4914.pdf

Installation instructionsAudi A4/A5 (B8 series) 2008 Engine sound systemFor scope of delivery 8T0.071.901*Audi Genuine Accessories

Edition 11/2012

Service

Service Department. Technical Information

Contents

1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Parts overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Sequence of operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 Assembly overview of the electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.3 Mounting the control unit connecting to the on-board supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.4 Assembly overview of the 4-cylinder TDI exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.5 Assembling the exhaust system: 4-cylinder TDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.6 Assembly overview of the 6-cylinder TDI exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.7 Assembling the exhaust system: 6-cylinder TDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.8 Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Service

All rights reserved.No reproduction without prior agreement from publisher.

Copyright 2012 Audi AG, Ingolstadt Printed in Germany

1 General notesPlease read and take note of these WARNING, Caution andNote descriptions before carrying out maintenance or repairwork.

WARNING

Text with this symbol contains information concerningyour safety and indicates potential accident and injuryrisks.

Caution

Text with this symbol indicates the risk of damage to yourvehicle.

Note

Text with this symbol contains additional information.

The pages that follow contain all of the information (subjectto technical changes) needed for installation of the soundexhaust system.

Installation of the sound exhaust system can only be per-formed by a qualified workshop. Special tools, test equip-ment and vehicle-specific literature will be needed to per-form the installation. Incorrect installation can result in per-sonal injury, damage to the vehicle or damage to other ve-hicles.

Audi AG shall not accept responsibility in the event of fail-ure to comply with these assembly instructions.

Installation instructions - Audi A4/A5 (B8 series) 2008 Edition 11/2012

1 General notes 1

2 Parts overviewThe sound exhaust system can be retrofitted on both leftand right-hand drive vehicles.

Parts required:

Assembly set 8T0.071.901

Comprising:

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 re-spective vehicle!

You will also need the following for vehicles with 4-cylinderTDI 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 ex-haust system Electronic parts catalogue.


2 2 Parts overview

3 Sequence of operations

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.


3 Sequence of operations 3

3.2 Assembly overview of the electrical connection

1-Electrical connection CAN bus

2-Retrofit wiring har-ness route for left-hand drive vehicles

3-Retrofit wiring har-ness route forright-hand drive vehi-cles

4-Electrical connection earthq 9 Nm

5-Electrical connection power supply

6-Electrical connection right sound activa-tor

7-Electrical connection left sound activa-tor

8-Control unit, soundAGA

9-Nutq 9 Nm

3.3 Mounting the control unit connectingto the on-board supply

Centre the control unit holder on the insulation matting andmark the drill points -1-.

Punch mark the drill points.

Drill the holes using a 3.0 mm drill bit (angle drill, cordlessscrewdriver). Make sure that the clearance to wires and thevehicle body is sufficient.

Caution

Do not drill into any wires!

For reasons associated with corrosion protection, use avacuum to continually collect the drilling chips while drill-ing. Corrosion damage due to drilling chips is not coveredby the vehicle's warranty.


4 3 Sequence of operations

Drill out the holes to 5.0 mm.

Deburr the holes thoroughly.

Carefully remove all chips from drilling, e.g. using a work-shop 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, makingsure it engages.

Screw the control unit to the holder.

Lay the retrofit wiring harness along the standard wiring har-ness to the relay and fuse carrier F -SF-. If the appropriateequipment is in place, use the cable ties with clip provided tosecure the retrofit wiring harness to the rear panel.

Lay the connector for the actuators to the correspondingwire grommets -arrow- .

Note

The clearance for the actuators is created by mounting the ac-tuators Assembling the exhaust system: 4-cylinder TDI onpage 9 and/or Assembling the exhaust system: 6-cylinderTDI on page 13.



Loosen the fuse carrier F -SF- and unclip the fuse carrier -E-.

Unpin the lilac/white wire and pin it into the connector hous-ing 1J0.972.751 provided.

Pin the open wire end lilac/white into the vacated slot in re-lay 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 intothe vacated chamber

Pin the unpinned wire from the vehicle wiring harness intothe connector housing provided (1J0.972.751).

Pin the unpinned wire from the vehicle wiring harness intothe connector housing provided (1J0.972.751) and connectto the connector (1J0.972.762) from the AGA wiring har-ness.

Check for secure engagement.

If there is no fuse in slot 3:

Pin the purple/white wire from the AGA wiring harness intothe 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-handside of the luggage compartment.



Left-hand drive vehicles Lay the retrofit wiring harness on the standard wiring har-

ness along the right sill and glove compartment to the databus diagnostic interface -J533- -A-.

Right-hand drive vehicles Lay the retrofit wiring harness on the standard wiring har-

ness along the rear bench seat and centre console to thedata 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 withthe connector provided 4B0.972.623.

Pin the orange/brown wire of the retrofit wiring harness intothe vacated slot.

Unpin the orange/black wire (slot 16) and pin into slot 1 withthe connector provided 4B0.972.623.

Pin the orange/black wire of the retrofit wiring harness intothe vacated slot.

Connect the two free connectors, making sure they engage.

Secure the retrofit wiring harness to protect against noiseand abrasion.

Note

The assembly should be carried out after the assembled ex-haust system is sound-tested.

The control unit must not be coded.



