All language subtitles for How.Its.Made.Dream.Cars.S04E06.1080p.DSCP.WEB-DL.AAC2.0.H.264-NTb

Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS"...

THE AUDI S8,
A LUXURY SPORTS CAR

WITH UNDERSTATED LOOKS
AND OUTRAGEOUS POWER.

♪♪

-- Captions by VITAC --
www.vitac.com

CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS

AUDI MANUFACTURES THE S8
IN NECKARSULM, GERMANY.

CAR MANUFACTURING BEGAN HERE
MORE THAN 100 YEARS AGO

WITH A COMPANY CALLED NSU.

NSU MERGED WITH AUDI

AFTER BEING BOUGHT
BY THE VOLKSWAGEN GROUP.

AUDI WAS FOUNDED
BY AUGUST HORCH IN 1909.

"HORCH" MEANS "LISTEN"
IN GERMAN.

THE LATIN TRANSLATION
OF "LISTEN" IS "AUDI."

AUDI IS WELL KNOWN FOR
ITS WELL-ENGINEERED LUXURY CARS.

THE "S" IN THE AUDI S8
STANDS FOR "SPORT."

THE S8 CAN SMOOTHLY STROLL
THROUGH THE TWISTING ROADS

OF NECKARSULM'S
CELEBRATED VINEYARDS

OR EASILY OVERTAKE
NEARLY EVERY CAR

ON THE OPEN ROAD.

AUDI'S NECKARSULM FACILITY
FOCUSES ON REDUCING WEIGHT

IN AUTO CONSTRUCTION.

IT HAS AN IN-HOUSE PRESS SHOP,
ALUMINUM-STEEL BODY SHOP,

AND TWO PURE ALUMINUM
BODY SHOPS.

HERE, A TECHNICIAN
LOADS AN ALUMINUM COMPONENT

INTO A WELDING JIG.

AUDI'S MOTTO IS
VORSPRUNG DURCH TECHNIK,

WHICH MEANS "ADVANCEMENT
THROUGH TECHNOLOGY."

A PAIR OF ROBOTS
SWING INTO ACTION,

WELDING PARTS TO CREATE

THE MULTI-MATERIAL
AUDI SPACE FRAME'S FRONT END.

A ROBOT LOWERS THE REAR END
OF THE SPACE FRAME INTO PLACE.

A TECHNICIAN LOADS ON EXTRUDED
AND FORGED ALUMINUM COMPONENTS,

WHICH WILL CONNECT THE FRONT
AND REAR OF THE SPACE FRAME.

THE UNDERBODY MOVES
TO THE NEXT STATION,

WHERE WELDING ROBOTS
JOIN ALL THE PARTS.

DESPITE THE EXTENSIVE USE
OF ROBOTS,

THE NECKARSULM FACILITY STILL
RELIES ON OVER 16,000 EMPLOYEES

AS OF 2015.

AUDI'S SPACE-FRAME TECHNOLOGY
FEATURES LOAD-CARRYING PROFILES,

STIFFENING SHEETS,
AND CAST-JOINING ELEMENTS,

CREATING A HIGH-STRENGTH
BUT LIGHTWEIGHT UNDERBODY.

CLAMPS AND VACUUM-POWERED
SUCTION CUPS

HOLD THE BODY
SIDE PANEL IN PLACE

AS IT MOVES TO THE AVT
STRUCTURAL BONDING SYSTEM.

HERE, A ROBOT APPLIES

AN AEROSPACE-GRADE
STRUCTURAL ADHESIVE

TO EVERY JOINING SURFACE
ON THE PANEL

WITH REMARKABLE PRECISION.

THE S8 PRODUCTION LINE

AT NECKARSULM
IS HEAVILY AUTOMATED.

ROBOTIC FIXTURES BRING
THE TWO BODY SIDE PANELS

TO THE FRAME SIMULTANEOUSLY.

