2009 Audi R8 Download Service & Repair Manual

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. Repair Manual R8 2008 ➤ Generic Scan Tool Engine ID BYH Edition 08.2015 Service Service Department. Technical Information

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. List of Workshop Manual Repair Groups Repair Group ST - Generic Scan Tool Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. Service All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2016 Audi AG, Ingolstadt D3E800A7B27

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. Contents ST - Generic Scan Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.3 High Voltage System General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.1 On Board Diagnostic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.2 Evaporative Emission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.3 Electronic Throttle Control (ETC) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.4 Electronic Power Control (EPC) Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.5 Engine Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.6 Malfunction Indicator Lamp (MIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.7 Controller Area Network (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.8 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.9 Ignition and Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.10 Variable Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.11 Exhaust-Gas Recirculation (EGR) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.12 Secondary Air Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.13 Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.14 SCR NOx Catalyst System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3.1 Preliminary Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3.2 Readiness Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3.3 Diagnostic Modes 01 - 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3.4 Engine DTC Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 3.5 Transmission DTC Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 3.6 Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 R8 2008 ➤ Generic Scan Tool - Edition 08.2015 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. R8 2008 ➤ Generic Scan Tool - Edition 08.2015 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. ST – Generic Scan Tool 1 General Information (Edition 08.2015) Included in the contents of this Generic Scan Tool (GST) manual is a summary table of the vehicle specific OBD II Emission Rela‐ ted DTCs. The DTC table contains DTC Malfunction Criteria, Threshold Values, Secondary Parameters, Enabling Conditions, Monitoring Time Length, Frequency of Checks, and MIL Illumi‐ nation information which can be used to accurately monitor and diagnose emissions related faults and perform functions required to run Modes 01 through 09 with a hand held scan tool. For a further description of specific monitor information, an OBD strat‐ egy document is referenced throughout this manual. This manual also contains the step by step procedures to accu‐ rately diagnose and repair a component or system once a DTC has been set. References to repair procedures and wiring dia‐ grams can be found within the diagnostic test procedures. ♦ ⇒ “1.1 Safety Precautions”, page 2 ♦ ⇒ “1.2 Clean Working Conditions”, page 3 ♦ ⇒ “1.3 High Voltage System General Warnings”, page 4 R8 2008 ➤ Generic Scan Tool - Edition 08.2015 1. General Information 1

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. 1.1 Safety Precautions Check for Technical Bulletins that may supersede any information included in this manual. WARNING Failure to follow these instructions may result in personal injury or possible death. Check the Technical Bulletins for information, cautions and warnings that may supersede or supplement any information included in this manual. When performing the drive cycle operation, pay strict attention to driving conditions and observe and obey all posted speed limits. Test equipment must always be secured to the rear seat and operated by a second person. If test and measuring equipment is operated from the passenger seat, the person seated could be injured in the event of an accident involving deployment of the passenger-side airbag. The fuel system is under pressure! Before opening the fuel system, place rags around the connection area. Then release pressure by carefully loosening the connection. The engine section of the fuel system, after the high pressure pump, is under extremely high pressure! When working on en‐ gine or fuel injection system, fuel pressure must be relieved to residual pressure before opening high pressure components. Refer to the Service Manual for the proper procedure. If the battery has not been disconnected, the fuel pump fuse must be removed before opening the fuel supply system as the fuel pump may be activated by the driver's door contact switch. Testing of the EVAP and ORVR systems can result in the es‐ cape of explosive fuel vapor. Do not smoke while testing the EVAP system, and make sure the area you are working in is well ventilated. Observe the following for all procedures, especially in the en‐ gine compartment due to lack of room: ♦ Route lines of all types (e.g. for fuel, hydraulic, EVAP can‐ ister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed. ♦ Watch for sufficient clearance to all moving or hot com‐ ponents. ♦ Do not touch or disconnect the Ignition Coils, ignition wires, connecting parts or adapter cables when the igni‐ tion is on or the engine is running or turning at starting RPM. ♦ Only disconnect and reconnect wires for injection and ig‐ nition system, including test leads, when the ignition is turned off. When removing and installing components from full or partially full fuel tanks, observe the following: ♦ The fuel tank must only be partially full. How much fuel can remain in the fuel tank may be read in the respective work description. Empty the fuel tank if necessary. R8 2008 ➤ Generic Scan Tool - Edition 08.2015 2 Rep. Gr.ST - Generic Scan Tool

