen sensor control behind catalytic converter
- Evaluation display group 037 and 038
- Oxygen sensor heater for oxygen sensor, checking
- Checking voltage supply for oxygen sensor heater
- Oxygen sensor signal wire and activation, checking
- Checking oxygen sensor wiring for Heated Oxygen Sensor (HO2S) -G39
- Checking wiring for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130
- Checking wiring for Heated Oxygen Sensor (HO2S) 2 -G108
- Checking wiring for Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131
- Intake manifold change-over, checking (A8 vehicles)
- Intake manifold change-over, checking function
- Intake Manifold Change -Over Valve -N156- and Intake Manifold Tuning (IMT) Valve -2- -N261-, checking
- Checking voltage supply to intake manifold change-over valve
- Checking vacuum system for leaks
- Intake manifold change -over valve, checking function
- Intake manifold change-over valve - N156-, checking
- Checking voltage supply of intake manifold change-over valve
- Checking activation of intake manifold change-over valve
- Checking solenoid valve for throughput and proper seal
- Checking vacuum system for proper seal
- Checking for leaks
- Checking power supply to solenoid valve
- Secondary Air Injection (AIR) Solenoid Valve -N112-, checking
- Secondary Air Injection (AIR) pump relay -J299-, checking
- Checking voltage supply for secondary air pump relay
- Check activation of secondary air injection pump relay
- Electronic throttle system, function
- Throttle valve control module -J338-, checking
- Throttle valve control module, adaptation
- Test conditions for adaptation of throttle valve control module
- Throttle valve control module, adaptation notes
- Angle sensor -1- for throttle drive (power accelerator actuation) -G187- and angle sensor -2- for throttle drive (power accelerator actuation) -G188-, checking
- Checking voltage supply to throttle valve control module
- Electronic Engine Power Control (EPC) warning light in instrument cluster, significance
- Checking function of warning light
- Throttle Position (TP) sensor -G79- and sender -2- for accelerator pedal position -G185-, checking
- Checking voltage supply of accelerator position sensors
- Checking signal wiring and wiring connections between accelerator position sensors and engine control module
- Brake light switch -F- and brake pedal switch -F47-, checking
- Relevance of figures in 4-digit readout in display field 2
- Checking voltage supply
- Checking wiring connections
- Engine speed (RPM) signal, checking
- A/C compressor shut-off, checking
- Crash signal, checking
- Engine mounts, checking
- Data exchange between Engine Control Module (ECM), ABS/EDL control module, Transmission Control Module (TCM) or instrument cluster, checking
- Checking bus system
- Automatic Test Sequence
- Checking two-wire bus system
- General information
- Malfunction message "dEF" on trip recorder display
- Notes for replacing instrument cluster
- Additional information
- Safety precautions
- Test requirements
- Check DTC Memory (function 02)
- Diagnostic Trouble Code (DTC) table
- Output Diagnostic Test Mode (DTM) (function 03)
- Initiating output Diagnostic Test Mode
- Erase DTC Memory (function 05)
- Requirements
- End Output (function 06)
- Code Control Module (function 07)
- Initiating coding
- Initiating "Read Measuring Value Block"
- Display group overview
- Adaptation (function 10)
- Adaptation table
- Initiating "Adaptation" function 10
- Resetting SRI after service
- Adaptation of fuel gauge
- Language version of driver information monitor
- Odometer display
- Adaptation of auxiliary heater
- Adaptation of fuel gauge sender resistance range
- Distance driven since service
- Time since service
- Minimum mileage performance
- Maximum mileage performance
- Maximum time interval
- Adaptation of oil quality
- Adaptation of total consumption quantity
- Adaptation for power train data-BUS
- Adaptation value
- Adaptation for comfort system databus
- Adaptation for information data-BUS
- Adapatation value
- Input values for replacing instrument cluster
- Perform the following steps after replacing instrument cluster
- Data exchange between control modules, checking
- Checking bus system
- Checking a "two-line bus system"
- Example 1
- Example 2
- Example 3
- If you cannot determine a cause for the malfunction, e.g. "power train data-BUS faulty", check whether one of the control modules may be responsible for the DTC
- Function
- Notes for use and adaptation of vehicle key
- Check Control Module Versions (function 01)
- Adaptation of vehicle keys
- Lost key procedure
- Determining the secret number
- Adaptation after replacing the instrument cluster
