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Workshop Manual

Audi A8 2003 ➤

10-cylinder direct petrol injection engine (5.2 ltr. 4-

valve), mechanics

Engine ID

BSM

Edition 10.2013

Service

Service Department. Technical Information

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Summary of Contents for 2003 A8

Page 1: ...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 Workshop Manual Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Engine ID BSM Edition 10 2013 Service Service Department Technical Information ...

Page 2: ...p 00 Technical data 10 Removing and installing engine 13 Crankshaft group 15 Cylinder head valve gear 17 Lubrication 19 Cooling 26 Exhaust system 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 w...

Page 3: ...nd right 46 5 3 Removing installing and adjusting mounting for torque reaction support 50 13 Crankshaft group 55 1 Cylinder block pulley end 55 1 1 Poly V belt drive exploded view 55 1 2 Removing and installing poly V belt 56 1 3 Removing and installing vibration damper 59 1 4 Renewing crankshaft oil seal pulley end 60 2 Cylinder block gearbox end 63 2 1 Drive plate exploded view 63 2 2 Removing a...

Page 4: ...earance of camshafts 138 3 3 Measuring radial clearance of camshafts 139 3 4 Removing and installing camshafts 140 3 5 Renewing valve stem oil seals cylinder head installed 145 3 6 Renewing valve stem oil seals cylinder head removed 149 3 7 Checking hydraulic valve compensation elements 153 3 8 Valve dimensions 154 3 9 Checking valve guides 154 3 10 Checking valves 155 17 Lubrication 156 1 Lubrica...

Page 5: ... pipe rear 212 1 19 Radiator and radiator fans exploded view 212 1 20 Removing and installing radiator 214 1 21 Removing and installing auxiliary radiator left side 217 1 22 Removing and installing auxiliary radiator right side 218 1 23 Removing and installing radiator cowl 220 1 24 Removing and installing radiator fans 221 1 25 Checking cooling system for leaks 221 26 Exhaust system 224 1 Exhaust...

Page 6: ... 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 Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 10 2013 iv Contents ...

Page 7: ...in this document Copyright by AUDI AG 00 Technical data 1 Engine number ARL003517 Edition 10 2013 Pull off engine cover panel front 1 arrows The engine number engine code and serial number can be found on top of the cylinder block at the front arrow Note The engine code is also included on the vehicle data sticker Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Ed...

Page 8: ...mm 92 8 Compression ratio 12 5 RON 98 1 Injection ignition system Bosch Motronic Firing order 1 6 5 10 2 7 3 8 4 9 Exhaust gas recirculation no Turbocharging supercharging no Knock control 4 sensors Lambda control 2 probes before catalyt ic converter 2 probes after catalytic converter Variable valve timing Inlet Exhaust Intake manifold change over yes Secondary air system yes Valves per cylinder 4...

Page 9: ...before connecting or discon necting electrical wiring for the injection or ignition system or tester cables Always switch off ignition before washing engine Erase any entries in event memory resulting from testing or installation Vehicle diagnostic tester Interrogate event memory then Generate readiness code Caution To prevent irreparable damage to the electronic components when disconnecting the ...

Page 10: ... if the airbag is triggered in an accident The use of test equipment while driving causes distraction There is an increased risk of injury if test equipment is not secured Test equipment must always be secured on the rear seat with a strap and operated from the rear seat by a second person 3 1 Procedure before opening high pres sure section of injection system WARNING The injection system consists...

Page 11: ...hen the system is open Do not work with compressed air Do not move the vehicle unless absolutely necessary Protect unplugged electrical connectors against dirt and mois ture and make sure connections are dry when attaching 4 2 Checking for leaks in the fuel system Allow engine to run for several minutes at moderate rpm Switch off ignition Check complete fuel system for leaks If leaks are found alt...

Page 12: ... Make sketches or take photographs if nec essary 4 6 Installing radiators and condensers Even when the radiator and condenser are correctly installed slight impressions may be visible on the fins of these components This does not mean that the components are damaged If the fins are only very slightly distorted this does not justify renewal of the radiator or the condenser 4 7 Checking vacuum syste...

Page 13: ...AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG mediately check the hand vacuum pump and connecting hoses for leaks Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 10 2013 4 General repair instructions 7 ...

Page 14: ...ct drained coolant in a clean container for re use or dis posal Fit all heat shields and heat insulation sleeves in the original positions when installing All cable ties which are released or cut open when removing must be fitted in the same position when installing Special tools and workshop equipment required Removal lever 80 200 Eye head bolt 3368 Used oil collection and ex traction unit V A G ...

Page 15: ...t Copyright by AUDI AG Stepladder VAS 5085 Scissor type assembly platform VAS 6131 A with support set for Audi VAS 6131 10 Drip tray for workshop hoist VAS 6208 Tensioning strap T10038 2x Puller T40039 Engine bung set VAS 6122 Procedure Caution Observe notes on procedure for disconnecting the battery Electrical system Rep gr 27 Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valv...

Page 16: ...ore disconnecting the battery so that the propshaft can be turned during removal With ignition switched off disconnect earth cable arrow at battery Electrical system Rep gr 27 Discharge the refrigerant system Air conditioner system with refrigerant R134a Pull off engine cover panels at front 1 and at rear 2 arrows Remove cover above coolant expansion tank arrows WARNING Hot steam or hot coolant ca...

Page 17: ...ws securing exhaust pipe for auxiliary additional heater to noise insulation Release quick release fasteners 1 and 2 and take off noise insulation panels Remove front and rear sections of front wheel housing liners left and right Rep gr 66 Place drip tray for workshop hoist VAS 6208 under engine Unscrew drain plug arrow at thermostat housing and drain off coolant Remove drain plug arrow at front c...

