Audi R8 Spyder 2016 – 2020 Complete Service Repair Workshop Manual
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TABLE OF CONTENTS:
00 – General, Technical Data 1
1 Engine Overview 1
11 Engine Overview with Adjustment Values, Gauge – Oil Gauge Tester (T40178)1
2 Revision History 3
00 – General, Technical Data 1
1 Identification 1
11 Engine Number/Engine Specifications 1
2 Safety Precautions 2
21 Safety Precautions when Working on Fuel Supply System 2
22 Safety Precautions when Working on Vehicles with Start/Stop System 2
23 Safety Precautions during Road Test with Testing Equipment 3
24 Safety Precautions when Working on Ignition System 3
25 Safety Precautions when Working on Cooling System 3
3 Repair Information5
31 Guidelines for Clean Working Conditions 5
32 Leak Test on Vehicle 5
33 Foreign Objects in Engine 6
34 Contact Corrosion 6
35 Line Routing and Securing 7
36 Protective Body Covers, Installing 7
37 Vacuum System, Checking 7
38 Radiator and Condenser Assembly 8
4 Special Tools 9
10 – Engine Assembly 10
1 Engine, Removing and Installing 10
11 Engine, Removing 10
12 Engine/Transmission Sub-Assembly, Lowering Onto Scissor Lift Table 36
13 Engine and Transmission, Separating 37
14 Engine, Securing to Engine and Transmission Holder 41
15 Engine, Installing 44
2 Subframe Mount 50
21 Overview – Subframe Mount 50
22 Engine Mount, Removing and Installing 52
23 Transmission Mount, Removing and Installing 53
3 Engine Cover 55
31 Overview – Engine Compartment Covers55
32 Engine Compartment Cover, Removing and Installing 57
4 Special Tools 60
13 – Crankshaft, Cylinder Block 67
1 Cylinder Block, Belt Pulley Side 67
11 Overview – Ribbed Belt Drive 67
12 Ribbed Belt, Removing and Installing 68
13 Ribbed Belt Tensioner, Removing and Installing69
14 Sub-Assembly Bracket, Removing and Installing70
15 Vibration Damper, Removing and Installing 70
16 Crankshaft Seal, Replacing, Belt Pulley Side 71
2 Cylinder Block, Transmission Side74
21 Overview – Cylinder Block, Transmission Side 74
22 Flywheel, Removing and Installing74
23 Crankshaft Seal, Replacing, Transmission Side76
3 Crankshaft78
31 Overview – Crankshaft 78
32 Main Bearing Shells Allocation 81
33 Crankshaft Dimensions 83
Audi R8 2015 ➤
10-Cylinder Gasoline Direct Injection 52L 4V Engine – Edition 032017
Contents i
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34 Crankshaft, Measuring Axial Clearance 83
35 Crankshaft, Measuring Radial Clearance83
36 Intake Module and Guide Frame, Removing and Installing 84
4 Pistons and Connecting Rod 91
41 Overview – Pistons and Connecting Rod91
42 Pistons, Removing and Installing93
43 Piston and Cylinder Bore, Checking 95
44 Connecting Rods, Checking Radial Clearance 96
5 Power Take-Off 97
51 Overview – Power Take-Off 97
52 Spur Gear Drive, Removing and Installing98
53 A/C Compressor Drive Seal, Replacing 101
6 Special Tools 103
15 – Cylinder Head, Valvetrain 107
1 Timing Chain Cover 107
11 Overview – Timing Chain Cover 107
12 Timing Chain Cover, Removing and Installing 109
2 Chain Drive120
21 Overview – Camshaft Timing Chains 120
22 Overview – Timing Mechanism Drive Chain 123
23 Overview – Drive Chain 125
24 Camshaft Timing Chain, Removing from Camshafts 125
25 Camshaft Timing Chain, Removing and Installing132
26 Timing Mechanism Drive Chain, Removing and Installing136
27 Power Take-Off Drive Chain, Removing and Installing 137
3 Cylinder Head 141
31 Overview – Cylinder Head141
32 Cylinder Head Cover, Removing and Installing 144
33 Cylinder Head, Removing and Installing148
34 Compression, Checking 155
4 Valvetrain158
41 Overview – Valvetrain 158
42 Camshaft, Measuring Axial Clearance 160
43 Camshaft, Measuring Radial Clearance 161
44 Camshaft, Removing and Installing 161
45 Hydraulic Lifter, Checking167
46 Valve Stem Seals, Removing and Installing 168
5 Intake and Exhaust Valves175
51 Valve Guides, Checking 175
52 Valves, Checking175
53 Valve Dimensions176
6 Special Tools 177
17 – Lubrication 183
1 Oil Pan/Oil Pump183
11 Overview – Oil Pan/Oil Pump 183
12 Engine Oil185
13 Oil Pump, Removing and Installing 185
14 Oil Level Thermal Sensor G266 , Removing and Installing 187
2 Engine Oil Cooler188
21 Overview – Engine Oil Cooler 188
22 Engine Oil Cooler, Removing and Installing 192
Audi R8 2015 ➤
10-Cylinder Gasoline Direct Injection 52L 4V Engine – Edition 032017
ii Contents
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with respect to the correctness of information in this document Copyright by AUDI AG
23 Mounting Plate for Engine Oil Cooler/Pressure Regulator Valve/Oil Filter Housing, Removing
and Installing 194
3 Crankcase Ventilation 197
31 Overview – Crankcase Ventilation197
32 Crankcase Ventilation Hoses, Removing and Installing 198
4 Oil Filter/Oil Pressure Switch 203
41 Overview – Oil Filter Housing/Oil Pressure Switch203
42 Oil Filter Housing, Removing and Installing 204
43 Oil Pressure Switch F1 , Removing and Installing206
44 Oil Pressure and Oil Pressure Switch, Checking207
45 Oil Temperature Sensor 2 G664 , Removing and Installing 209
