Service Installation instructions Audi A4/A5 (B8 series) 2008 Engine sound system For scope of delivery 8T0.071.901* Audi Genuine Accessories Service Department. Technical Information
Service Contents 1 General notes.............................................................................................. 1 2 Parts overview............................................................................................. 2.................................................................................. 3 3.1 Preparations................................................................................................. 3 3.2 Assembly overview of the electrical connection.......................................................... 4 3.3 Mounting the control unit connecting to the on-board supply........................................ 4 3.4 Assembly overview of the 4-cylinder TDI exhaust system............................................... 8 3.5 Assembling the exhaust system: 4-cylinder TDI.......................................................... 9 3.6 Assembly overview of the 6-cylinder TDI exhaust system............................................... 13 3.7 Assembling the exhaust system: 6-cylinder TDI.......................................................... 13 3.8 Final tasks................................................................................................... 16 All rights reserved. No reproduction without prior agreement from publisher. Copyright 2012 Audi AG, Ingolstadt Printed in Germany
1 General notes Please read and take note of these WARNING, Caution and Note descriptions before carrying out maintenance or repair work. WARNING Text with this symbol contains information concerning your safety and indicates potential accident and injury risks. Caution Text with this symbol indicates the risk of damage to your vehicle. Note Text with this symbol contains additional information. The pages that follow contain all of the information (subject to technical changes) needed for installation of the sound exhaust system. Installation of the sound exhaust system can only be performed by a qualified workshop. Special tools, test equipment and vehicle-specific literature will be needed to perform the installation. Incorrect installation can result in personal injury, damage to the vehicle or damage to other vehicles. Audi AG shall not accept responsibility in the event of failure to comply with these assembly instructions. 1 General notes 1
2 Parts overview The sound exhaust system can be retrofitted on both left and right-hand drive vehicles. Parts required: Assembly set 8T0.071.901 Comprising: Installation instructions - Audi A4/A5 (B8 series) 2008 Units Part number Description 1 8T0.071.905 Actuator, left 1 8T0.071.905.A Actuator, right 2 8T0.071.910 Adjustable trim panel, chrome black 6 Stainless steel pop rivet, 4 x 9.5 mm (V2A) 2 1K0.253.141.M Clamping sleeve 1 8T0.071.954 Wiring harness 1 8T0.071.953* Control unit 1 8T0.071.952 Control unit holder 1 8T0.071.956 Sound exhaust system dual nozzle 1 Installation instructions Check the parts to ensure they can be installed in the respective vehicle! You will also need the following for vehicles with 4-cylinder TDI engines: Assembly set 8T0.071.901.A Comprising: Units Part number Description 1 8K0.253.409.E Middle silencer, complete 1 8K0.253.144.F Mounting for middle silencer 2 N.903.484.11 Hexagon nut with washer 1 8K0.253.144.M Mounting for end silencer, right 1 1K0.253.141.M Clamping sleeve 1 N.903.484.11 Securing nut for end silencer, right 1 8F0.804.172 Heat shielding plate for Cabrio and Sportback 1 8K0 804 172 Heat shielding plate for other vehicles 4 N.907.965.02 Securing nuts for heat shielding plate 4-cylinder TDI engines require the diffuser for the dual exhaust system Electronic parts catalogue. 2 2 Parts overview
3.1 Preparations Disconnect the battery -A-. Remove the right and left luggage compartment trim Rep. gr. 70. Remove the sill panel(s) from the right side of the vehicle Rep. gr. 70. Remove the glove compartment Rep. gr. 68. If installed, remove the control unit for the digital sound package -J525- incl. holder Rep. gr. 91. Right-hand drive vehicles Remove the rear seat bench Rep. gr. 72. Remove the centre console Rep. gr. 68. Remove the dash panel cover on the driver side Rep. gr. 68. Installation instructions - Audi A4/A5 (B8 series) 2008 3
3.2 Assembly overview of the electrical connection 1 - Electrical connection CAN bus 2 - Retrofit wiring harness route for lefthand drive vehicles 3 - Retrofit wiring harness route for right-hand drive vehicles 4 - Electrical connection earth q 9 Nm 5 - Electrical connection power supply 6 - Electrical connection right sound activator 7 - Electrical connection left sound activator 8 - Control unit, sound AGA 9 - Nut q 9 Nm Installation instructions - Audi A4/A5 (B8 series) 2008 3.3 Mounting the control unit connecting to the on-board supply Centre the control unit holder on the insulation matting and mark the drill points -1-. Punch mark the drill points. Drill the holes using a 3.0 mm drill bit (angle drill, cordless screwdriver). Make sure that the clearance to wires and the vehicle body is sufficient. Caution Do not drill into any wires! For reasons associated with corrosion protection, use a vacuum to continually collect the drilling chips while drilling. Corrosion damage due to drilling chips is not covered by the vehicle's warranty. 4