Page 18: ...pyright by AUDI AG Disconnect coolant hoses 1 3 and drain off coolant Disconnect coolant hose next to drive shaft left side from coolant pipe arrow and drain off coolant Remove bolts 2 and 3 Detach bottom front coolant pipe from hoses 1 and 4 Disconnect hoses 1 and 2 from connecting pipes for sec ondary air Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 1...

Page 19: ...de and drain off remaining coolant Unscrew nut 1 and remove coolant hose 2 from auxiliary radiator right side Unplug electrical connector 1 at activated charcoal filter sol enoid valve 1 N80 and detach vacuum hose 2 Detach activated charcoal filter solenoid valve 1 N80 from bracket and move it clear to the side with hose still attached Detach coolant hose arrow leading from coolant pipe to cool an...

Page 20: ...ir cleaner and detach vacuum hose for air flap Remove bottom section of air cleaner left side Extract hydraulic fluid for power steering from reservoir using used oil collection and extraction unit V A G 1782 Note Lay a cloth under the separating point to catch escaping hydraulic fluid Disconnect hydraulic pressure line for power steering arrow at front left of engine Seal off open pipes lines and...

Page 21: ...intake manifold USA models Open hose clips and move air hose 4 to one side Caution Do not open hose connection 3 on USA models All vehicles Unscrew bolts arrows and remove top section of air cleaner right side Disconnect air hose arrow at bottom of bottom section of air cleaner right side Disconnect both vacuum hoses 1 Remove air duct 2 Remove bolts arrows Turn over bottom section of air cleaner a...

Page 22: ...on in this document Copyright by AUDI AG Detach coolant hose right side arrow at engine Remove bolt arrow on mounting for torque reaction support Remove electrical connectors for Lambda probes 1 and 2 from bracket on right of engine compartment Detach vacuum hoses 1 and 2 and move clear Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 10 2013 16 Rep gr 10 R...

Page 23: ...onnection Disconnect fuel supply line arrow at connecting piece Seal off open pipes lines and connections with clean plugs from engine bung set VAS 6122 Remove crankcase breather hose 2 Unplug electrical connectors 1 and 5 Remove bolts 3 and 4 Unplug connectors for ignition coils of cylinder bank 1 right side and move wiring clear Pull ignition coils out with puller T40039 Slacken bolts in the seq...

Page 24: ...st pollen filter to do so open the four quick release fasteners Note Cover air duct at air conditioner housing with clean cloth to pre vent anything falling in Remove bolts arrows for cowl panel trim 1 on both sides Caution To avoid cracking the cowl panel trim during removal apply a small amount of soap solution to the joint between the wind screen and the cowl panel trim and pull the trim vertic...

Page 25: ...ectrical wires remain connected To remove turn air quality sensor G238 approx 90 anti clockwise arrow and remove from retainer Release retaining clips 1 4 Open electronics box plenum chamber cover slightly and pull off to front Disconnect the electrical multi pin connectors arrows using spark plug connector pliers V A G 1922 Detach engine wiring harness at electronics box and at bulk head Place en...

Page 26: ...ective cover above main fuse holder Fold cover 2 to side Remove nut 4 Detach terminal 30 wire to starter Note Disregard items 1 and 3 Unscrew wiring clamp 1 in wheel housing front right Pull wiring harness out from interior arrow Unplug electrical connector 2 Unbolt earth cable 1 at longitudinal member Unbolt bracket for wiring harness from longitudinal member arrows Move electrical wiring harness...

Page 27: ...e pipes and hoses are not stretched kinked or bent Remove bolts 1 and 2 Detach refrigerant lines from AC compressor Seal off open pipes lines and connections with clean plugs from engine bung set VAS 6122 Remove bolts arrows at bracket for air conditioner reservoir Note The air conditioner reservoir remains installed Note Lay a cloth under the separating point to catch escaping hydraulic fluid Dis...

Page 28: ...nscrew bolts left and right arrows evenly Take out anti roll bar Fit eye head bolt 3368 from below in bore on suspension turret on both sides Secure eye head bolts 3368 with nut 2 and washer 1 screw down nut several turns but not all the way down Tie up wheel bearing housing on each side using tensioning strap T10038 as illustrated Caution To prevent damage to the joints on the upper links the wei...

Page 29: ...k must not be allowed to hang down without support Tie up both links to wheel bearing housing as illustrated arrows Repeat procedure on other side of vehicle Unbolt drive shaft from flange shaft on gearbox Caution Take care not to damage brake hose Pivot wheel bearing housing outwards and remove drive shaft Repeat procedure on other side of vehicle Unbolt cross piece front arrows Note To avoid any...

Page 30: ...ollows Set up scissor type assembly platform VAS 6131 A with support set for Audi VAS 6131 10 as follows Platform coordinates Parts from support set for Audi VAS 6131 10 B3 10 1 10 4 10 5 10 11 G3 10 1 10 4 10 5 10 11 B6 10 1 10 3 10 5 10 7 G6 10 1 10 3 10 5 10 7 B10 10 1 10 2 10 5 10 8 G10 10 1 10 2 10 5 10 8 D16 10 1 10 2 10 5 10 12 Initially tighten the support elements on the assembly platform...

Page 31: ...ove bracket for electrical connectors 1 and 2 for Lamb da probes from tunnel cross member arrows Note The electrical connectors remain attached Position support element from VAS 6131 10 at rear of gear box as shown in the illustration Turn all spindles for the support elements upwards until all lo cating lugs make contact with the mounting points When all support elements make contact raise assemb...