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. ♦ Before starting work, switch on the exhaust extraction sys‐ tem and place an extraction hose close to the installation opening of the fuel tank to extract escaping fuel fumes. If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m 3 /h can be used. ♦ Prevent fuel from contacting the skin. Wear fuel-resistant gloves! When servicing the engine control module (ECM), it may be necessary to use a heat gun. The heat gun, shear bolts, and parts of the protective housing will become extremely hot. Use extreme caution when working with or handling these parts to avoid personal injury. Observe operating instructions when working with a heat gun. To prevent damage (burning) to the wiring and harness con‐ nections, insulation and the electronic components, perform outlined work steps exactly! The cooling system is under pressure. To avoid scalding, use caution when opening the cooling system and servicing cooling system components! Caution The battery must only be disconnected and connected with the ignition switched off. Otherwise, the engine control module (ECM) can be damaged. The use of nails, paper clips, or another unauthorized materials to back-probe electrical harness connectors is strictly prohibi‐ ted and may cause damage to the electrical harness connec‐ tors, terminal ends or to a component. Use only the manufacturers test lead kit or an equivalent aftermarket test lead kit for back-probing all electrical harness connectors. Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the engine and will damage the oxygen sensors. Secure all hose connections with the correct hose clips (the same as original equipment). If engine is to be cranked without starting, for example as part of a compression test, remove the fuses for the voltage supply of Ignition Coils and the fuel injector. An electrostatic charge can lead to functional problems of elec‐ trical components of the engine, transmission and selector lever mechanism. Touch a grounded object, e.g. a water pipe or a hoist, before working on electrical components. Do not make direct contact with electrical harness connector terminals. Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals. 1.2 Clean Working Conditions Even minor contaminations can lead to malfunctions in the fuel injection system. When working on the fuel supply/injection sys‐ tem, pay careful attention to the following rules of cleanliness: ♦ Thoroughly clean all connections and the surrounding area before disconnecting. R8 2008 ➤ Generic Scan Tool - Edition 08.2015 1. General Information 3

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. ♦ Place removed parts on a clean surface and cover. Use lint- free cloths. ♦ Carefully cover opened components or seal, if repairs are not performed immediately. ♦ When the system is open, do not work with compressed air. Do not move vehicle unless absolutely necessary. ♦ Install clean components: Remove the parts being replaced immediately prior to installation of the new parts. Do not use parts that have been stored unpacked (e.g. in tool boxes etc.). ♦ Electrical connectors that have been disconnected: Protect from dirt and moisture. Make sure connections are clean and dry when reconnecting. 1.3 High Voltage System General Warnings Before performing any work on the high voltage system, always check with the importer if there are any questions regarding the terms “technician trained in electrical systems”, “high voltage technician”, “high voltage expert”, “high voltage systems”, or “hy‐ brid systems”. Qualifications necessary for most of these terms are also provided below ⇒ page 9 . Before beginning work on the high voltage system, a high voltage technician ⇒ page 9 , must de-energize the high voltage sys‐ tem. Refer to appropriate repair manual for high voltage system de-energizing. For a list of work procedures requiring the high voltage system to be de-energized, refer to the tables listed below in: Working on the High Voltage System, Conventional Work Near High Voltage Components, and General Work ⇒ page 6 . R8 2008 ➤ Generic Scan Tool - Edition 08.2015 4 Rep. Gr.ST - Generic Scan Tool