THEN ANOTHER TEAM OF ROBOTS

SPOT-WELD THE PANELS
TO THE UNDERBODY.

THIS BODY IN WHITE
IS NEARLY COMPLETE.

WHEN FINISHED IT WILL HAVE
AN UNLADEN WEIGHT

JUST UNDER 4,400 POUNDS.

AUDI PLACES GREAT IMPORTANCE
ON LIGHTWEIGHT CONSTRUCTION.

THROUGHOUT THE ASSEMBLY PROCESS,

LASER ALIGNMENT RIGS

CHECK FOR ANY DEVIATIONS
FROM THE DESIGN PARAMETERS.

THE COMPLETED BODY IN WHITE
HAS 320 FEET

OF WELDING SEAMS, 782 RIVETS,

AND 308 SELF-TAPPING SCREWS.

IT'S COMPOSED OF
70% ALUMINUM EXTRUSIONS,

8% VACUUM-CAST NODES,

AND 22% SHEET-ALUMINUM PANELS,

RESULTING IN A STRUCTURE
OF MINIMAL WEIGHT

BUT MAXIMUM STABILITY.

THE PAINT SHOP APPLIES
FIVE COATS OF FINISH

TO THE BODY IN WHITE.

EACH COAT IS 120 MICRONS DEEP,

NO THICKER THAN A HUMAN HAIR.

NOZZLES SPRAY PAINT
WITH AN ELECTROSTATIC CHARGE.

THE CHARGE CAUSES
THEM TO REPEL EACH OTHER,

RESULTING IN OPTIMAL
DISTRIBUTION ACROSS THE SURFACE.

HOWEVER, A STRONG BOND

IS CREATED BETWEEN
THE GROUNDED CAR BODY

AND THE CHARGED PAINT PARTICLES.

THIS FINISHED S8 BODY

IS READY TO JOIN
ITS CHASSIS AND POWERTRAIN.

Narrator: DESPITE THE UNDERSTATED
LOOK OF THE AUDI S8,

UNDERNEATH THE HOOD
IS SHEER BRUTE POWER.

TO ENSURE
EACH S8 ENGINE MEASURES UP

TO THE RIGOROUS DEMANDS

OF AUDI'S ENGINEERING
DEPARTMENT,

QUALITY-CONTROL EXPERTS
RUN A VARIETY OF TESTS.

THE ENGINE FOR THE S8 IS AUDI'S
4-LITER TFSI POWER PLANT.

TFSI STANDS FOR TURBO FUEL
STRATIFIED INJECTION.

THAT MEANS FUEL
IS PRESSURE-INJECTED DIRECTLY

INTO THE COMBUSTION CHAMBER.

THE RESULT IS A POWERFUL
YET EFFICIENT ENGINE.

THE ENGINE FEATURES
CYLINDER-ON-DEMAND TECHNOLOGY.

WHICH MEANS FOUR
OF ITS CYLINDERS

DEACTIVATE AT NORMAL SPEED,
CONSERVING FUEL.

A TECHNICIAN JOINS
THE TRANSMISSION TO THE ENGINE

AND BOLTS IT IN PLACE.

THE TRANSMISSION
IS AN EIGHT-SPEED TIPTRONIC

WITH DSP AND SPORT PROGRAM.

THE TIPTRONIC FEATURES

A HYDRAULIC TORQUE CONVERTER
LOCK-UP CLUTCH.

A SECOND TECHNICIAN MOUNTS

THE AIR-CONDITIONING
COMPRESSOR SYSTEM.

THE DRIVETRAIN THEN MOVES ON
TO THE NEXT PHASE.

AN OVERHEAD CRANE SYSTEM
ALIGNS ITSELF WITH THE UNDERBODY

AND CAREFULLY LOWERS THE ENGINE.

TECHNICIANS THEN USE
SPECIALIZED ZERO-GRAVITY DRIVERS

WITH PREPROGRAMMED TORQUE
SPECIFICATIONS

TO SECURELY BOLT
THE COMPONENTS TOGETHER.