Page 32: ...e and body have been detached Carefully guide out engine gearbox assembly with subframe from engine compartment when lowering to avoid damage Lower the engine gearbox assembly using scissor type as sembly platform VAS 6131 A initially only as far as distance a Dimension a approx 300 mm Push ball socket 2 of selector lever cable off gearbox selector lever using removal lever 80 200 Unclip retaining...

Page 33: ...mbly removed and secured to scissor type assembly platform VAS 6131 A Remove bracket for electrical connectors 1 4 for Lambda probes from subframe arrow Detach electrical connectors from bracket and unplug con nectors Take electrical connectors 1 and 2 for Lambda probes out of bracket and unplug connectors Note Disregard arrows Remove bolts 2 and 3 Pull the guide tube for oil dipstick out upwards ...

Page 34: ...y AUDI AG Unscrew bolt arrow at bracket for exhaust pipes left side Unscrew nuts arrows Unscrew nuts in the sequence 9 1 and remove front left exhaust manifold with catalytic converter Unplug electrical connectors 1 and 2 for Lambda probes Note Illustration shows electrical connectors in their installation posi tion Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics ...

Page 35: ... AG Unscrew nuts in the sequence 6 1 and remove rear left exhaust manifold with catalytic converter Unscrew bolts arrows and remove mounting for torque re action support Unscrew bolts 1 5 and remove bracket for torque reaction support Remove bolts 2 and 3 Loosen hose clips 1 4 5 and detach coolant pipe right side from coolant hoses Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 ...

Page 36: ...ument Copyright by AUDI AG Unscrew bolt arrow at bracket for exhaust pipes right side Unscrew nuts arrows Unscrew nuts in the sequence 9 1 and remove front right exhaust manifold with catalytic converter Unscrew nuts in the sequence 6 1 and remove rear right exhaust manifold with catalytic converter Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 10 2013 3...

Page 37: ...S 6131 A Remove bolts arrows for front gearbox mountings left and right Screw down spindles of support elements 2 left and right at subframe as far as possible Remove locating lugs from spindles Unscrew the two base plates for support elements for sub frame on scissor type assembly platform VAS 6131 A Take out subframe 3 from the side Screw down spindles of support elements 1 left and right at eng...

Page 38: ...tform coordinates Parts from support set for Audi VAS 6131 10 B3 1 10 1 10 4 10 5 10 11 G3 1 10 1 10 4 10 5 10 11 C7 10 1 10 4 10 5 10 12 F7 10 1 10 4 10 5 10 12 B11 10 1 10 4 10 5 10 12 G11 10 1 10 3 10 5 10 13 G15 1 10 1 10 4 10 5 10 10 D16 1 10 1 10 2 10 5 10 12 1 Support elements remain unchanged Position support elements from VAS 6131 10 at left of en gine gearbox assembly as shown in illustr...

Page 39: ...w Touch gearbox housing with your hand without wearing gloves to eliminate static charge Caution Before touching mechatronic unit discharge static by touching earthed component e g touch gearbox hous ing Do NOT touch connector contacts in 16 pin connector with your hands as static discharge might damage the control unit and the mechatronic unit irreparably Turn retainer catch anti clockwise arrow ...

Page 40: ...e speed sender G28 Move wiring clear Unbolt bracket for wiring from engine support right side arrow Unbolt earth cable 4 at starter Detach electrical wiring 2 and 3 at starter Remove bolts 1 and 5 and detach starter Insert guide pin of adapter T40058 as follows The smaller diameter section arrow 1 faces the engine The larger diameter section arrow 2 faces the adapter Audi A8 2003 10 cylinder direc...

Page 41: ...al direction of rotation arrow Unscrew 6 bolts arrows for torque converter working through opening of removed starter turn crankshaft 1 3 turn in direction of engine rotation each time Remove engine gearbox securing bolts 3 7 Note Disregard item A Loosen clamping bolts 1 on sides of scissor type assembly platform VAS 6131 A and pull rear section of platform to gether with gearbox towards the rear ...

Page 42: ... and gearbox support Special tools and workshop equipment required Lifting tackle 3033 Engine and gearbox sup port VAS 6095 with bracket VAS 6095 1 7 Workshop hoist VAS 6100 Lift arm extension work shop hoist VAS 6101 Procedure Unplug electrical connector arrow at engine mounting left side Remove bolts 1 4 and detach engine support with engine mounting Audi A8 2003 10 cylinder direct petrol inject...

Page 43: ...h engine support with engine mounting Attach the lifting tackle 3033 to engine lifting eyes and work shop hoist VAS 6100 with lift arm extension workshop hoist VAS 6101 as shown in the illustration Lift engine off the support elements on scissor type assembly platform VAS 6131 A Using bracket VAS 6095 1 7 secure engine to engine and gearbox support VAS 6095 as shown in the illustration Tightening ...

Page 44: ...ith the correct type of hose clips same as original equipment Electronic parts catalogue Fit all heat shields and heat insulation sleeves in the original positions when installing Fit all cable ties in the original positions when installing Install engine supports left and right page 45 Check whether dowel sleeves A for centring engine and gearbox are fitted in cylinder block install missing dowel...

Page 45: ...ghtly greased oiled phosphated or black finished nuts and bolts Additional lubricants such as engine or gearbox oil may be used but do not use lubricants containing graphite Do not use degreased parts Tolerance for tightening torques 15 Securing engine to gearbox Item Bolt Nm 1 M10x40 45 2 M10x135 1 65 3 M12x105 65 4 5 M12x100 65 6 8 9 10 11 M12x75 65 7 M12x155 65 A Dowel sleeves for centralising ...