3.4 Assembly overview of the 4-cylinder TDI exhaust system

1-Mounting2-Clamping sleeveq Install so that it is

free from tensionbefore tighteningthe exhaust systemRep. gr. 26

3-Nutq 23 Nm

4-Screwq replaceq 20 Nm

5-Nutq replaceq 20 Nm

6-Mounting7-Actuator8-Exhaust tipq 2xq position according

to the body versionconcerned

9-Pop rivetq 6x

10-Nut11-Shieldq select according to

the body versionconcernedPartsoverview on page 2

q retrofit on the right side of the vehicle

12-Actuator13-Silencerq replace



3.5 Assembling the exhaust system: 4-cyl-inder TDI

Detach the pipe clip -1-, and support the flex pipe -2-; secureif 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 discardthe Cw trim -3-.

Removing the shield plate -2-:

Unscrew nuts -1- and remove shield plate -2- from the leftside of the vehicle -2-.

Remove and discard the grommets -arrow- on the left andright side of the vehicle.

Guide the advanced wires of the retrofit wiring harness fromthe vehicle interior through the holes and insert wire grom-mets.



Select the right shield plate from the assembly set to matchthe vehicle type Page 2.

Assemble the shield plate on the left and right (from the as-sembly set), paying attention to the position of the wires be-low and the edge of the shield plates -arrow-.

Remove the diffuser and install the dual diffuser Rep. gr.63.

On the Audi A5 Coup and Audi A5 Cabrio only

Special tools and workshop equipment required Chain pipe cutter -VAS 6254-

Shortening the middle silencer at right angles using thechain 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 notprotrude over the bottom edge of the clamping sleeve.

The screwed connection points to the left, viewed in the di-rection of travel.

Place the middle silencer in the installation position andscrew the mountings to the vehicle. Continue to support themiddle silencer



Assembling the exhaust tips Select the punch point to match the body version and drill a 4.0-mm hole.

A-Coup/Cabrio

B-Saloon/Avant and Sportback vehicles from model year 2012

C-Sportback vehicles from model years up to and including2011

Note the installation position of the actuators and insert andrivet the exhaust tips Fig. Aligning the exhaust tips onpage 12

Assembling the actuators Position the mountings onto the actuators.

Place the actuators in the installation position, attach theconnectors, position and tighten the mountings -1-.

Position the clamping sleeves -2- central to the separatingcut.

Installation position: screw fittings forward.

Before tightening the clamping sleeves -2-, install the ex-haust system so that it is free from tension Rep. gr. 26 andFig. on page 12.



Aligning the exhaust tips

Dimension -x- left = dimension -x- right

Rotate the clamping sleeves so that the screw ends do notprotrude over the bottom edge of the clamping sleeve.

Tightening torques Page 8



3.6 Assembly overview of the 6-cylinder TDI exhaust system

1-Y-pipeq remains in the vehi-

cle2-Nutq 23 Nm

3-Clamping sleeveq Install so that it is

free from tensionbefore tighteningthe exhaust systemRep. gr. 26

4-Actuator5-Exhaust tipq 2xq position according

to the body versionconcerned

6-Pop rivetq 6 x

7-Nutq replaceq 20 Nm

8-Mounting9-Actuator10-Sound exhaust sys-

tem dual nozzle

3.7 Assembling the exhaust system: 6-cyl-inder TDI

Special tools and workshop equipment required Chain pipe cutter -VAS 6254-



Separate the exhaust pipe at right-angles at the cut-offpoints at the middle punch point -arrows- using the chainpipe 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 thesoft-head hammer. The dual nozzle is now in the installationposition.

Install the Y pipe.

Removing shield plates -2-:

Unscrew nuts -1- and remove the shield plates -2- from theleft and right side of the vehicle -2-.



Remove and discard the grommets -arrow- on the left andright side of the vehicle.

Guide the advanced wires of the retrofit wiring harness fromthe vehicle interior through the holes and insert wire grom-mets.

Assemble the shield plate, at the same time being aware ofthe position of the wires below and at the edge of the shieldplates -arrow-.

Assembling the exhaust tips Select the punch point to match the body version and drill a 4.0-mm hole.

A-Coup/Cabrio

B-Saloon/Avant and Sportback vehicles from model year 2012

C-Sportback vehicles from model years up to and including2011

Note the installation position of the actuators and insert andrivet the exhaust tips Fig. Aligning the exhaust tips onpage 16

Assembling the actuators Position the mountings onto the actuators.



Place the actuators in the installation position, attach theconnectors, position and tighten the mountings -1-.

Position the clamping sleeves -2- central to the separatingcut.

Installation position: screw fittings forward.

Before tightening the clamping sleeves -2-, set the exhaustsystem so there is no tension Rep. gr. 26 andFig. 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 notprotrude 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.



Secure the retrofit wiring harness using the cable ties provi-ded, to prevent noise and abrasion.

Re-install all removed parts.

Where necessary, paint the inside of the exhaust tips withmatt black paint.

Note

The genuine AUDI replacement exhaust system holds ECEtype approval (E24 031446). It is therefore not necessary to car-ry any additional documents with the system, or enter informa-tion in the vehicle registration certificate.



Contents1 General notes2 Parts overview3 Sequence of operations3.1 Preparations3.2 Assembly overview of the electrical connection3.3 Mounting the control unit connecting to the on-board supply3.4 Assembly overview of the 4-cylinder TDI exhaust system3.5 Assembling the exhaust system: 4-cylinder TDI3.6 Assembly overview of the 6-cylinder TDI exhaust system3.7 Assembling the exhaust system: 6-cylinder TDI3.8 Final tasks

4914.pdf

Documents

assembly set 8t0

cylinder tdi exhaust

right2 8t0

left1 8t0

assembly instructions

assembly overview

control unit1 8t0

number description1