THE S8 ENGINE
HAS AN INNOVATIVE COMPACT LAYOUT

WITH EXTENSIVE INSULATION
AND MINIMAL FRICTIONAL LOSSES.

THIS IMPROVES
THERMODYNAMIC PERFORMANCE.

THE ENGINE, TRANSMISSION,

AND UNDERBODY LOWER
ONTO AN ASSEMBLY POUND.

TECHNICIANS INSTALL
THE CATALYTIC CONVERTER

BEFORE MOUNTING THE SUSPENSION.

THE S8 COMES WITH FIVE-LINK
FRONT SUSPENSION,

UPPER AND LOWER WISHBONES,

TUBULAR ANTI-ROLL BAR,
AND AIR SUSPENSION.

THE REAR FEATURES
TRAPEZOIDAL-LINK SUSPENSION

WITH WISHBONES,

TUBULAR ANTI-ROLL BAR,
AND AIR SUSPENSION.

THESE ELEMENTS CONTRIBUTE
TO THE CAR'S SMOOTH RIDE,

WHICH IS SUSTAINED
THROUGH A SYSTEM

CALLED ACTIVE ENGINE MOUNTS.

ACTIVE ENGINE MOUNTS USE

AN ELECTROMAGNETIC
OSCILLATING COIL ACTUATOR

TO TRANSMIT A RAPID STROKE
TO HYDRAULIC FLUID

IN THE MOUNTING.

THE PROCESS GENERATES

OUT-OF-PHASE
COUNTER OSCILLATIONS

WHICH CANCEL OUT
THE ENGINE'S VIBRATIONS.

NEXT, A TEAM MEMBER
MOUNTS THE CAR'S DISC BRAKES.

THE S8 IS EQUIPPED
WITH BOTH FRONT

AND REAR DISC BRAKES,

WHICH FORM PART OF
THE DUAL-CIRCUIT BRAKE SYSTEM.

THE PAIR OF TECHNICIANS
LOWER THE FRONT AXLE INTO PLACE

ALONG WITH THE ENGINE
AND TRANSMISSION.

THEN THEY INSTALL
THE EXHAUST SYSTEM.

THE SYSTEM'S TWO CLOSE-COUPLED
CERAMIC CATALYTIC CONVERTERS

ARE EACH EQUIPPED
WITH TWO OXYGEN SENSORS

TO MONITOR THE CAR'S
EMISSIONS PERFORMANCE.

WITH INSTALLATION COMPLETE,

THE UNDERBODY HEADS OFF
TO THE NEXT STATION.

AN OVERHEAD CRANE LOWERS
THE REAL-AXLE SUBASSEMBLY

INTO PLACE.

THE SUBASSEMBLY
INCLUDES THE SPORT DIFFERENTIAL

FOR AUDI'S FOUR-WHEEL-DRIVE
SYSTEM KNOWN AS QUATRO.

NEXT, THE TECHNICIAN
INSTALLS THE DRIVESHAFT.

THIS CHANNELS POWER
FROM THE ENGINE

TO THE REAR WHEELS

USING AUDI'S
SPECIALIZED SPORT DIFFERENTIAL.

IT VARIES THE TORQUE
BETWEEN THE REAR WHEELS

ACCORDING
TO THE DRIVING CONDITIONS.

THE TECHNICIAN FINISHES
THE RUNDOWN OF THE BOLTS

WITH A TORQUE-CONTROLLED DRIVER

SUPPORTED
BY A LIFT-ASSIST SYSTEM.

WITH THE ENGINE, TRANSMISSION,
AND DRIVESHAFT IN PLACE,

ASSEMBLY OF THE UNDERBODY
IS NEARLY COMPLETE.

A TECHNICIAN USES A LIFT-ASSIST

TO INSTALL THE S8's
DOUBLE-CHAMBERED FUEL TANK

UNDERNEATH THE REAR
PASSENGER SEATS.