Page 46: ...rt elements right side at scis sor type assembly platform VAS 6131 A Note The mounting points for engine front and gearbox rear remain unchanged Set up scissor type assembly platform VAS 6131 A with support set for Audi VAS 6131 10 as follows Platform coordinates Parts from support set for Audi VAS 6131 10 B3 1 10 1 10 4 10 5 10 11 G3 1 10 1 10 4 10 5 10 11 B6 10 1 10 3 10 5 10 7 C6 10 1 10 3 10 5...

Page 47: ...t wiring harness and coolant hoses to engine gearbox as sembly Install heat shield for drive shaft left side Install exhaust pipes left side page 230 Install exhaust pipes right side page 233 Install coolant pipe left side page 207 Install coolant pipe right side page 211 Carefully guide engine gearbox assembly together with sub frame into the body from below using scissor type assembly platform V...

Page 48: ...e according to the markings previously made on the longitudinal members Tighten subframe bolts only to specified torque do not turn further Do not tighten bolts to final setting until after wheel alignment check has been performed Rep gr 40 WARNING The vehicle must not be driven at this stage Tighten bolts 4 securing engine cross member page 45 Audi A8 2003 10 cylinder direct petrol injection engi...

Page 49: ...ll mounting for torque reaction support and adjust page 50 Electrical connections and routing Current flow diagrams Electrical fault finding and Fitting locations Observe notes on procedures required after connecting bat tery Electrical system Rep gr 92 Install and adjust wiper arms Electrical system Rep gr 92 Caution Do not use a battery charger to boost starting There is danger of damaging the v...

Page 50: ...ter performing wheel alignment check Tightening torques Note Tightening torques apply only to lightly greased oiled phosphated or black finished nuts and bolts Additional lubricants such as engine or gearbox oil may be used but do not use lubricants containing graphite Do not use degreased parts Tolerance for tightening torques 15 Component Nm Bolts nuts M6 9 M8 20 M10 40 M12 65 Audi A8 2003 10 cy...

Page 51: ...pport 6 40 Nm 7 40 Nm 8 23 Nm 9 68 Nm 10 Engine cross member 11 Engine mounting right side With right electrohy draulic engine mounting solenoid valve N145 Removing and installing page 46 12 42 Nm 13 Engine support right side Version fitted in vehicle may differ from illustra tion Removing and installing page 46 14 40 Nm 15 40 Nm 16 42 Nm 17 Engine support left side Version fitted in vehicle may d...

Page 52: ...ion in this document Copyright by AUDI AG 19 68 Nm 20 23 Nm 21 Bolt M8 23 Nm M10 40 Nm 5 2 Removing and installing engine mount ing left and right Special tools and workshop equipment required Support bracket 10 222 A Adapters 10 222 A 21 Engine support bracket supplementary set T40093 Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 10 2013 46 Rep gr 10 Re...

Page 53: ... Copyright by AUDI AG Removing Note Fit all cable ties in the original positions when installing Pull off engine cover panel rear 2 arrows Remove cover above coolant expansion tank arrows Pull off rubber seal 1 and remove plenum chamber covers 2 and 3 Unbolt bracket left side for refrigerant line from suspension turret arrow Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve m...

Page 54: ...d for left and right side of vehicle The centre support point 2 of the adapters is located on front bolts for cross piece for suspension strut The adapters are attached by means of the rear securing bolts 3 for the cross piece for suspension strut The knurled screw 1 must be screwed down until support plate rests on suspension turret Secure spindles of support bracket 10 222 A to rear engine lifti...

Page 55: ... take off noise insulation panels Unscrew bolts 2 on retaining clamps left and right for anti roll bar and move anti roll bar 1 downwards Remove bolts 1 2 3 on left and right and detach engine cross member Engine mounting left side Unplug electrical connector arrow on left electrohydraulic engine mounting solenoid valve N144 Remove bolts 1 4 and detach engine support with engine mounting Audi A8 2...

Page 56: ...gine support Installing Installation is carried out in the reverse order note the following Install subframe Rep gr 40 Install anti roll bar Rep gr 40 Tightening torques 5 1 Assembly mountings exploded view page 45 5 3 Removing installing and adjusting mounting for torque reaction support Special tools and workshop equipment required Electric drill Stepped centre bit 24 mm Removing Open quick rele...

Page 57: ... hose Rest of world vehicles Detach crankcase breather hose 3 from air hose Remove air hose 4 from intake manifold USA models Open hose clips and move air hose 4 to one side Caution Do not open hose connection 3 on USA models All vehicles Unscrew bolts arrows and remove top section of air cleaner right side Disconnect both vacuum hoses 1 Remove air duct 2 Remove bolts arrows Turn over bottom secti...

Page 58: ...ier front right Remove bolts arrows Detach air duct from lock carrier rear right Mark out drilling on lock carrier as illustrated according to di mensions a and b Distance a 40 mm Distance b 55 mm Drill a hole of 24 mm dia Note Drill a pilot hole and then drill out to 24 mm dia using the stepped centre bit Remove bolts 1 and 2 on bracket for torque reaction sup port Slacken bolt 3 a few turns Audi...

Page 59: ...his document Copyright by AUDI AG Remove bolt arrow on mounting for torque reaction support Unscrew bolts arrows and remove mounting for torque re action support Installing Turn adjuster ring 1 on mounting for torque reaction support clockwise to stop Tighten bolts 1 and 3 for bracket for torque reaction support Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edit...