5 Oil Circuit211
51 Overview – Oil Circuit 211
52 Oil Spray Jets/Valves 212
53 Oil Tank, Removing and Installing214
6 Special Tools 216
19 – Cooling System219
1 Coolant System/Coolant 219
11 Connection Diagram – Coolant Hoses 219
12 Cooling System, Checking for Leaks 220
13 Coolant, Draining and Filling 221
2 Coolant Pump/Coolant Thermostat 228
21 Overview – Coolant Pump228
22 Overview – Coolant Thermostat 229
23 Overview – Electric Coolant Pump230
24 Electric Coolant Pump, Removing and Installing230
25 Coolant Pump, Removing and Installing231
26 Coolant Thermostat, Removing and Installing 233
27 Coolant Thermostat, Checking 235
28 Engine Coolant Temperature Sensor G62 , Removing and Installing 236
3 Coolant Pipes 238
31 Overview – Coolant Pipes238
32 Overview – Lower Coolant Pipes240
33 Overview – Coolant Expansion Tank 242
34 Coolant Hoses, Assembling 243
35 Coolant Pipes, Removing and Installing 243
36 Lower Coolant Pipes, Removing and Installing 246
37 Transmission Coolant Pump, Removing and Installing 256
4 Radiator/Radiator Fan 258
41 Overview – Radiator/Radiator Fan258
42 Overview – Auxiliary Cooler 260
43 Radiator, Removing and Installing261
44 Radiator Fan, Removing and Installing 265
45 Auxiliary Cooler, Removing and Installing267
5 Special Tools 269
24 – Multiport Fuel Injection 272
1 Injection System 272
11 Component Location Overview – Injection System272
2 Air Filter 282
21 Overview – Air Filter Housing 282
22 Air Filter Housing, Removing and Installing 283
23 Air Filter Housing Bracket, Aligning 284
Audi R8 2015 ➤
10-Cylinder Gasoline Direct Injection 52L 4V Engine – Edition 032017
Contents iii
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3 Intake Manifold 286
31 Overview – Intake Manifold286
32 Overview – Intake Manifold Lower Section with Fuel Rail288
33 Intake Manifold Upper Section, Removing and Installing289
34 Intake Manifold Lower Section with Fuel Rail, Removing and Installing294
35 Throttle Valve Control Module, Removing and Installing296
4 Fuel Injectors 299
41 Overview – Fuel Rail with Fuel Injectors 299
42 Fuel Injectors, Removing and Installing 302
43 Fuel Injectors, Cleaning 306
5 Sensors 308
51 Fuel Pressure Sensor, Removing and Installing308
52 Mass Airflow Sensor G70 , Removing and Installing 308
6 High Pressure Pump 310
61 Overview – High Pressure Pump310
62 High Pressure Pipe, Removing and Installing 311
63 High Pressure Pump, Removing and Installing 312
7 Heated Oxygen Sensor 315
71 Overview – Heated Oxygen Sensor 315
72 Heated Oxygen Sensor, Removing and Installing316
8 Engine Control Module 318
81 Overview – Engine Control Module318
82 Engine Control Module J623 , Removing and Installing 320
9 Special Tools 323
26 – Exhaust System, Emission Controls 325
1 Exhaust Pipes/Mufflers 325
11 Overview – Muffler325
12 Muffler, Removing and Installing327
13 Exhaust System, Checking for Leaks 328
2 Emissions Control System329
21 Overview – Emissions Control System 329
22 Catalytic Converter, Removing and Installing 331
23 Exhaust Flap Vacuum Diaphragm, Checking 333
3 Exhaust Temperature Regulation334
31 Overview – Exhaust Temperature Regulation 334
32 Exhaust Gas Temperature Sensor 2 G448 , Removing and Installing 334
4 Secondary Air System 336
41 Overview – Secondary Air Injection System 336
42 Secondary Air Injection Pump Motor V101 , Removing and Installing 338
43 Secondary Air Injection Pump Motor 2 V189 339
44 Secondary Air Injection Solenoid Valve, Checking 340
45 Combination Valve, Removing and Installing 342
46 Secondary Air Injection Sensor 1 G609 , Removing and Installing 346
5 Special Tools 348
28 – Ignition/Glow Plug System 349
1 Ignition System 349
11 Overview – Ignition System349
12 Test Data and Spark Plugs 350
13 Ignition Coils with Power Output Stages, Removing and Installing 350
14 Knock Sensor, Removing and Installing 353
15 Camshaft Position Sensor, Removing and Installing 354
16 Engine Speed Sensor G28 , Removing and Installing 356
Audi R8 2015 ➤
10-Cylinder Gasoline Direct Injection 52L 4V Engine – Edition 032017
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2 Special Tools 358
3 Revision History 359
Audi R8 2015 ➤
10-Cylinder Gasoline Direct Injection 52L 4V Engine – Edition 032017
Contents
00 – General, Technical Data1
1 Safety Precautions1
11 Safety Precautions when Working on Fuel System 1
12 Safety Precautions when Working on Vehicles with Start/Stop System2
13 Safety Precautions during Road Test with Testing Equipment 2
2 Repair Information3
21 Guidelines for Clean Working Conditions3
22 Test Conditions 3
23 Fuel Tank, Checking for Leaks 3
24 Contact Corrosion4
25 Protective Body Covers, Installing4
26 Line Routing and Securing4
20 – Fuel Supply 5
1 Fuel Tank5
11 Overview – Fuel Tank 5
12 Ground Connection, Routing and Securing to Discharge Electrostatic Charge 12
13 Fuel Tank, Draining 14
14 Fuel Tank, Removing and Installing 25
2 Fuel Delivery Unit/Fuel Level Sensor 42
21 Overview – Fuel Delivery Unit/Fuel Level Sensor42