Drill out the holes to 5.0 mm. Deburr the holes thoroughly. Carefully remove all chips from drilling, e.g. using a workshop vacuum cleaner. In order to provide adequate protection against corrosion, apply the following products with a brush. Single-component primer filler/surfacer LGF.008.001.42/A3 Two-component vario filler/surfacer, grey LGF.786.004.A3 Audi paint to match the vehicle's colour Body cavity preserving agent D.330.KD2.A1 Position and rivet the control unit holder on the insulation matting. Insert the control unit on the retrofit wiring harness, making sure it engages. Screw the control unit to the holder. Lay the retrofit wiring harness along the standard wiring harness to the relay and fuse carrier F -SF-. If the appropriate equipment is in place, use the cable ties with clip provided to secure the retrofit wiring harness to the rear panel. Lay the connector for the actuators to the corresponding wire grommets -arrow-. Note The clearance for the actuators is created by mounting the actuators Assembling the exhaust system: 4-cylinder TDI on page 9 and/or Assembling the exhaust system: 6-cylinder TDI on page 13. 5
Loosen the fuse carrier F -SF- and unclip the fuse carrier - E-. Unpin the lilac/white wire and pin it into the connector housing 1J0.972.751 provided. Pin the open wire end lilac/white into the vacated slot in relay carrier -E-. Connect the two free connectors, making sure they engage. Up to and including model year 2011: Unclip fuse carrier ST4. Unpin the wire from the fused outgoing circuit in chamber 3 Pin the purple/white wire from the AGA wiring harness into the vacated chamber Pin the unpinned wire from the vehicle wiring harness into the connector housing provided (1J0.972.751). Pin the unpinned wire from the vehicle wiring harness into the connector housing provided (1J0.972.751) and connect to the connector (1J0.972.762) from the AGA wiring harness. Check for secure engagement. If there is no fuse in slot 3: Pin the purple/white wire from the AGA wiring harness into the empty slot for fuse 3 (fuse carrier ST4). Insert fuse 15A (N.017.131.12) into slot 3. Screw the earth wire onto the earth point on the right-hand side of the luggage compartment. 6
Left-hand drive vehicles Lay the retrofit wiring harness on the standard wiring harness along the right sill and glove compartment to the data bus diagnostic interface -J533- -A-. Right-hand drive vehicles Lay the retrofit wiring harness on the standard wiring harness along the rear bench seat and centre console to the data bus diagnostic interface -J533- -A-. All vehicles Disconnect the connector -A2-. Open the plug. Unpin the orange/brown wire (slot 6) and pin into slot 2 with the connector provided 4B0.972.623. Pin the orange/brown wire of the retrofit wiring harness into the vacated slot. Unpin the orange/black wire (slot 16) and pin into slot 1 with the connector provided 4B0.972.623. Pin the orange/black wire of the retrofit wiring harness into the vacated slot. Connect the two free connectors, making sure they engage. Secure the retrofit wiring harness to protect against noise and abrasion. Note The assembly should be carried out after the assembled exhaust system is sound-tested. The control unit must not be coded. 7
3.4 Assembly overview of the 4-cylinder TDI exhaust system 1 - Mounting 2 - Clamping sleeve q Install so that it is free from tension before tightening the exhaust system Rep. gr. 26 3 - Nut q 23 Nm 4 - Screw q replace q 20 Nm 5 - Nut q replace q 20 Nm 6 - Mounting 7 - Actuator 8 - Exhaust tip q 2x q position according to the body version concerned 9 - Pop rivet q 6x 10 - Nut 11 - Shield q select according to the body version concerned Parts overview on page 2 q retrofit on the right side of the vehicle 12 - Actuator 13 - Silencer q replace Installation instructions - Audi A4/A5 (B8 series) 2008 8
3.5 Assembling the exhaust system: 4-cylinder TDI Detach the pipe clip -1-, and support the flex pipe -2-; secure if necessary. Caution Risk of damage to the decoupler. Do not bend the decoupler more than 10 Do not place any strain on the decoupler Do not damage the wire mesh on the decoupler Unscrew the exhaust pipe holder and remove the rear part of the exhaust system. Dispose of pipe clip -1-. Removing the Cw trim -3-: Unscrew nuts -1-, remove clip -2- and remove and discard the Cw trim -3-. Installation instructions - Audi A4/A5 (B8 series) 2008 Removing the shield plate -2-: Unscrew nuts -1- and remove shield plate -2- from the left side of the vehicle -2-. Remove and discard the grommets -arrow- on the left and right side of the vehicle. Guide the advanced wires of the retrofit wiring harness from the vehicle interior through the holes and insert wire grommets. 9