Page 60: ...ort Then turn adjuster ring one turn clockwise Tighten bolt arrow on mounting for torque reaction support Installation is carried out in the reverse order note the following Install headlight Electrical system Rep gr 94 Install bumper cover front Rep gr 63 Install air cleaner housing Rep gr 24 Fit front wheels Rep gr 44 Check headlight adjustment Maintenance Booklet 404 Tightening torques 5 1 Asse...

Page 61: ...t for alternator 9 9 Nm 10 Bracket for idler roller 11 Vibration damper Removing and installing page 59 12 Bolt Renew Only use genuine bolts same as original equip ment property class 12 9 Apply locking fluid when installing non self lock ing bolts for locking flu id refer to Electronic parts catalogue Tightening torque and sequence page 56 13 Idler roller for poly V belt 14 22 Nm 15 Cap 16 Poly V...

Page 62: ...equence Note Renew the bolts tightened with specified tightening angle Tighten bolts in 4 stages as follows Stage Bolts Tightening torque angle specification 1 arrow 15 Nm in diagonal sequence 2 arrow 22 Nm in diagonal sequence 3 arrow Turn 90 further in diagonal sequence 4 arrow Turn 90 further in diagonal sequence 1 2 Removing and installing poly V belt Special tools and workshop equipment requi...

Page 63: ...is document Copyright by AUDI AG Removing Pull off engine cover panel front 1 arrows Pull bonnet seal away from lock carrier and wing panels Detach vacuum hoses 1 and 2 and move clear Vehicles with auxiliary heater remove bolts arrows securing exhaust pipe for auxiliary additional heater to noise insulation Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 1...

Page 64: ...poly V belt with chalk or felt tip pen If the belt runs in the opposite direction when it is refitted this can cause breakage Unscrew tensioning bolt arrow and remove poly V belt Installing Installation is carried out in the reverse order note the following Fit poly V belt 2 onto pulleys in the following sequence 1 Alternator 3 Idler roller 4 Vibration damper 5 Tensioning roller Note When installi...

Page 65: ...lacken off 8 bolts arrow on vibration damper several turns counterhold with ring spanner on centre nut for alternator pul ley Note Before removing mark direction of rotation of poly V belt with chalk or felt tip pen If the belt runs in the opposite direction when it is refitted this can cause breakage Unscrew tensioning bolt arrow and remove poly V belt Remove vibration damper Installing Installat...

Page 66: ...nt Copyright by AUDI AG Tighten bolts for vibration damper page 56 Install poly V belt page 56 Install radiator cowl page 220 Install radiator page 214 Fill cooling system page 190 1 4 Renewing crankshaft oil seal pulley end Special tools and workshop equipment required Oil seal extractor T40019 Assembly tool T40048 Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics ...

Page 67: ...head of oil seal extractor place it in posi tion and screw it into oil seal as far as possible applying firm pressure Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out Clamp flats of oil seal extractor in vice Remove oil seal with pliers Clean running surface and sealing surface Fit assembly aid T40048 1 onto assembly sleeve T40048 2 and slide oil seal 1 ...

Page 68: ...ft using two M8 55 mm bolts arrows Screw in bolts hand tight to start with Tighten bolts alternately 1 2 turn at a time to press in oil seal onto stop Remaining installation steps are carried out in reverse sequence note the following Install vibration damper page 59 Install poly V belt page 56 Install radiator cowl page 220 Install radiator page 214 Fill cooling system page 190 Audi A8 2003 10 cy...

Page 69: ...k installation posi tion for re installation 2 Washer 3 4 mm thick Mark installation posi tion for re installation 3 60 Nm turn 90 further Renew 4 Crankshaft 5 Centring sleeve For torque converter Check whether fitted 6 Crankshaft oil seal gearbox end Renewing page 64 7 Spacer 1 5 mm thick Mark installation posi tion for re installation 2 2 Removing and installing drive plate Special tools and wor...

Page 70: ...der to loosen bolts Mark installation position of drive plate on crankshaft with a felt tip pen Unbolt drive plate Take out shim located behind Installing Installation is carried out in the reverse order note the following Install drive plate with shim Use new securing bolts Reverse position of counterhold tool 10 201 in order to tighten bolts Tightening torques 2 1 Drive plate exploded view page ...

Page 71: ...36 Remove drive plate page 63 Pry out oil seal using extractor tool T20143 2 Clean running surface and sealing surface Fit assembly aid T10122 1 onto assembly sleeve T10122 2 and slide oil seal A onto assembly sleeve Take off assembly aid Fit assembly sleeve T10122 2 with oil seal 1 onto crank shaft Press in oil seal with thrust sleeve T10122 3 evenly so that it is flush all round Remaining instal...

Page 72: ...ets Renew 3 Oil seal for crankshaft pul ley end Renewing page 60 4 Dowel sleeve 3x Insert in retaining frame Installation position page 68 5 9 Nm 6 Guide tube for oil dipstick 7 O ring Renew 8 Bolts For retaining frame Renew Use old bolts when measuring radial clear ance Different bolt lengths Tightening sequence page 68 9 Baffle plate 10 Bolt Tightening torque and sequence page 67 11 Bolt For sea...

Page 73: ...rame with the correct colour coding for new crankshafts page 69 for used and machined crankshafts page 70 15 Crankshaft Measuring axial clearance page 71 Measuring radial clearance page 72 Crankshaft dimensions page 71 16 Thrust washer Only fitted on 4th crankshaft bearing Oil groove faces outwards Measuring axial clearance of crankshaft page 71 17 Bearing shell For cylinder block with oil groove ...