22 Fuel Delivery Unit/Fuel Level Sensor, Removing and Installing 45
23 Fuel Level Sensor in Right Fuel Tank Chamber, Removing and Installing 55
24 Fuel Level Sensor in Left Fuel Tank Chamber, Removing and Installing63
3 Connector Couplings 73
31 Connector Couplings, Disconnecting 73
4 Fuel Filter77
41 Overview – Fuel Filter 77
42 Fuel Filter, Removing and Installing 78
5 EVAP System 86
51 Connection Diagram – EVAP System 86
52 Overview – EVAP System88
53 EVAP Canister, Removing and Installing90
54 Fuel Tank Pressure Sensor G400 , Removing and Installing 92
55 Fuel System, Checking for Leaks92
6 Accelerator Mechanism 95
61 Overview – Accelerator Pedal Module 95
62 Accelerator Pedal Position Sensors G79 / G185 , Removing and Installing 95
7 Fuel Pump97
71 Transfer Fuel Pump G6 , Checking 97
72 Function of the Suction Jet Pumps101
73 Fuel Pump Control Module J538 , Removing and Installing 101
8 Special Tools 105
9 Revision History 108
00 – General, Technical Data1
1 Identification 1
11 Transmission Identification1
2 Safety Precautions2
21 Safety Precautions when Working on Vehicle 2
22 Safety Precautions when Working on Vehicles with Start/Stop System3
23 Safety Precautions during Road Test with Testing Equipment 3
24 Safety Precautions when Tow Starting and Towing 3
3 Repair Information5
31 Guidelines for Clean Working Conditions5
32 General Information 5
33 General Repair Information 6
34 Body Protectors, Installing7
35 Contact Corrosion8
36 Wire Routing and Securing 8
4 Technical Data 9
41 Capacities9
5 Overview – Transmission10
30 – Clutch 11
1 Clutch 11
11 Overview – Dual Clutch 11
12 Overview – Clutch Carrier13
13 Clutch Carrier, Removing and Installing 13
14 Clutch, Removing and Installing 16
15 Clutch Cover, Removing and Installing 19
16 Driveshaft Bearing, Replacing 20
2 Special Tools 23
34 – Controls, Housing 25
1 Selector Mechanism 25
11 Overview – Selector Mechanism 25
12 Overview – Parking Lock Emergency Release 27
13 Gearshift Mechanism, Checking27
14 Selector Lever Handle, Removing and Installing32
15 Selector Lever Boot on Selector Lever Handle, Disconnecting and Assembling34
16 Emergency Release from P 34
17 Selector Mechanism, Removing and Installing 36
18 Parking Lock Emergency Release Cable, Removing and Installing 36
2 Transmission, Removing and Installing 39
21 Transmission, Removing39
22 Transmission, Installing 45
23 Transmission Tightening Specifications 46
3 Securing on Engine and Transmission Holder 48
4 Subframe Mount 50
41 Overview – Subframe Mount 50
5 ATF Circuit52
51 Overview – ATF Circuit 52
52 Overview – Oil Pan54
53 Overview – Drain and Check Plugs 55
54 Overview – Auxiliary Hydraulic 56
Audi R8 2015 ➤
7-Speed Dual Clutch Transmission 0BZ (S tronic) – Edition 012017
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55 ATF Cooler, Removing and Installing 56
56 ATF Filter, Removing and Installing 58
57 Transmission Fluid Pan, Removing and Installing59
58 Auxiliary Hydraulic, Removing and Installing 60
6 ATF64
61 ATF Level, Checking 64
62 ATF, Draining and Filling68
7 Mechatronic 72
71 Overview – Mechatronic 72
72 Mechatronic, Removing and Installing 73
8 Special Tools 80
35 – Gears, Shafts 85
1 Parking Lock 85
11 Overview – Parking Lock85
12 Parking Lock Cover, Removing and Installing 86
13 Parking Lock, Removing and Installing 88
2 Special Tools 92
39 – Final Drive, Differential 93
1 Seals, Rear Final Drive 93
11 Component Location Overview – Seals 93
12 Left Seal, Replacing 93
13 Right Seal, Replacing 96
14 Input Shaft Seal, Replacing 96
15 Driveshaft Seal in Transmission, Replacing 98
2 Differential, Rear Final Drive 99
21 Overview – Differential 99
22 Left Flange Shaft, Removing and Installing 100
23 Left Flange Shaft Bearing, Removing and Installing 101
24 Final Drive Cover with Right Flange Shaft, Removing and Installing 102
25 Right Flange Shaft, Removing and Installing 102
26 Right Flange Shaft Bearing, Removing and Installing 104
3 Transmission Control, Rear Final Drive 107
31 Component Location Overview – Transmission Control 107
32 Overview – Transmission Housing Sensor109
33 Transmission Control Module, Removing and Installing111
34 Transmission Input Speed Sensor G182 / Clutch Temperature Sensor 1 G658 , Removing
and Installing 113
35 Clutch Temperature Sensor 2 G659 , Removing and Installing 116
4 Front Final Drive and Front Differential 117
5 Special Tools 118
6 Revision History 122
00 – General, Technical Data1
1 Safety Precautions1
11 Safety Precautions when Working on Vehicles with Start/Stop System1
12 Safety Precautions during Road Test with Testing Equipment 1
2 General Information 2
21 Tire Types2
22 Drive Axle General Information 2
3 Repair Information3
31 Shock Absorber Leaks 3
32 Shock Absorber Noises 4
33 Shock Absorbers, Checking when Removed 4
34 Shock Absorbers, Checking on Shock Tester 5
35 Threshold “a” in mm 6
36 Guidelines for Clean Working Conditions6
37 General Information 7
38 General Repair Information 8
39 Contact Corrosion8
310 Seals and Gaskets8