Select the right shield plate from the assembly set to match the vehicle type Page 2. Assemble the shield plate on the left and right (from the assembly set), paying attention to the position of the wires below and the edge of the shield plates -arrow-. Remove the diffuser and install the dual diffuser Rep. gr. 63. On the Audi A5 Coupé and Audi A5 Cabrio only Special tools and workshop equipment required Chain pipe cutter -VAS 6254- Shortening the middle silencer at right angles using the chain pipe cutter -VAS 6254-: X - 60 mm Continue for all vehicles Position the mountings -1- on the middle silencer - 2x Fit the new clamping sleeve such that the screw ends do not protrude over the bottom edge of the clamping sleeve. The screwed connection points to the left, viewed in the direction of travel. Place the middle silencer in the installation position and screw the mountings to the vehicle. Continue to support the middle silencer 10
Assembling the exhaust tips Select the punch point to match the body version and drill a 4.0-mm hole. A - Coupé/Cabrio B - Saloon/Avant and Sportback vehicles from model year 2012 C - Sportback vehicles from model years up to and including 2011 Note the installation position of the actuators and insert and rivet the exhaust tips Fig. Aligning the exhaust tips on page 12 Assembling the actuators Position the mountings onto the actuators. Place the actuators in the installation position, attach the connectors, position and tighten the mountings -1-. Position the clamping sleeves -2- central to the separating cut. Installation position: screw fittings forward. Before tightening the clamping sleeves -2-, install the exhaust system so that it is free from tension Rep. gr. 26 and Fig. on page 12. 11
Aligning the exhaust tips Dimension -x- left = dimension -x- right Rotate the clamping sleeves so that the screw ends do not protrude over the bottom edge of the clamping sleeve. Tightening torques Page 8 12
3.6 Assembly overview of the 6-cylinder TDI exhaust system 1 - Y-pipe q remains in the vehicle 2 - Nut q 23 Nm 3 - Clamping sleeve q Install so that it is free from tension before tightening the exhaust system Rep. gr. 26 4 - Actuator 5 - Exhaust tip q 2x q position according to the body version concerned 6 - Pop rivet q 6 x 7 - Nut q replace q 20 Nm 8 - Mounting 9 - Actuator 10 - Sound exhaust system dual nozzle Installation instructions - Audi A4/A5 (B8 series) 2008 3.7 Assembling the exhaust system: 6-cylinder TDI Special tools and workshop equipment required Chain pipe cutter -VAS 6254-13
Separate the exhaust pipe at right-angles at the cut-off points at the middle punch point -arrows- using the chain pipe cutter -VAS 6254-. Loosen the front clamping sleeve -1- and lower the Y pipe -3-. Position the dual nozzle -2- on the Y pipe -3-. Position the plastic or wooden part -1- on the dual nozzle -2-. Hammer the dual nozzle -2- into the Y pipe -3- using the soft-head hammer. The dual nozzle is now in the installation position. Install the Y pipe. Removing shield plates -2-: Unscrew nuts -1- and remove the shield plates -2- from the left and right side of the vehicle -2-. 14
Remove and discard the grommets -arrow- on the left and right side of the vehicle. Guide the advanced wires of the retrofit wiring harness from the vehicle interior through the holes and insert wire grommets. Assemble the shield plate, at the same time being aware of the position of the wires below and at the edge of the shield plates -arrow-. Assembling the exhaust tips Select the punch point to match the body version and drill a 4.0-mm hole. A - Coupé/Cabrio B - Saloon/Avant and Sportback vehicles from model year 2012 C - Sportback vehicles from model years up to and including 2011 Note the installation position of the actuators and insert and rivet the exhaust tips Fig. Aligning the exhaust tips on page 16 Assembling the actuators Position the mountings onto the actuators. 15
Place the actuators in the installation position, attach the connectors, position and tighten the mountings -1-. Position the clamping sleeves -2- central to the separating cut. Installation position: screw fittings forward. Before tightening the clamping sleeves -2-, set the exhaust system so there is no tension Rep. gr. 26 and Fig. Aligning the exhaust tips on page 16 Aligning the exhaust tips Dimension -x- left = dimension -x- right Rotate the clamping sleeves so that the screw ends do not protrude over the bottom edge of the clamping sleeve. Tightening torques Page 13 3.8 Final tasks Connect the battery -A- Rep. gr. 27. Carry out a functional check. 16
Secure the retrofit wiring harness using the cable ties provided, to prevent noise and abrasion. Re-install all removed parts. Where necessary, paint the inside of the exhaust tips with matt black paint. Note The genuine AUDI replacement exhaust system holds ECE type approval (E24 031446). It is therefore not necessary to carry any additional documents with the system, or enter information in the vehicle registration certificate. 17