Narrator: TEAM MEMBERS
ARE READY TO ASSEMBLE

THE AUDI S8'S OPULENT INTERIOR.

TECHNICIANS INSTALL
A WIRING HARNESS INSIDE THE CAR.

THE HARNESS IS COMPLEX,
WITH NUMEROUS CONNECTIONS.

THAT'S NO SURPRISE,
CONSIDERING THE S8 IS EQUIPPED

WITH AN EXTENSIVE
TECHNOLOGY PACKAGE

WHICH INCLUDES PARKING SENSORS,
A TOP-VIEW CAMERA,

ELECTRONIC VEHICLE
IMMOBILIZATION DEVICE

WITH ALARM SYSTEM
AND BACKUP HORN,

ELECTRICALLY FOLDING
EXTERIOR MIRRORS,

ELECTRIC TILT AND TELESCOPIC
STEERING WHEEL ADJUSTMENTS,

HEATED LEATHER STEERING WHEEL,

A TIRE-PRESSURE
MONITORING SYSTEM,

FOUR-ZONE AUTOMATIC
AIR-CONDITIONING,

AND POWER-ASSISTED DOOR CLOSURE.

ONCE THE WIRING HARNESS
IS INSTALLED,

TEAM MEMBERS
BRING IN THE DASHBOARD.

A TECHNICIAN INSTALLS
THE STEERING COLUMN

WITH EXTREME CARE AND PRECISION.

THE S8's INTERIOR
PANELING COMES NEXT.

IT CAN BE CUSTOMIZED TO INCLUDE
LEATHER, WOOD, ALUMINUM,

AND CARBON-FIBER ELEMENTS.

THE DELUXE SPORT
22-WAY POWER FRONT SEATS

HAVE A MEMORY SYSTEM.

THERE IS NO NEED
TO FINE-TUNE THEM

EVERY TIME YOU CHANGE OCCUPANTS.

THEY ALSO COME WITH MASSAGE
AND HEATING FUNCTIONS.

THIS S8 IS READY TO RECEIVE
ITS FAMED AUDI LOGO,

WHICH SYMBOLIZES THE 1932 MERGER
OF FOUR GERMAN CAR COMPANIES...

AUDI, DKW, WANDERER, AND HORCH.

A TECHNICIAN INSTALLS

A THREE-SPOKE MULTI-FUNCTION
HEATED LEATHER STEERING WHEEL

WITH SHIFT PADDLES.

THE AUDI BADGE MODULE ALSO
CONTAINS THE DRIVER-SIDE AIRBAG.

THE S8 CAN BE ORDERED
WITH AUTOMATIC SOFT-CLOSE DOORS,

MEANING THAT EVEN IF YOU'RE
LOADED DOWN WITH GROCERIES

AND CAN'T SWING
THE DOOR COMPLETELY SHUT,

THE CAR WILL FINISH
THE JOB FOR YOU.

THIS AUDI S8 CAR BODY
IS COMPLETELY ASSEMBLED

AND READY TO MEET
ITS DRIVETRAIN.

THE JOINING OF THE BODY

WITH THE CHASSIS
IS A FULLY AUTOMATED PROCESS.

THE PALLET
TRANSPORTING THE CHASSIS

ALIGNS ITSELF
UNDER THE BODY PERFECTLY.

AS THE PALLET RAISES THE CHASSIS
AND THE POWERTRAIN

INTO THE BODY, TECHNICIANS
MONITOR THE PROCESS CLOSELY.

TEAM MEMBERS USE A SPECIALIZED
LIFT-ASSIST FIXTURE

TO INSTALL THE CAR'S
COOLING SYSTEM.

AUDI S8 RADIATORS
COME FROM MODI, A COMPANY

THAT HAS SPECIALIZED
IN HEAT-TRANSFER SYSTEMS

SINCE 1916.