311 Bolts and Nuts 8
312 Electrical Components 8
313 Damaged Threads in Longitudinal Member, Repairing (Subframe to Body) 9
314 Wheel Bearing in Curb Weight Position, Lifting Vehicles with Coil Spring9
4 Technical Data 12
41 Suspension12
42 Steering 12
5 Disposal 13
51 Gas-Filled Shock Absorbers, Venting and Emptying 13
6 Special Tools 15
40 – Front Suspension16
1 Front Axle16
11 Overview – Front Axle 16
2 Subframe17
21 Overview – Stabilizer Bar17
22 Stabilizer Bar, Removing and Installing 18
23 Coupling Rod, Removing and Installing 20
3 Suspension Strut and Upper Control Arm21
31 Overview – Suspension Strut and Upper Control Arm 21
32 Suspension Strut, Removing and Installing 22
33 Upper Control Arm, Removing and Installing 23
4 Lower Control Arm and Ball Joint26
41 Overview – Lower Control Arm and Ball Joint 26
42 Lower Control Arm, Removing and Installing 27
5 Wheel Bearing 30
51 Overview – Wheel Bearing30
52 Wheel Bearing Housing, Removing and Installing30
53 Wheel Bearing Unit, Removing and Installing 33
54 Wheel Bearing Unit, Servicing 33
6 Drive Axle36
61 Overview – Drive Axle 36
62 Drive Axle, Removing and Installing 37
Audi R8 2015 ➤
Suspension, Wheels, Steering – Edition 032017
Contents i
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63 Drive Axle Threaded Connection, Loosening and Tightening 39
64 Drive Axle, Disassembling and Assembling 40
7 Special Tools 47
42 – Rear Suspension51
1 Rear Axle51
11 Overview – Rear Axle 51
2 Stabilizer Bar 52
21 Overview – Stabilizer Bar52
22 Stabilizer Bar, Removing and Installing 53
23 Coupling Rod, Removing and Installing 54
3 Control Arm, Tie Rod 56
31 Overview – Transverse Link 56
32 Overview – Tie Rod57
33 Upper Transverse Link, Removing and Installing58
34 Lower Transverse Link, Removing and Installing58
35 Tie Rod, Removing and Installing60
4 Suspension Strut/Shock Absorber, Spring62
41 Overview – Suspension Strut, Shock Absorber and Spring 62
42 Suspension Strut, Removing and Installing 63
5 Wheel Bearing and Trailing Arm66
51 Overview – Wheel Bearing66
52 Wheel Bearing Housing, Removing and Installing67
53 Wheel Bearing Unit, Removing and Installing 69
54 Wheel Bearing Unit, Servicing 71
6 Drive Axle73
61 Overview – Drive Axle 73
62 Drive Axle Threaded Connection, Loosening and Tightening 74
63 Drive Axle, Removing and Installing 75
64 Drive Axle, Disassembling and Assembling 77
7 Special Tools 83
43 – Self-Leveling Suspension 87
1 Electronic Damping 87
11 Component Location Overview – Electronic Damping 87
12 Electronic Damping Control Module J250 , Removing and Installing 88
13 Standard Vehicle Height, Readapting 88
2 Level Control System Sensor 90
21 Overview – Front Level Control System Sensor 90
22 Overview – Rear Level Control System Sensor 91
23 Left/Right Front Level Control System Sensor G78 / G289 , Removing and Installing 92
24 Left/Right Rear Level Control System Sensor G76 / G77 , Removing and Installing 92
44 – Wheels, Tires, Wheel Alignment93
1 Wheels and Tires93
2 Tire Pressure Monitoring System94
21 Component Location Overview – Tire Pressure Monitoring System 94
22 Overview – Tire Pressure Monitoring Sensor 95
23 Tire Pressure Monitoring Control Module J502 , Removing and Installing 96
24 Tire Pressure Monitoring Antenna, Removing and Installing 97
25 Tires, Changing, Vehicles with Tire Pressure Monitoring System97
26 Metal Valve Body, Removing and Installing 98
3 Vehicle Alignment100
31 Axle Alignment Information 100
Audi R8 2015 ➤
Suspension, Wheels, Steering – Edition 032017
ii Contents
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32 Test Requirements100
33 Measurement Preparations 101
34 Axle Alignment Procedure102
35 Need for Axle Alignment, Evaluating 103
36 Production Control Number (PR Number) Explanations104
37 Wheel Run-Out Compensation 104
38 Curb Weight Position, Checking for Axle Alignment 104
39 Axle Alignment Specified Values105
310 Rear Axle Camber, Adjusting 106
311 Rear Axle Toe, Adjusting107
312 Front Axle Camber, Adjusting 108
313 Front Axle Toe, Adjusting109
314 Steering Angle Sensor G85 Basic Setting109
4 Dynamic Steering111
41 Active Steering Control Module J792 , Removing and Installing111
42 Dynamic Steering Basic Setting 112
5 Special Tools 115
48 – Steering117
1 Steering Wheel 117
11 Overview – Steering Wheel117
12 Steering Wheel, Removing and Installing118
2 Steering Column 120
21 Overview – Steering Column 120
22 Steering Column, Checking for Damage121
23 Steering Column, Handling and Transporting 121
24 Steering Column, Removing and Installing 123
25 Steering Intermediate Shaft, Removing and Installing 124
3 Steering Gear 127
31 Overview – Steering Gear127
32 Steering Gear, Removing and Installing 129
33 Boot, Removing and Installing 131
34 Tie Rod, Removing and Installing132
35 Tie Rod End, Removing and Installing 133
36 Steering Gear End Positions, Adapting 134
4 Special Tools 136
5 Revision History 138
00 – General, Technical Data1
1 Identification 1
11 PR Number Allocation – Brakes 1