Page 74: ...Width of beads of sealant 2 0 mm Fit gaskets 1 4 Fitting location of dowel sleeves Check that dowel sleeves arrows are inserted in retaining frame at positions shown in illustration Installing retaining frame Note Renew the bolts tightened with specified tightening angle Tighten bolts in 5 stages in the sequence shown Stage Bolts Tightening torque tightening angle 1 1 12 30 Nm 2 13 24 20 Nm 3 1 12...

Page 75: ...dicated by letters on the front left of the cylinder block legible from outside as shown in illustration Letter on cylinder block Colour coding of bearing R Red G Yellow B Blue Note The code letters are also stamped on the retaining frame Allocation of crankshaft bearing shells for retaining frame ver sion I Bearing shells of the correct thickness are matched to the bearings in the retaining frame...

Page 76: ...g to the colour codes stamped on the cylinder block On a used or machined crankshaft the main bearing journals must be measured in order to allocate the correct bearing shells Basic dimension for main bearing journal 65 00 mm Repair undersize for main bearing journal 64 75 mm There are oversized thicker bearing shells available for ma chined crankshafts These bearing shells have the same col oured...

Page 77: ...ing dimen sion Crankshaft bearing journal mm Crankshaft conrod journal mm Basic dimen sion 65 000 0 022 0 042 54 000 0 022 0 042 Repair under size 64 750 0 022 0 042 53 750 0 022 0 042 3 5 Measuring axial clearance of crankshaft Special tools and workshop equipment required Universal dial gauge bracket VW 387 Dial gauge VAS 6079 Procedure Secure dial gauge VAS 6079 with universal dial gauge bracke...

Page 78: ...d clean bearing journals Place Plastigage onto bearing journal or into bearing shells length of Plastigage should correspond to width of bearing The Plastigage must be positioned in the centre of the bearing shell Fit retaining frame and secure with old bolts page 68 without rotating crankshaft Remove retaining frame once more Compare width of Plastigage with measurement scale Radial clearance New...

Page 79: ... pairs page 75 3 Bearing shells Ensure that retaining lugs are securely seat ed Renew used bearing shells There are oversized bearings available for machined crankshaft conrod journals Elec tronic parts catalogue 4 Conrod Only renew as a com plete set Mark cylinder allocation in colour page 75 Installation position of conrod pairs page 75 Axial clearance for each conrod pair when new 0 20 0 38 mm ...

Page 80: ...cylinder opening approx 15 mm from bottom of cylinder Use a piston without piston rings to push in the ring Piston ring new mm Wear limit mm 1st compression ring 0 20 0 35 0 80 2nd compression ring 0 20 0 40 0 80 Oil scraper ring 0 20 0 40 1 1 Specification not yet available Measuring ring to groove clearance Clean groove in piston before checking clearance Piston ring new mm Wear limit mm 1st com...

Page 81: ...pistons Mark cylinder allocation in colour on piston crown Note Do not use a centre punch or scriber as this would damage the coating of the piston crown Installation position Arrows on piston crowns point to pulley end Large valve recesses 1 point to centre of engine Marking conrods Note Only renew conrods as a complete set Do not interchange conrod bearings Prior to removal use a coloured pen to...

Page 82: ...inder bore mm Piston mm 84 510 0 005 84 490 1 84 610 0 005 84 590 1 1 Dimensions including coating thickness 0 01 mm The coating will wear down in service 4 3 Measuring radial clearance of conrods Special tools and workshop equipment required Plastigage Procedure Remove conrod bearing caps Clean bearing caps and bearing journals Place Plastigage onto bearing journal or into bearing shells correspo...

Page 83: ... page 64 3 Dowel sleeve 2x 4 Cylinder head gasket left side 5 Bolt Tightening torque and sequence page 78 6 Timing chain cover left side Removing and installing page 78 7 O ring Renew 8 Intermediate coolant pipe left side Use suitable drift to drive out 9 O ring Renew 10 Bolt Tightening torque and sequence page 78 11 Timing chain cover right side Removing and installing page 78 12 O ring Renew 13 ...

Page 84: ...que and sequence Tighten bolts in 2 stages in the sequence shown Stage Bolts Tightening torque 1 1 8 Screw in by hand until contact is made 2 1 8 9 Nm Timing chain cover bottom tightening torque and sequence Note Renew the bolts tightened with specified tightening angle Tighten bolts for timing chain cover bottom in 6 stages as follows Stage Bolts Tightening torque angle specification 1 arrows 5 N...

Page 85: ...ssor type assembly platform VAS 6131 A with gearbox attached Note Fit all heat shields and heat insulation sleeves in the original positions when installing All cable ties which are released or cut open when removing must be fitted in the same position when installing Remove bolts 2 and 3 Pull the guide tube for oil dipstick out upwards arrow Loosen hose clips 1 and 4 and detach coolant pipe left ...

Page 86: ...in cover left side from bonded joint Remove bolts 1 8 and carefully release timing chain cover right side from bonded joint Installing Note Renew O rings Secure all hose connections with the correct type of hose clips same as original equipment Electronic parts catalogue Fit all heat shields and heat insulation sleeves in the original positions when installing Fit all cable ties in the original po...

Page 87: ...pe 2 Fit intermediate coolant pipe in timing chain cover Apply bead of sealant arrow onto clean sealing surfaces of timing chain cover as shown in illustration Width of sealant bead 2 5 mm Note The timing chain covers must be installed within 5 minutes after applying sealant Fit timing chain cover and tighten bolts Timing chain cover left side page 78 Timing chain cover right side page 78 Remainin...