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. WARNING Read and follow the information below when de-energizing the high voltage system to reduce the risk of fatal injury. ♦ Only a qualified technician (high voltage technician) should disable the high voltage system. ♦ The high voltage technician (HVT) makes sure the system is de-energized and cannot be re-energized again. ♦ The high voltage technician assures that the system can‐ not be re-energized again by safely storing the key, the High Voltage System Maintenance Connector - TW- and the pilot line connector. ♦ The high voltage technician (HVT) puts a sign on the ve‐ hicle saying the voltage is disabled. ♦ Only hybrid electrically instructed persons may perform all work (maintenance, tire changing, Convenience System) on vehicles with a high voltage system. If there is any un‐ certainty, discuss with the responsible high voltage tech‐ nician. ♦ A high voltage technician must disable the system before any work can be performed on the high voltage electrical system or any other service work to the body. ♦ Only a high voltage expert (HVE) may perform repairs to the vehicle if it is not possible to disable the high voltage electrical system. ♦ Individuals with electrical medical equipment must not work on vehicles with a high voltage electrical system. Ex‐ amples of electrical medical equipment include pain med‐ ication pumps, implanted heart defibrillators, pacemakers, insulin pumps and hearing aids. WARNING Working with high voltage cables: ♦ Do not support yourself or lay tools on the high voltage cables or on any of its components. ♦ When working near high voltage components and high voltage cables, do not use tools that generate heat, that have sharp edges or that are used for cutting or shaping, such as welding, soldering, hot air or thermal adhesive equipment. ♦ When working near high voltage components and high voltage cables, do not use tools that generate heat such as welding, soldering, hot air or thermal adhesive equip‐ ment. ♦ Do not excessively bend or flex high voltage cables. ♦ Always contact a high voltage technician (HVT) if there are questions or if something is not clearly understood. Check the contact surfaces on the potential equalization cables before installation. The contact surfaces must be clean. There must be no rust or grease on them. Follow all guidelines for clean working conditions. R8 2008 ➤ Generic Scan Tool - Edition 08.2015 1. General Information 5

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. Observe the following precautions when working on the high volt‐ age system: ♦ Only technicians who are trained in electrical systems should work on high voltage system (hybrid) vehicles. ♦ When working on a hybrid vehicle, always inspect the hybrid components in the area where the work is being performed. ♦ Do not excessively bend or flex high voltage cables. ♦ Always contact a high voltage technician or a high voltage ex‐ pert specializing in electrical systems if something is not un‐ derstood or if there are questions. ♦ All the work described below is referencing removing, instal‐ ling and replacing the individual components. Working on the High Voltage System During the Following Work Minimum Qualifications, refer to ⇒ page 9 De-energizing the high volt‐ age system High voltage technician Re-energizing the high volt‐ age system High voltage technician When Working on the Following Compo‐ nents The High Voltage System Must Be De-energized By A High Voltage Technician Prior To Beginning the Work? Minimum Qualifications, refer to ⇒ page 9 Yes No Electro-Drive Drive Motor - V141- X Technician trained in electrical systems Electric Drive Power and Control Electron‐ ics - JX1- X Technician trained in electrical systems High Voltage System Maintenance Con‐ nector - TW- X Technician trained in electrical systems Electric A/C Compressor High Voltage Ca‐ ble - P3- X Technician trained in electrical systems Drive Motor High Voltage Wiring Harness - PX2- X Technician trained in electrical systems High Voltage Wiring Harness For High Volt‐ age Battery - PX1- X Technician trained in electrical systems Hybrid Battery Unit - AX1- , Removing and Installing X Technician trained in electrical systems Charging the Hybrid-Battery - A38- with High Voltage Battery Charger - VAS6565- X High voltage technician Battery Regulation Control Module - J840- X High voltage technician Battery Fan 1 - V457- X Technician trained in electrical systems Air guides next to the Hybrid Battery Unit - AX1- X Technician trained in electrical systems Air guides under the Hybrid Battery Unit - AX1- X Technician trained in electrical systems Electrical A/C Compressor - V470- X Technician trained in electrical systems Drive Motor Temperature Sensor - G712- X Technician trained in electrical systems Drive Motor Rotor Position Sensor 1 - G713- X Technician trained in electrical systems R8 2008 ➤ Generic Scan Tool - Edition 08.2015 6 Rep. Gr.ST - Generic Scan Tool

2009 Audi R8 Download Service & Repair Manual

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