2 Safety Precautions2
21 Safety Precautions when Working on Vehicles with Start/Stop System2
22 Safety Precautions during Road Test with Testing Equipment 2
3 Repair Information3
31 Guidelines for Clean Working Conditions3
32 General Repair Information 3
33 Contact Corrosion3
4 Technical Data 4
41 Technical Data, Brakes 4
5 Brake Inspection 6
51 General Information 6
52 AWD Vehicles, Checking6
53 Parking Brake, Checking6
54 Visual Characteristics of Ceramic Brake Rotors7
55 Surface Cracks in Cooling Duct Crosspieces 9
56 Cracks in Ceramic Brake Rotor Connection Area9
57 Chamfer 10
58 Nicks on Ceramic Brake Rotor 11
59 Crack in Cooling Channel11
510 Ceramic Brake Rotor, Determining Wear12
511 Ceramic Brake Rotor, Determining Wear using Carbon-Ceramic Brake Wear Tester
VAS681316
45 – Antilock Brake System 23
1 General Information 23
11 Anti-Lock Braking System (ABS) Repair Information 23
2 Component Location Overview 24
21 Component Location Overview – ABS/ESP 24
3 Control Module and Hydraulic Unit26
31 Overview – Control Module and Hydraulic Unit 26
32 ABS Control Module J104 / ABS Hydraulic Unit N55 , Removing and Installing27
4 Sensors 32
41 Overview – Front Axle Speed Sensor 32
42 Overview – Rear Axle Speed Sensor 33
43 Brake Lamp Switch, Removing and Installing 33
44 Sensor Electronics Control Module, Removing and Installing 35
45 Right and Left Front ABS Wheel Speed Sensor G45 / G47 , Removing and Installing 35
46 Right and Left Rear ABS Wheel Speed Sensor G44 / G46 , Removing and Installing 35
5 Special Tools 37
46 – Mechanical Components39
1 Front Brakes 39
11 Overview – Front Brakes 39
12 Brake Pads, Removing and Installing 43
13 Brake Caliper, Removing and Installing 53
14 Brake Caliper, Replacing59
15 Brake Rotor, Removing and Installing 66
16 Brake Shield, Removing and Installing 70
17 Brake Pad Wear Indicator Wire, Removing and Installing70
Audi R8 2015 ➤
Brake System – Edition 082017
Contents i
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2 Rear Brakes 73
21 Overview – Rear Brakes 73
22 Brake Pads, Removing and Installing 75
23 Brake Caliper, Removing and Installing 80
24 Brake Caliper, Replacing82
25 Brake Rotor, Removing and Installing 85
26 Brake Shield, Removing and Installing 88
27 Brake Pad Wear Indicator Wire, Removing and Installing88
3 Parking Brake 90
31 Component Location Overview – Parking Brake90
32 Overview – Parking Brake91
33 Overview – Brake Caliper92
34 Electromechanical Parking Brake Control Module J540 , Removing and Installing 93
35 Left and Right Parking Brake Motor V282 / V283 , Removing and Installing 94
36 Parking Brake, Manually Loosening 97
37 Brake Pads, Removing and Installing 97
38 Brake Caliper, Removing and Installing 100
39 Brake Caliper Piston, Removing and Installing 102
4 Brake Pedal 104
41 Overview – Brake Pedal 104
42 Brake Pedal Mounting Bracket, Removing and Installing106
43 Brake Pedal, Disconnecting from Brake Booster107
44 Brake Pedal, Attaching to Brake Booster108
45 Brake Pedal, Removing and Installing 108
5 Special Tools 110
47 – Hydraulic Components 112
1 Front Brake Caliper 112
11 Overview – Front Brake Caliper 112
12 Brake Caliper Piston, Removing and Installing 114
2 Rear Brake Caliper117
21 Overview – Rear Brake Caliper 117
22 Brake Caliper Piston, Removing and Installing 118
3 Brake Booster/Brake Master Cylinder 121
31 Overview – Brake Booster/Brake Master Cylinder121
32 Brake Booster, Removing and Installing123
33 Brake Master Cylinder, Removing and Installing127
34 Brake Fluid Reservoir, Removing and Installing129
35 Brake Fluid Level Warning Switch F34 , Removing and Installing131
4 Vacuum System 132
41 Overview – Electric Vacuum Pump132
42 Check Valve, Checking 133
43 Vacuum Line, Removing and Installing 133
44 Brake Booster Pressure Sensor, Removing and Installing 134
45 Electric Vacuum Pump, Removing and Installing134
5 Brake Lines 136
51 Brake Line Routing136
6 Hydraulic System137
61 Brake Fluid General Information137
62 Hydraulic System, Bleeding 139
63 Leak Test143
7 Special Tools 144
8 Revision History 147
00 – General, Technical Data1
1 Identification 1
11 Heater and A/C Unit Identification1
2 General Information 2
21 Type Labels 2
22 Odors in Vehicles with A/C System Information 3
23 Information for Operating Parking/Auxiliary Heater 4
24 Seat Heating 5
25 Rear Window Defogger 10
26 A/C System Control and Regulation Components outside Vehicle Interior 12
27 A/C System Control and Regulation Components in Vehicle Interior 14
3 Safety Precautions19
31 Safety Precautions when Handling Refrigerant 19
32 Safety Precautions when Working on Vehicles with Start/Stop System21
33 Safety Precautions during Road Test with Testing Equipment 21
34 Safety Precautions when Working on Cooling System 22
4 Repair Information23
41 Guidelines for Clean Working Conditions23
42 General Information 23
43 General Repair Information 24
44 Contact Corrosion24
45 Line Routing and Securing25
46 Radiator and Condenser Assembly 25
47 Heating Output, Checking26