Page 88: ...atalogue Removing Engine separated from gearbox page 27 engine attached to scissor type assembly platform VAS 6131 A or secured to engine and gearbox support page 36 Engine oil drained Maintenance Booklet 404 Remove drive plate page 63 Remove timing chain covers left and right page 78 Remove intake manifold Rep gr 24 Remove oil filter housing page 177 Remove bolts arrows Remove bolts 1 13 and rele...

Page 89: ...leeve on cylinder block in such a way that the bev elled side points upwards Note Bevelling the dowel sleeve makes it easier to fit the timing chain cover bottom with the cylinder head installed WARNING Wear safety goggles Remove remaining sealant on timing chain cover and cylinder block cylinder head using rotating plastic brush or similar Caution Make sure that no sealant residue gets into the e...

Page 90: ...ylinder head gaskets top and bottom they must be free of oil and grease Note Note the use by date of the sealant Cut off tube nozzle at front marking diameter of nozzle ap prox 2 mm Clean holes arrow in cylinder head gaskets and fill them with sealant Caution The cylinder head gasket must not to be bent more than a small amount If the cylinder head gasket has been bent and kinked it must be renewe...

Page 91: ...on Take care not to damage the cylinder head gaskets when fitting the cover If the cylinder head gasket has been damaged it must be renewed Tighten bolts for timing chain cover bottom page 78 Remaining installation steps are carried out in reverse sequence note the following Install crankshaft oil seal gearbox end page 64 Install oil filter housing page 177 Install intake manifold Rep gr 24 Instal...

Page 92: ...0 4 Camshaft adjuster for inlet camshaft Identification Intake Removing and installing 1 5 Removing timing chain from camshafts page 89 5 Camshaft timing chain left side Before removing mark running direction with paint If a used chain ro tates in the opposite di rection when it is refit ted this can cause breakage Removing from camshafts page 89 Removing and installing page 96 6 5 Nm turn 90 furt...

Page 93: ...n Exhaust Removing and installing 1 5 Removing timing chain from camshafts page 89 4 Bolt for camshaft Renew Pre tightening torque 60 Nm Final tightening torque 80 Nm 90 5 Bolt for camshaft Renew Pre tightening torque 60 Nm Final tightening torque 80 Nm 90 6 Camshaft adjuster for inlet camshaft Identification Intake Removing and installing 1 5 Removing timing chain from camshafts page 89 7 Camshaf...

Page 94: ... onto chain tensioner 12 5 Nm turn 90 further Renew 13 Thrust washer for drive sprocket 14 Drive sprocket for camshaft timing chain right side Installation position bearing mounting for drive sprocket for cam shaft timing chain right side Dowel pins in bearing mounting 3 for drive sprocket for cam shaft timing chain right side must engage in drillings in thrust washer 1 and in cylinder block drill...

Page 95: ... AG 1 5 Removing timing chain from camshafts Special tools and workshop equipment required Locking pin 3242 Torque wrench V A G 1332 Open ring spanner insert V A G 1332 9 Adapter T40058 Camshaft clamp T40070 2x Locking pin T40071 2x Key T40079 Removing Engine removed and in position on scissor type assembly platform VAS 6131 A with gearbox attached Audi A8 2003 10 cylinder direct petrol injection ...

Page 96: ...ve cylinder head cover left side page 120 right side page 123 Remove timing chain covers left and right page 78 Insert guide pin of adapter T40058 as follows The smaller diameter section arrow 1 faces the engine The larger diameter section arrow 2 faces the adapter Using adapter T40058 turn the crankshaft in the normal di rection of rotation arrow to TDC The threaded holes arrows in the camshafts ...

Page 97: ...olts remain free Unscrew plug arrow from sump top section Screw locking pin 3242 into bore or groove in crankshaft tightening torque 20 Nm if necessary turn crankshaft back wards and forwards slightly to fully centralise locking pin Press guide rail of chain tensioner for camshaft timing chain left side inwards as far as the stop using a screwdriver 1 Then lock chain tensioner by inserting locking...

Page 98: ...Risk of irreparable damage to engine Block off the opening in the valve timing housing with a clean cloth to prevent small items from dropping into the engine Unscrew bolts 1 and 2 at cylinder head left side and re move both camshaft adjusters Mark positions of camshaft adjusters with paint for re installa tion Unscrew bolts 1 and 2 at cylinder head right side and re move both camshaft adjusters I...

Page 99: ...ve locking pin T40071 Note Re install camshaft adjuster right side in the same position as before pay attention to marks applied when removing Renew the camshaft bolts Position camshaft timing chain on drive chain sprocket and camshaft adjusters and loosely screw in bolts 1 and 2 It should just be possible to turn both camshaft adjusters on the camshaft without axial movement Remove locking pin T4...

Page 100: ...let camshaft 60 Nm 1 2 On exhaust camshaft 60 Nm Detach key T40079 Remove camshaft clamp T40070 from both cylinder heads arrows Tighten camshaft adjuster bolts on cylinder head left side as follows Stage Bolt Tightening torque 2 1 Tighten on exhaust camshaft to final tightening torque Item 2 page 86 2 2 Tighten on inlet camshaft to final tight ening torque Item 3 page 86 Tighten camshaft adjuster ...

Page 101: ...rotations in nor mal direction of rotation arrow until crankshaft is at TDC again Note If you turned the crankshaft beyond TDC turn it back approx 30 and set to TDC again The threaded holes arrows in the camshafts must face up wards Fit camshaft clamps T40070 to both cylinder heads and tighten bolts arrows to 25 Nm The camshaft clamp T40070 is positioned correctly if the holes for the cylinder hea...

