Audi 8T8.071.126.A Install guide

Service 6
Service Department. Technical Information
Fitting instruction
Audi A5 Sportback (8T) 2010 
Body
Roof bars, for scope of delivery 8T8.071.126.A
Edition 8.09

Service
6
All rights reserved.
No reproduction without prior agreement from publisher.
Printed in Germany
Copyright © 2009 Audi AG, Ingolstadt
Contents
1 General notes .......................................................................................
2 Safety notes ........................................................................................
3Parts.................................................................................................
3.1 Scope of delivery ...................................................................................
3.2 Parts overview ......................................................................................
4 Installing/removing roof bars on vehicle ...........................................................
4.1 Installing roof bars on vehicle ......................................................................
4.2 Installing add-on components ......................................................................
4.3 Removing the roof bars from the vehicle .........................................................
4.4 General notes .......................................................................................
4.5 Setting the roof bar width .........................................................................
1
2
5
5
5
7
7
11
11
12
12

Audi A5 Sportback (8T) 2010 
No. 122, Body, Edition 8.09
1 General notes 1
6
1Generalnotes
Please read these instructions carefully and note the
WARNING, Caution and Note descriptions before installing
the roof bars.
Text with this symbol contains additional useful information.
Audi AG shall not accept responsibility in the event of failure
to comply with these assembly instructions.
WARNING!
♦Text with this symbol contains information concerning
your safety and how you can reduce the risk of serious
and fatal injuries.
♦Pay special attention to the WARNING symbol. Ensure
that you read the relevant texts thoroughly.
Caution!
♦Text with this symbol contains information on how to
avoid vehicle damage.
♦A Caution symbol indicates that failure to follow
information can lead to vehicle damage.
Note

Audi A5 Sportback (8T) 2010 
No. 122, Body, Edition 8.09
2 Safety notes
6
2
2Safetynotes
Permissible roof load
Sensitivity to side winds
Load — load correctly for the load in question
Load — width
WARNING!
Do not exceed the permissible roof load of 75kg (165lbs.).
Do not exceed the gross vehicle weight rating of roof bars,
add-on components and load of 75 kg (165 lbs.).
WARNING!
The driving and braking behaviour and the vehicle's
sensitivity to side winds are changed due to roof load.
Adapt your driving style accordingly.
It is recommended that you do not exceed 130 km/h
(81 mph).
WARNING!
Load roof load on roof bars in the correct manner for the
load in question.
Avoid loading on one side.
WARNING!
Do not exceed the maximum width of the roof bars.
ZUB-0321
max.
75 kg
165 lbs
ZUB-0322
ZUB-0323
ZUB-0324
max

Audi A5 Sportback (8T) 2010 
No. 122, Body, Edition 8.09
2 Safety notes 3
6
Load — Do not tension roof bars against each other
Load — install the roof bars first, then install the add-on
components
Load — room to open boot lid
WARNING!
Do not tension roof bars against each other.
WARNING!
Only fit the add-on components once the roof bars have
been installed on the vehicle.
Caution!
To avoid damage to the vehicle, ensure that you open the
boot lid carefully when transporting roof boxes and longer
items. It is recommended that you adjust the opening angle,
if necessary (see Vehicle operating instructions for this) for
vehicles with automatic boot lids.
WARNING!
Please read these assembly instructions carefully before
starting installation. Non-compliance with these assembly
instructions and safety notes will compromise your safety
and that of third parties.
ZUB-0220
B
ZUB-0326
A
B
ZUB-0327

Audi A5 Sportback (8T) 2010 
No. 122, Body, Edition 8.09
2 Safety notes
6
4
WARNING!
All bolt connections and connections for the roof bars and
for the add-on components must be checked prior to
travelling to ensure they are positioned and installed
correctly. Tighten if necessary.
Recheck bolted connections and connections at appropriate
intervals and tighten if necessary. The bolted connections
and connections must be checked at short intervals if
travelling on a poor stretch of road.
If this guideline is not observed, this can result in the roof
bars or the add-on components becoming loose or falling
off — risk of accident!
WARNING!
For the safety of other road-users, the roof bars and any
add-on components must be removed from the vehicle
when they are not being used.
WARNING!
Repairs or the replacement of parts must only be performed
by a qualified workshop. It is recommended that genuine
spare parts available from your Audi partner are used.
Caution!
The height of the vehicle will change due to the installation
of the roof bars with/without add-on components. Please pay
attention to this when entering garages, driving through
tunnels, underpasses etc.
Caution!
Do not enter a car wash with roof bars with/without add-on
components installed.