48 Cooling Output, Checking33
49 Refrigerant Circuit, Discharging 47
410 Working on Refrigerant Circuit 48
411 Vehicles with A/C System, Painting 48
412 Refrigerant Circuit Seals49
413 Actuator Information 50
414 Dust and Pollen Filter Information53
5 Technical Data 54
51 Refrigerant Capacities 54
52 Approved Refrigerant Oils and Refrigerant Oil Capacities56
53 Oil Distribution 60
80 – Heating, Ventilation 61
1 Component Location Overview – Heater61
87 – Air Conditioning62
1 Component Location Overview – A/C System 62
11 Component Location Overview – Components Outside of Vehicle Interior 62
12 Component Location Overview – Components in Front Vehicle Interior69
2 Refrigerant Circuit78
21 System Overview – Refrigerant Circuit 78
22 Overview – Refrigerant Circuit 83
23 Connection Points of Refrigerant Lines, Detaching and Assembling 87
24 High Pressure Sensor G65 , Removing, Installing and Checking91
25 Expansion Valve, Removing and Installing 95
26 Refrigerant Lines on Condensers, Removing and Installing 99
27 Condensers, Removing and Installing 102
28 Receiver/Dryer with Dryer, Removing and Installing 106
Audi R8 2015 ➤
Heating, Ventilation and Air Conditioning – Edition 062016
Contents i
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with respect to the correctness of information in this document Copyright by AUDI AG
29 Refrigerant Line with Inner Heat Exchanger, Removing and Installing 109
210 Service Connection Differences, Depending on Refrigerant (R134a or R1234yf)112
211 Service Connections on Low and High Pressure Side, Removing and Installing115
212 A/C System, Starting after Charging Refrigerant Circuit118
3 A/C Compressor 121
31 A/C Compressor Input Shaft, Loosening and Tightening121
32 A/C Compressor, Removing and Installing on Bracket 122
33 Refrigerant Lines, Disconnecting and Connecting to A/C Compressor 123
34 A/C Compressor, Removing and Installing 130
35 A/C Compressor Drive Unit, Removing and Installing 135
36 A/C Compressor Input Shaft, Removing and Installing 141
4 Actuators144
41 Temperature Control Door Motor V68 , Removing and Installing144
42 Defroster Door Motor V107 , Removing and Installing 148
43 Center Vent Adjustment Motor V102 , Removing and Installing150
44 Footwell Door Motor V261 , Removing and Installing 153
45 Back Pressure Door Motor V71 , Removing and Installing 156
46 Fresh Air Door Motor V438 , Removing and Installing 159
5 Front Heater and A/C Unit163
51 Overview – Heater and A/C Unit with Air Intake Manifold163
52 Overview – Attachments for Heater and A/C Unit and Air Intake Manifold170
53 Overview – Evaporator Housing 172
54 Overview – Air Routing On and In Heater and A/C Unit 173
55 Evaporator, Removing and Installing 175
56 Evaporator, Cleaning 179
57 Evaporator Vent Temperature Sensor G263 , Removing and Installing188
58 Left Front Upper Body Vent Temperature Sensor G385 ( Right Front Upper Body Vent
Temperature Sensor G386 ), Removing and Installing 190
59 Heater and A/C Unit, Removing and Installing 191
510 Heater and A/C Unit, Disassembling and Assembling 197
511 Dust and Pollen Filter, Removing and Installing 197
512 Fresh Air Blower V2 (with Fresh Air Blower Control Module J126 ), Removing and
Installing 199
513 Fresh Air Blower Control Module J126 , Removing and Installing201
514 Footwell Vent Temperature Sensor G192 , Removing and Installing 202
515 Heater Core, Removing and Installing 203
516 Coolant Pipes to Heater Core, Removing and Installing210
517 Condensation Water Drain Hoses, Checking, Removing and Installing211
6 Air Routing219
61 Overview – Air Routing and Air Distribution in Vehicle Interior 219
62 Front Vents, Removing and Installing 221
63 Heating and A/C System Air Intake Manifold, Removing and Installing 227
64 Vehicle Interior Forced Air Extraction, Checking, Removing and Installing 229
65 Overview – Heating and A/C System Fresh Air Intake 231
66 Fresh Air Intake, Checking, Removing and Installing 234
67 Fresh Air Intake Housing Water Drain 235
7 Display Control Head 237
71 Overview – Front A/C Display Control Head E87237
72 Front A/C Display Control Head E87 , Removing and Installing242
8 Coolant Circuit 244
81 Incorporating the Heating and A/C System in the Coolant Circuit244
82 After-Run Coolant Pump V51 , Removing and Installing247
83 Coolant Shut-Off Valve N82 , Removing and Installing 247
84 Coolant Circuit, Bleeding247
9 Additional Components for Control and Regulation 251
Audi R8 2015 ➤
Heating, Ventilation and Air Conditioning – Edition 062016
ii Contents
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
91 Sunlight Photo Sensor G107 , Removing and Installing251
92 Outside Air Temperature Sensor G17 , Removing and Installing252
93 Air Quality Sensor G238 Function253
94 Air Quality Sensor G238 , Checking 255
95 Humidity Sensor In Fresh Air Intake Duct G657 Function262
96 Air Quality Sensor G238 / Humidity Sensor In Fresh Air Intake Duct G657 , Removing and
Installing 263
97 Humidity Sensor G355 , Removing and Installing265
10 Special Tools 266