- Adaptation after replacing the Engine Control Module (ECM)
- Adaptation after replacing the instrument cluster and the Engine Control Module (ECM)
- Procedure
- Login procedure
- Login Procedure, instrument cluster
- Login procedure, Engine Control Module (ECM)
- Emergency start function using VAG 1551
- CCS, checking
- CCS, activating
- CCS, deactivating
- Electrical test using VAG 1598/31 test box
- Output Diagnostic Test Mode (function 03)
- Basic Setting (function 04)
- Perform basic setting
- Coding table
- Safety precautions
- Transmission controls
- Malfunction recognition by the TCM
- TCM backup functions
- Mechanical backup with non-active control module
- Malfunction Indicator Lamp (MIL), function
- MIL functional check
- Conditions for recognition of a driving cycle (Dcy)
- On Board Diagnostic (OBD), functions
- Electrical and electronic components, locations
- Removing and installing Transmission Control Module (TCM) -J217
- Installing
- VAG 1551 Scan Tool (ST), connecting and selecting function
- Test requirements
- VAG 1551 Scan Tool (ST), overview of available functions
- Code Control Module (scan tool function 07)
- Diagnostic Trouble Code (DTC) table
- Output Diagnostic Test Mode (DTM) (function 03)
- Requirement
- Read Measuring Value Block (function 08)
- Electrical testing
- Testing
- Multi-pin connector (88-pin connector) of TCM -J217- (socket numbers on VAG 1598/20)
- Overview of test steps (of 88-pin connector)
- Disconnecting connector
- Wiring harness between Transmission Control Module (TCM) and transmission, checking
- Transmission diagram for all-wheel drive
- Shift element positions
- General
- Function
- VAG1551 Scan Tool (ST), connecting and entering address word
- Selecting functions
- Requirements
- End Output
- Bus
- CAN
- The DTC table indicates the bus must be checked
- Is there is a malfunction?
- While checking the bus lines, differentiate between the following two situations
- Three or more control modules are communicating across a "two-line bus system"
- Example 1
- Example 2
- Example 3
- Reconnecting battery, procedures
- Basic setting for the up and down power windows function
- Setting the clock
- Adaptation of throttle valve control module
- Application notes
- Road test
- If there is a complaint, a pin-pointed troubleshooting must be carried out
- Test requirements
- Technical publications required
- Function of Bosch ABS 5.0 Series
- Electronic brake force distribution
- Table of warning light functions
- Function of On Board Diagnostic (OBD)
- Technical data of On Board Diagnostic (OBD)
- Check control module version
- Check DTC memory
- Encode control module
- Read measured value block
- Test table, Display group 1
- Test table, Display group 3
- Electrical testing
- Function of Bosch ABS 5.3 Series
- Two communications systems are in use
- Output Diagnostic Test Mode (DTM)
- Test table, Display group 2
- Note on DTC table
- Electronic Stabilization Program (ESP)
- Safety measures and troubleshooting basics
- Test drive
- Test conditions
- Technical information required
- ESP function
- EBD
- ESP
- Examples
- Hydraulic pump for traction control -V156- and the sensor for brake pressure -G201
- Steering Angle Sensor -G85
- Airbag spiral spring/return spring with slip ring -F138
- Sender for rotation rate -G202
- Sensor for transverse acceleration -G200
- The parking brake switch
- The ABS solenoid valve relay -J106- and the ABS return flow pump relay -J105
- ABS/ESP Control Module CAN Bus
- Indicator light functions, overview
- On Board Diagnostic (OBD), specific functions
- On Board Diagnostic (OBD), technical data
- Control module versions (scan tool function 01), checking
- DTC table
- Basic setting (scan tool function 04)
- Login procedure (scan tool function 11)
- Display group 1: Zeroing the steering angle sensor -G85
- Display group 2: Activating hydraulic pump for traction control -V156
- Display group 3: Activating ESP driving test
- Output Diagnostic Test Mode (DTM) (scan tool function 03)
- Code Control Module (scan tool function 07)
- Measuring Value Block (scan tool function 08), reading
- Test table: display group 1 (001)
- Electrical test table
- Safety precautions
- On Board Diagnostic (OBD) functions
- DTC table for tire pressure monitoring
- Performing coding
- Code: 20129
- Adaptation
- Tire pressure monitoring system, operating for the first time
- V.A.G 1551 scan tool, connecting
- General information
- Conditions
- Control module identification (example)
- Check DTC Memory (function 02)
- Erase DTC Memory (function 05)
- End output (function 06)
- Diagnostic Trouble Code (DTC) table
- Output Diagnostic Test Mode (function 03)