Audi A5 Sportback (8T) 2010 
No. 122, Body, Edition 8.09
3 Parts 5
6
3Parts
3.1 Scope of delivery
–Before installing the roof bars, check parts for
completeness.
3.2 Parts overview
1 - Profile cap (4x)
2 - Hexagon bolt M6 x 12
(8x)
3 - Profile cap rebound
strap (4x)
4 - Profile cover
5 - Profile tube
front
rear
The labels “front left”
and “rear left” can
each be found on a
sticker on the
underside of the profile
tubes.
6 - Hinge wire (4x)
7 - Base bracket (4x)
8- Screw4x15(8x)
9 - Base support
front left
front right
rear left
rear right
10 - Insert (4x)
11 - Roof support
front left
front right
rear left
rear right
Units Description Information
1 Front roof bars Label on the underside in direction of travel left
1 Rear roof bars Label on the underside in direction of travel left
1 Profile cover Length 2500mm
1 4-Nm torque wrench
1 Assembly tool
2Key
1 Assembly instructions
1 2 3 4
5
7
8
9
10
11
121315
16
17
18
6
14
ZUB-0328
19
20
21
22
24
23
Note

Audi A5 Sportback (8T) 2010 
No. 122, Body, Edition 8.09
3 Parts
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6
12 - Claw fastener
front left
front right
rear left
rear right
13 - Tensioning bolt (4x)
14 - Assembly tool
15 - 4-Nm torque wrench
16 - Cover flap (4x)
17 - Lock (4x)
18 - Key (2x)
19 - Washer M6 (8x)
20 - Claw bolt
21 - Circlip
22 - Base bracket bolt
23 - Circlip
24 - Labels
front
rear

Audi A5 Sportback (8T) 2010 
No. 122, Body, Edition 8.09
4 Installing/removing roof bars on vehicle 7
6
4 Installing/removing roof bars on
vehicle
4.1 Installing roof bars on vehicle
Preparing roof bars for installation:
–Open the lock -17- using the key -18-.
–Note the key number of your roof bars. This will facilitate
replacement in the event of loss.
_____________________________________________________
–Open the cover flaps -16-.
–Connect the torque wrench -15- to bolts -13- and unscrew
until obvious resistance is felt.
–Swivel out the claw fasteners -12- and hook the narrow
end of the claw fasteners in the installation position on the
base supports -9-.
ZUB-0329
18
17
15
ZUB-0330
16
15
13
ZUB-0331
912
12

Audi A5 Sportback (8T) 2010 
No. 122, Body, Edition 8.09
4 Installing/removing roof bars on vehicle
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8
Determining the installation position:
The positioning bolts -X- are located beneath the rubber lips
between the decorative trim and the roof frame.
The illustration shows the car from the left-hand side.
A - approx. 22cm
B - approx. 32cm
•Clean the contact area between the vehicle roof and the
roof bars thoroughly (they should be free from dust and
grease).
Installing the roof bars:
–Carefully position both roof bars -5- on the vehicle roof in
the area of the positioning bolts -X-. The claw fasteners
must be in the installation position when positioning the
roof bars. Observe the labels on the underside of the profile
tubes -24- when positioning the roof bars.
The labels must be on the left-hand side of the vehicle and the
printed arrow must point in the direction of travel.
–Pull the rubber seal gently outward and carefully insert the
installation aid -14- between the positioning bolts and
rubber lip. Then align the centre of the assembly tool with
the positioning bolts -X-. The positioning bolts -X- must be
visible.
A
B
14
ZUB-0333
X
Note
A00-00000ZUB-0332
x
x
xx
x
Note
ZUB-0334
14
X
X

Audi A5 Sportback (8T) 2010 
No. 122, Body, Edition 8.09
4 Installing/removing roof bars on vehicle 9
6
–Unhook the claw fastener -12- from the installation posi-
tion on the support bracket- 9- by pulling upward, then
swivel down.
–Insert the claw fastener -12- in the positioning bolts -X-
above the assembly tool and slide it carefully in as far as it
will go.
Positioning the claw fastener:
1. Note the starting position and slide the roof bar forward on
the claw fastener -12- until the stop in the direction of trav-
el.
ZUB-0344
12
14
X
9
12
ZUB-0335
X
12
X
12
ZUB-0406