THE S8's TALL RECTANGULAR GRILLE

IS SO EMBLEMATIC
OF THE AUDI LOOK

YOU ALMOST DON'T EVEN THE NEED

THE FOUR-RING SYMBOL
TO IDENTIFY THE CAR'S MAKER.

A TECHNICIAN USES
A SPECIALIZED DOLLY SYSTEM

TO BRING THE RIGHT FRONT WHEEL
TO THE CAR.

HE THREADS THE LUG NUTS ON
WITH THE HELP OF A GUIDE.

USING AN AUTOMATED DRIVER,
HE TIGHTENS ALL FIVE LUGS

TO THE PRECISE TORQUE.

WITH ALL FOUR WHEELS MOUNTED,
THIS S8 IS ALMOST COMPLETE.

ONLY ONE FINAL STEP REMAINS.

A TEAM MEMBER SNAPS
THE ENGINE COVER INTO PLACE.

THIS CAR IS READY
TO LEAVE THE ASSEMBLY LINE

AND GO TO DYNAMIC TESTING.

ON A ROLLING ROAD,

HE PUTS THE S8
THROUGH IT'S PACES.

HE REVS IT UP
AS THE DIGITAL PROGRAM CHECKS

TO MAKE SURE IT MEETS
EVERY PERFORMANCE PARAMETER.

A STRIP OF ROUGHLY
COBBLESTONED CIRCLES

LINE THE INNER CIRCUMFERENCE
OF THE AUDI TEST TRACK.

DRIVING THE S8 OVER THIS SURFACE

ALLOWS THE DRIVER TO NOTE
ANY SQUEAKS OR RATTLES

THAT MIGHT NEED TO BE CORRECTED.

IT'S TIME TO HIT THE THROTTLE

AND SEE WHAT THIS SUPERCAR
CAN DO AT SPEED.

Narrator: THIS S8 HAS MET
EVERY PERFORMANCE PARAMETER.

BUT WHEN THIS MUCH TIME
AND EFFORT

IS PUT INTO A VEHICLE,

TECHNICIANS STILL DOUBLE-CHECK
TO ENSURE IT'S PERFECT

BEFORE SHIPPING IT OFF.

AS PART OF AUDI'S MULTI-STEP
QUALITY-CONTROL PROGRAM,

A SPECIALIST INSPECTS
EVERY ASPECT OF THE CAR.

HE USES A GAP GAUGE TO ENSURE
THAT THE SPACES BETWEEN PANELS

MEET A PRESET STANDARD.

THE PAINT JOB MUST BE FLAWLESS.

A SPRAY BOTTLE AND CLOTH

HELP HIM IDENTIFY
EVEN THE MOST MINUTE BLEMISHES

IN THE SURFACE.

BUT, OF COURSE, THE EXTERIOR
OF THE S8 IS ONLY ONE ASPECT

OF THE CAR.

FOR THE SUMPTUOUS INTERIOR,

WOOD PANELING IS ONE OF THE MANY
CUSTOMER OPTIONS AVAILABLE.

BUYERS CAN CHOOSE
FROM A WIDE RANGE

OF OPTIONS FOR THE PAINT JOB.

IF THEY DON'T FIND
WHAT THEY'RE LOOKING FOR,

AUDI CAN MATCH THE COLOR
OF A FAVORITE ITEM

OF CLOTHING, FURNITURE,
OR JEWELRY.

FOR THE INTERIOR UPHOLSTERY
OF THE S8,

AUDI PROVIDES AN ARRAY
OF LEATHER FINISHES AND COLORS.

THE S8 COMES STANDARD
WITH COMFORT SPORTS SEATS.

A QUILTED LEATHER UPHOLSTERY
DEMONSTRATES AUDI'S COMMITMENT

TO OLD-SCHOOL CRAFTSMANSHIP.

UNDERNEATH THAT CRAFTSMANSHIP
IS A HIGH-TECH COLLECTION

OF SEATING TECHNOLOGY.