11 Revision History 267
Audi R8 2015 ➤
Heating, Ventilation and Air Conditioning – Edition 062016
Contents
00 – General, Technical Data1
1 Repair Information1
11 General Repair Information 1
12 CAN Bus Wires Repair Information 1
91 – Communication2
1 Infotainment System 2
11 Overview – Infotainment System2
12 Overview – Infotainment System Components 4
13 Infotainment System Display, Removing and Installing 5
14 Information Electronics Control Module 1 J794 , Removing and Installing 5
15 Multimedia System Control Head E380 , Removing and Installing 6
16 Driver Volume Control E67 , Removing and Installing 7
2 Sound System 8
21 Overview – Sound System8
22 Overview – Sound System Components11
23 Control Module/Digital Sound System Amplifier, Removing and Installing 16
24 Left and Right Rear Treble Speaker R14 / R16 , Removing and Installing 19
25 Left/Right Front Treble Speaker R20 / R22 , Removing and Installing 19
26 Front Midrange Speaker, Removing and Installing 20
27 Rear Midrange Speaker, Removing and Installing20
28 Left/Right Front Bass Speaker R21 / R23 , Removing and Installing 21
29 Subwoofer R211 , Removing and Installing 21
210 Center Speaker R208 , Removing and Installing21
211 Center Speaker 2 R219 , Removing and Installing 22
212 Speaker 1 and 2 in Left/Right Front Headrest R317 / R318 / R319 / R320 22
3 Antenna Systems24
31 Overview – Antenna Systems 24
32 Overview – Antenna System Components25
33 Antenna Amplifier, Removing and Installing 28
34 GPS Antenna, Removing and Installing 31
35 Satellite Antenna R170 , Removing and Installing31
36 Traffic Data Antenna, Removing and Installing 33
37 Close Range Communication Antenna, Removing and Installing34
38 Bumper Antennas, Removing and Installing 34
39 LTE Antenna 2 R306 , Removing and Installing35
310 Antenna Wires AM/FM1/TV1, Removing and Installing 35
4 Radio 37
41 General Information 37
42 Radio, Removing and Installing 37
5 Telephone System38
51 Overview – Telephone 38
52 Overview – Telephone System Components 44
53 Overview – Microphone Unit 46
54 Microphone Unit in Front Roof Module R164 , Removing and Installing48
55 Seat Belt Microphone Control Module, Removing and Installing48
56 Cellular Telephone Amplifier R86 , Removing and Installing 49
57 Telephone Baseplate R126 , Removing and Installing 50
6 Navigation System52
61 General Information 52
62 Component Location Overview – Navigation System 52
63 Navigation System Control Module, Removing and Installing 55
Audi R8 2015 ➤ , Audi R8 Spyder 2016 ➤
Communication – Edition 112016
Contents i
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
64 Chip Card Reader Control Module, Removing and Installing 55
7 TV System56
71 Overview – TV System 56
72 Component Location Overview – TV System 57
73 TV Tuner, Removing and Installing 59
8 Rearview Camera System62
81 General Information 62
82 Overview – Rearview Camera System 62
83 Rearview Camera R189 , Removing and Installing 63
84 Rearview Camera System Control Module J772 , Removing and Installing 65
85 Rearview Camera System, Calibrating 66
9 Multifunction Steering Wheel 72
91 General Information 72
92 Overview – Multifunction Steering Wheel72
93 Guide Ring, Removing and Installing 74
94 Buttons E387 , E541 / E408 and E818 (Satellite Switch), Removing and Installing 76
95 Right/Left Multifunction Buttons on Steering Wheel E441 / E440 , Removing and Installing
77
96 Tiptronic Downshift Button E480 / Tiptronic Upshift Button E479 , Removing and installing
78
10 Connection for External Multimedia Devices 79
101 Overview – Connection for External Multimedia Devices79
102 External Audio Source Connection R199 , Removing and Installing 79
11 Special Tools 81
12 Revision History 83
Audi R8 2015 ➤ , Audi R8 Spyder 2016 ➤
Communication – Edition 112016
ii
27 – Starter, Generator and Cruise Control 1
1 Battery 1
11 General Information 1
12 Battery Types 1
13 Warnings and Safety Precautions3
14 Battery Post/Terminal 5
2 Battery, Checking6
21 Test Sequence 6
22 Visual Inspection8
23 Visual Indicator Color Display, Checking9
24 Battery Test with Vehicle Diagnostic Tester 11
25 Battery Tester VAS616112
26 Battery Tester with Printer VAS5097A 18
27 Current Draw Test23
28 Battery, Checking Resting Voltage, Vehicles in Storage or Inventory 24
3 Battery, Charging26
31 Battery Charger VAS5095A 26
32 Battery Charger VAS590032
33 Battery Charger VAS590343
34 Battery Charger VAS590654
35 Solar Battery Maintainer VAS6102A 57
36 Severely Discharged Batteries 58
4 Generator60
41 Generator, Checking 60
42 Overview – Generator, Bosch through MY 200061
43 Overview – Bosch Generator from 2001 62
44 Voltage Regulator, Bosch Generator from 2001, Removing and Installing 63
45 Overview – Bosch Generator from 2007 63
46 Voltage Regulator, Removing and Installing, Bosch Generator from 2007 64
47 Carbon Brushes, Checking, All Bosch Generators from 2001 65
48 Overview – Generator, Valeo through MY 2000 65
49 Overview – Valeo Generator from 2001 67