Audi A5 Sportback (8T) 2010 
No. 122, Body, Edition 8.09
4 Installing/removing roof bars on vehicle
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10
2. Slide the roof bar half way back on the claw fastener -12-.
Once this procedure is complete, the positioning bolt -X-
must be aligned so that it sits centrally between the
starting position and the stop.
3. Remove the assembly tool.
4. Perform the identical procedure on the other side of the
vehicle.
–Align the roof bar on the side — note the position on the
roof edge -arrow-.
The gap -a- must not exceed 1mm.
If the rubber supports on the support bracket housing are not
flush to the surface, we recommend that you have the width
adjustment checked by a qualified workshop ⇒“4.5 Setting
the roof bar width” on page 12. Remove the roof bars before
doing so.
–Gently tighten the bolts -13- alternately using the torque
wrench -15-.
–Check the position of the support base housing -A- and
claw fastener -B- and correct if necessary.
–Tighten one tensioning bolt -13- after another using the
torque wrench -15- until the torque wrench makes an
audible clicking sound. This indicates that the correct
torque has been applied.
–Close the cover flap -16- and close the lock -17- with the
key -18-.
–Follow the same procedure to install the second roof bar.
X
12
ZUB-0407
ZUB-0345
A
B
C
ZUB-0336
A
B
C
a
a
12
ZUB-0337
A
B
15
16
13 15

Audi A5 Sportback (8T) 2010 
No. 122, Body, Edition 8.09
4 Installing/removing roof bars on vehicle 13
6
4.2 Installing add-on components
–Secure the add-on components in accordance with the
relevant assembly instructions.
–To install the add-on components, remove the profile cap
-1- from the profile tube -5- -arrow A-.
–Insert the add-on components in the T groove -arrow B-.
–Slide the profile cap -1- back on -arrow C-.
When the add-on components are not in use, secure the T
groove with the profile cover -4-.
–Adjust the profile cover -4- to the length of the roof bars
with the profile caps -1- closed.
–Place profile cover -4- on the T groove on the roof bars -5-
and press into the T groove -arrow-.
♦When driving with a roof load, ensure that the German
Road Traffic Regulations (StVZO) or any country-specific
regulations are observed.
♦For reasons of convenience, it is common for the roof bars
with/without add-on components to remain on the vehicle,
even if they are not in use. As a result of the increased
wind resistance, your vehicle will consume more fuel and
will produce additional noise.
♦We therefore recommend that you remove the roof bars
after use.
♦Increased wind noise can result from driving with the roof
bars attached.
4.3 Removing the roof bars from the vehicle
–Remove the load and the add-on components.
–Open the lock using the key and open the cover flap -16-.
–Unscrew the left and right tensioning bolts -13- alternately
using the torque wrench -15- until obvious resistance is
felt.
–Slide the claw fastener -12- against the direction of travel
until the stop.
–Detach the left and right-hand claw fasteners -12- from the
positioning bolts -X- and hook the narrow end into
installation position on the support bracket -9-.
–Remove the roof bars from the vehicle roof.
–Unhook the claw fasteners -12- from the installation
position and swivel downward.
ZUB-0338
C
A
1
B
5
ZUB-0339
1
5
4
Note
ZUB-0340
15
X 12
13 15
16
9

Audi A5 Sportback (8T) 2010 
No. 122, Body, Edition 8.09
4 Installing/removing roof bars on vehicle
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14
–Turn bolt -13- approx. 10 times to screw in.
–Close the cover flap -16- and lock the lock with the key.
4.4 General notes
Technical data
Weight of roof bar set: approx. 6 kg
Roof load/load
Maintenance instructions:
The roof bars should always be cleaned and kept in good
order. It is particularly important to remove any dirt and salt
in the winter.
4.5 Setting the roof bar width
Instructions for the qualified workshop if the position of the
support bracket for the relevant vehicle is not set correctly.
–Install the roof bars on the vehicle ⇒page 9.
–Use an Allen key (5 mm) to unscrew the hexagon bolts -2-
on the right-hand support bracket far enough that the sup-
port bracket can still be moved. The roof bar remains on
the vehicle roof during this process.
To determine the roof load:
Weight of the roof bars
+ The weight of body part
+ The weight of the load
=Roofload
WARNING!
Never exceed
♦the maximum permissible roof load (75 kg 165 lbs.)
♦the gross axle weight rating
♦the gross vehicle weight rating
of your vehicle ⇒Vehicle operating instructions.
ZUB-0342
2

Audi A5 Sportback (8T) 2010 
No. 122, Body, Edition 8.09
4 Installing/removing roof bars on vehicle 15
6
–Adjust the roof bar so that the rubber support on the
right-hand support bracket housing sits flush with the roof
edge -arrow-.
The gap -a- must not exceed 1 mm.
–Tighten the hexagon bolts -2- to 8 Nm.
–Repeat the procedure on the other roof bar.
WARNING!
Check that all hexagon bolts have been tightened (8 Nm). If
this guideline is not observed, this can result in the roof
bars becoming loose or falling off — risk of accident!
ZUB-0345
A
B
C
ZUB-0336
A
B
C
a
a
ZUB-0343
2