BESIDES ELECTRIC LUMBAR SUPPORT,

THE SEATS FEATURE AN UPPER-
BACKREST ADJUSTMENT FUNCTION,

WHICH ALLOWS PASSENGERS TO ANGLE
THE TOP THIRD OF THE BACKREST.

EVEN THOUGH THE S8 WAS DEVELOPED
BY AUDI'S PERFORMANCE DIVISION,

THE INTERIOR
OF THE CAR IS ALL LUXURY.

SOUNDPROOFING
AND NOISE-REDUCTION TECHNOLOGY

MAKE THE RIDE QUIET EVEN
WHEN CRUISING DOWN THE HIGHWAY.

THE CABIN IS OPULENT
BUT PRACTICAL.

SCREENS MOUNTED ON THE BACKS
OF THE FRONT SEATS

HELP PASS THE TIME
ON LONG TRIPS.

AUDI'S NECKARSULM FACILITY
ISN'T JUST A FACTORY,

IT'S ALSO THE SITE
OF AN AUDI FORUM

WHERE THE COMPANY
DISPLAYS ITS PRODUCTS.

OF COURSE THE S8
IS PROMINENTLY DISPLAYED.

THE CAR'S SHAPE
AND UNDERSTATED LOOKS

GIVE LITTLE SIGN OF THE POWER

THAT LIES BENEATH THE HOOD.

BUT THERE ARE SMALL DETAILS
HERE AND THERE

THAT HINT AT ITS POWER
AND PERFORMANCE.

IN THE EVENING,
THE AUDI FORUM IN NECKARSULM

TRANSFORMS INTO A STAGE

FOR ALL KINDS
OF CULTURAL EVENTS,

FROM POP CONCERTS
TO LITERARY READINGS.

BUT DURING THE DAY,

IT'S WHERE CUSTOMERS
CAN SEE THEIR NEW CAR

FOR THE FIRST TIME.

THE S8 IS BASED
ON AUDI'S LEGENDARY A8,

CONSIDERED BY SOME

TO BE THE ULTIMATE
GERMAN LUXURY SEDAN.

EVERY DETAIL
OF THE S8'S INTERIOR

IS EMBLEMATIC
OF THE OPULENT A8.

BUT WHEN MULTIPLE DRIVE MODES
APPEAR ON THE DISPLAY,

ALLOWING DRIVERS TO CUSTOMIZE
THEIR EXPERIENCE,

IT BECOMES CLEAR THAT THIS CAR
CAN GENERATE POWER

AT A HIGHER LEVEL.

THERE IS ONLY ONE WAY
TO REALLY SEE

WHAT THIS CAR CAN DO...

TAKE IT OUT ON THE OPEN ROAD.

THE SHAPE
OF THE MATRIX L.E.D. HEADLIGHTS

AND THE BRUSHED-ALUMINUM
EXTERIOR MIRROR HOUSINGS

SET THE S8 APART.

BUT IT'S THE TURBO FUEL-INJECTED
4-LITER V-8 UNDER THE HOOD

THAT TRULY DISTINGUISHES THE S8
FROM ITS COMPETITION.

THE ENGINE IS THE HIDDEN MUSCLE

THAT REVS THIS SERENE
AND OPULENT-LOOKING SEDAN

TO FEROCIOUS SPEEDS.

THE TFSI POWER PLANT CRANKS OUT
520 HORSEPOWER AT 5,800 RPMS,

WITH A MAXIMUM TORQUE
OF ABOUT 550 FOOT-POUNDS

BETWEEN 1,700 AND 5,500 RPMS.

THE S8 GOES FROM ZERO TO 60
IN JUST 4.1 SECONDS,

WITH A TOP SPEED
OF 155 MILES PER HOUR.

THE S8 CAN OUTMATCH
MOST HIGH-PERFORMANCE CARS

ON THE OPEN ROAD

WHILE ITS PASSENGERS
SIT BACK IN PLUSH COMFORT

AND QUIET STYLE.