410 Voltage Regulator, Valeo Generator from 2001, Removing and Installing68
411 Carbon Brushes, Valeo Generator from 2001, Checking68
412 Voltage Regulator, Removing and Installing, Valeo Generator from 200769
413 Carbon Brushes, Checking, Valeo Generator from 200769
414 Ribbed Belt Pulley without Freewheel, Removing and Installing70
415 Ribbed Belt Pulley with Freewheel, Removing and Installing 71
416 Ribbed Belt Pulley with Freewheel, Checking 73
417 Overview – Hitachi Generator 73
418 Voltage Regulator, Removing and Installing – Hitachi Generator74
419 Carbon Brushes, Checking, Hitachi Generator 75
5 Special Tools 76
92 – Windshield Washer System 79
1 Washer Fluid Hoses 79
11 Washer Fluid Line Hose Connections, Disconnecting and Connecting 79
12 Smooth Hose Washer Fluid Line, Repairing 81
13 Corrugated Hose Washer Fluid Line, Repairing 81
2 Special Tools 83
94 – Exterior Lights, Lamps and Switches 84
Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au
Electrical Equipment General Information – Edition 072017
Contents i
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
1 HID Headlamp Usage and Safety Precautions 84
96 – Interior Lights, Lamps and Switches 86
1 Immobilizer86
11 General Information 86
12 Faulty Transponder or Lost Key 86
13 Induction coil, replacing 86
14 Lock Set, Replacement Procedure87
2 Trailer Hitch 88
21 Trailer Hitch Socket, Removing and Installing – Version 188
22 Trailer Hitch Socket, Removing and Installing – Version 289
23 Trailer Hitch Socket, Removing and Installing – Version 391
24 Trailer Hitch Socket, Removing and Installing – Version 492
97 – Wires 95
1 Vehicle Diagnosis, Testing and Information Systems 95
11 Vehicle Diagnostic Tester , Connecting 95
2 Wiring Harness and Connector Repairs 97
21 Vehicle Electrical System, General Repair Information 97
22 Wiring Harness Repair Set101
23 Tool Descriptions103
24 Wiring Harnesses, Repairing 108
25 Fiber-Optic Cables, Repairing 135
26 Antenna Wires, Repairing146
27 Connector Housings and Connectors, Repairing158
28 Connector Housings, Releasing and Disassembling 161
3 Contact Surface Cleaning Set VAS6410168
31 Contact Surface Cleaning Set VAS6410 , Using168
4 ESD Work Surface VAS6613 174
41 ESD Work Surface VAS6613 , Using 174
5 Special Tools 175
6 Revision History 178
Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au
Electrical Equipment General Information – Edition 072017
ii
00 – General, Technical Data1
1 Vehicle Data 1
11 Type Label / VIN 1
12 Vehicle Data Label1
2 Safety Precautions2
3 General Information 3
4 General Information 4
5 Contact Corrosion5
6 Body Construction6
61 Aluminum Structure 10
7 Repair Concept for Carbon Fiber-Reinforced Polymer (CFRP) Structural Repairs 16
71 Diagnostic Procedure up to Repair 16
8 Assessment Sheet for Carbon Fiber-Reinforced Polymer (CFRP) Structure with Accident
Damage 17
81 Mandatory Reporting before Repair 17
82 Damaged Area 17
9 Threaded Pins N 912 244 02, Servicing 26
10 What is Carbon Fiber-Reinforced Polymer (CFRP)? 27
101 Repairs in Carbon Fiber Reinforced Polymer (CFRP) Areas 27
102 Assembly27
103 The Designer Material FRP (Fiber Reinforced Plastic) 28
104 Information Carbon Fiber Reinforced Polymer (CFRP) Installing in Production Vehicles29
105 Occupational Safety 32
11 Body Repair Station Steel/Aluminum VAS667334
12 Molded Foam Part35
13 Flow Drill Bolt Connections, Servicing 36
131 Original Position36
132 Flow Drill Bolt Repair Set VAS6631 37
14 Materials for Joint Techniques 39
15 Body Construction40
16 Flattening41
17 Surface Treatment42
18 One Side Accessible Rivets 43
19 Contoured Surface44
20 Body Dimensions45
201 Body Front45
202 Body Rear46
203 Floor Assembly 47
21 Tools 49
22 Straightening Rack53
221 Body Structure Damage, Repairing, Audi AG Vehicles 53
50 – Body Front 54
1 Front Longitudinal Member, Replacing, Partial Section 54
11 Tools 54
12 Procedure54
2 Front Crossmember, Replacing 73
21 Tools 73
22 Procedure73
Audi R8 2015 ➤
Body Repairs – Edition 072017
Contents i
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document Copyright by AUDI AG
3 Luggage Compartment Floor, Replacing80
31 Tools 80
32 Procedure80
4 Side Luggage Compartment Panel, Replacing 90
41 Tools 90
42 Procedure90
5 Fender Longitudinal Member, Replacing98
51 Tools 98
52 Procedure98
6 Cowl Panel, Replacing 102
61 Tools 102
62 Procedure103
7 Special Tools 153
51 – Body Center, Chassis, Roof 154
1 Roof, Replacing 154
11 Tools 154
12 Procedure155
2 Front Roof Cross Member, Replacing 164
21 Tools 164
22 Procedure164
3 Door Frame, Replacing 168
31 Tools 168
32 Procedure169
4 B-Pillar, Replacing, CFRP Components 186
41 Tools 186
42 Procedure187
5 B-Pillar, Replacing, Spyder, CFRP Components228
51 Tools 228
52 Procedure229
6 Special Tools 269
53 – Body Rear 271
1 Rear Longitudinal Member, Replacing 271
11 Tools 271
12 Procedure272
2 Rear Longitudinal Member, Replacing, Spyder 285
3 Special Tools 294
4 Revision History 295
Audi R8 2015 ➤
Body Repairs – Edition 072017
ii
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