- Code Control Module (function 07) for central locking
- Coding table for vehicles up to 06.97
- Coding table for vehicles from 07.97
- Read Measuring Value Block (function 08)
- Vehicle key for radio remote control, programming/erasing
- Work step of adapting new radio-controlled keys
- Work procedure for re-adapting existing radio-controlled keys
- Work sequence for erasing memory positions
- Function
- Interior monitoring system, functional test
- Interior monitoring system diagnostic
- Diagnostic table
- Corrective action
- Sensor Check
- Replace control module
- Check wiring
- Removing
- Installing
- Assignment of connector at control module
- Assignment of connector at sensor
- Momentary contact deactivation switch, checking
- On Board Diagnostic (OBD) of interior monitoring system, initiating
- Equipment version without side curtain airbag system
- Equipment version with side curtain airbag system
- Output Diagnostic Test Mode (DTM) (function 03) (vehicles without side curtain airbag)
- Special tools, testers and auxiliary items required
- Test sequence
- Output Diagnostic Test Mode (DTM) (function 03) (vehicles with side curtain airbag)
- Code Control Module (function 07) (vehicles without side curtain airbag)
- Code Control Module (function 07) (vehicles with side curtain airbag)
- Adaptation (function 10)
- General information
- Technical data
- System changes from m.y. 1998
- System changes from m.y. 2000 (with revised driver's information display)
- Requirements
- Diagnostic Trouble Code (DTC) Memory, checking (function 02)
- If a DTC was recognized
- Diagnostic Trouble Code (DTC) table
- Changes to model year 2000 and up vehicles
- Output Diagnostic Test Mode (DTM) (function 03)
- Initiating output DTM
- Output Diagnostic Test Mode (DTM) Idle speed control test, initiating
- Basic Setting (function 04)
- End Output (function 06)
- Code Control Module (function 07)
- Coding variants
- Example for A/C control head -E87- up to index "H"
- Example for A/C control head -E87- from index "J"
- Coding A/C control head -E87- (up to index "H")
- Coding A/C control head -E87-, beginning at index "J"
- Coding A/C control head -E87-, model year 2000 and up
- Read Measuring Value Block (function 08)
- Read Measuring Value Block, initiating
- Overview of display group numbers which can be selected
- Display group 001 - A/C compressor cut-off conditions, voltage for A/C clutch -N25-, voltage to terminal 15 and requirement for recirculating air mode/sensor for air quality -G238
- Display group 006-Temperature regulator flap motor -V68
- Display group 012-ACF flap motor -V114
- Display group 013-Left center air vent switch -F183- and right center vent switch -F184-, center vent position sensor -G142- and calculated ambient temperature for outside air temp
- Display group 014-Outside air temperature sensor -G17- and fresh air intake duct temperature sensor -G89-, left vent temperature sensor -G150- and right vent temperature sensor -G1
- Display group 015-Instrument panel interior temperature sensor -G56-, calculated coolant temperature and sunlight photo sensor -G107
- Display group 001: Instantaneous occurring compressor shut off conditions, voltage for A/C clutch, -N25-, Voltage to terminal "15" and requirement recirculation mode/sensor for air
- Display group 021: Idle RPM increase, activating fan for coolant and activating washer system
- Display group 022: Allocation ignition key and signal for "time ignition off"
- Tools required
- Connecting VAG1598/19 test box to connector of A/C control head -E87
- Test step 9 - Signal for washer/wiper system
- Electrical test changes for model year 2000 and up vehicles
- Bus
- Example
- Can-Bus malfunction "Faulty databus drive," checking
- Malfunction is indicated only by A/C control head -E87
- In another control module a malfunction is indicated
- Can-Bus notes
- Required measuring and test items
- Test requirements
- Windshield defroster, disconnecting
- Solar sunroof, checking
- Checking function of solar sunroof
- Data Link Connector (DLC), checking wiring connections
- APPLICATION
- SERVICE INTERVALS
- CHECKING FLUID LEVEL
- Rear Final Drive
- RECOMMENDED FLUID
- FLUID CAPACITIES
- DRAINING & REFILLING
- 01L Transaxle
- Transfer Case
- ATF LINES & ATF COOLER FLUSHING
- SELECTOR LEVER CONTROLS
- ON-VEHICLE REPAIRS
- DRIVE SHAFT
- Carbon Fiber
- Steel
- LOCKING CABLE
- Checking
- Adjustments
- 1997-99
- 2000-03
- Removal & Installation (Carbon Fiber)
- Removal & Installation (Steel)
- LEFT DRIVE FLANGE
- Removal & Installation
- REAR FINAL DRIVE FLANGE SEALING RINGS
- SELECTOR LEVER CABLE
- TRANSMISSION RANGE SWITCH
- TORQUE SPECIFICATIONS