Page 102: ...aft tim ing chains Removing Engine separated from gearbox page 27 engine attached to scissor type assembly platform VAS 6131 A or secured to engine and gearbox support page 36 Engine oil drained Maintenance Booklet 404 Remove drive plate page 63 Remove cylinder head cover left side page 120 right side page 123 Remove timing chain covers left and right page 78 Remove intake manifold Rep gr 24 Remov...

Page 103: ...new bolts which are tightened to a specified angle as well as seal Caution Avoid damage to valves and piston crowns The crankshaft must not be at TDC at any cylinder when the camshafts are turned Press guide rails of chain tensioners for camshaft timing chains left and right inwards in direction of arrow as far as stop Then lock chain tensioners by inserting locking pin T40071 If necessary clean o...

Page 104: ...ll timing chain covers left and right page 80 Install cylinder head cover left side page 120 right side page 123 Install drive plate page 63 After installing engine fill up with engine oil and check oil level Maintenance Booklet 404 Tightening torques 1 4 Camshaft timing chain exploded view page 85 1 7 Removing and installing chain tensioner for camshaft timing chain Removing Remove camshaft timin...

Page 105: ...new bolts which are tightened to a specified angle as well as seal Caution Avoid damage to valves and piston crowns The crankshaft must not be at TDC at any cylinder when the camshafts are turned Press guide rails of chain tensioners for camshaft timing chains left and right inwards in direction of arrow as far as stop Then lock chain tensioners by inserting locking pin T40071 If necessary clean o...

Page 106: ...Camshaft timing chain exploded view page 85 1 8 Drive chain for valve gear exploded view 1 Guide rail 2 17 Nm turn 90 further Renew 3 22 Nm 4 Thrust washer for drive sprocket 5 Drive sprocket for timing chain left side 6 17 Nm turn 90 further Renew 7 Drive chain for valve gear Before removing mark running direction with paint If a used drive chain rotates in the op posite direction when it is refi...

Page 107: ...n bearing mounting 3 for drive sprocket for cam shaft timing chain right side must engage in drillings in thrust washer 1 and in cylinder block drillings 2 Drive sprocket for camshaft timing chain right side 4 Bolt 42 Nm 1 9 Removing and installing drive chain for valve gear Special tools and workshop equipment required Locking pin T40071 Removing Engine separated from gearbox page 27 engine attac...

Page 108: ... for valve gear Installing Installation is carried out in the reverse order note the following Note Renew the bolts tightened with specified tightening angle Position drive chain for valve gear onto drive chain sprockets according to marks applied when removing Install guide rail and tighten bolts 1 Install chain tensioner and tighten bolts 2 Push guide rail of chain tensioner for drive chain in d...

Page 109: ... balance shaft 7 Bearing cap 8 Balance shaft Removing and installing page 116 9 Bolt Tightening torque Item 2 page 116 10 Drive chain for auxiliary drives Before removing mark running direction with paint If a used drive chain rotates in the op posite direction when it is refitted this can cause breakage Removing and installing page 103 11 Crankshaft 12 Drive chain sprocket for auxiliary drives 13...

Page 110: ...n in this document Copyright by AUDI AG Adapter T40058 Locking pin T40071 Setting tool T40128 Removing Engine separated from gearbox page 27 engine attached to scissor type assembly platform VAS 6131 A or secured to engine and gearbox support page 36 Engine oil drained Maintenance Booklet 404 Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 10 2013 104 Rep ...

Page 111: ...apter T40058 turn the crankshaft in the normal di rection of rotation arrow to TDC Unscrew plug arrow from sump top section Screw locking pin 3242 into bore or groove in crankshaft tightening torque 20 Nm if necessary turn crankshaft back wards and forwards slightly to fully centralise locking pin Remove vibration damper page 59 Remove drive plate page 63 Remove timing chain covers left and right ...

Page 112: ...emove chain sprocket for balance shaft Unscrew bolts 2 3 4 and remove chain tensioner Remove drive chain for auxiliary drives Installing Installation is carried out in the reverse order note the following Note Renew bolts which are tightened to a specified angle as well as seals gasket and O rings Crankshaft 1 locked in TDC position with locking pin 3242 Remove bolts 2 and 4 Remove cover for balan...

Page 113: ...ten bolts 2 and 4 on cover for balance shaft Remaining installation steps are carried out in reverse sequence note the following Install timing chain cover bottom page 82 Install crankshaft oil seal gearbox end page 64 Install oil filter housing page 177 Install intake manifold Rep gr 24 Install timing chain covers left and right page 80 Install drive plate page 63 Install vibration damper page 59...

Page 114: ...inal equipment Electronic parts cata logue 7 Drive shaft for air condition er compressor Tighten to 60 Nm 8 O ring Renew 9 Power steering pump 10 Flat section O ring Renew if damaged Installation position in power steering pump drive page 108 11 Oil pump drive shaft 12 Oil seal for power steering pump drive Renewing page 110 13 Compression spring Only up to engine number BSM 006 225 Installation p...

Page 115: ... with drive shaft for air conditioner compressor from stub shaft of spur gear for air conditioner compressor drive Screw spindle of oil seal extractor T40195 all the way out Lubricate threaded head of oil seal extractor place it in posi tion and screw it into oil seal as far as possible applying firm pressure Turn inner part of oil seal extractor against spur gear drive until the oil seal is pulle...

Page 116: ...2 Note Secure with correct type of hose clip same as original equipment Electronic parts catalogue Press dust cap arrow with hose clip fitted onto stub shaft of spur gear for air conditioner compressor drive and secure Install air conditioner compressor Rep gr 87 1 14 Renewing oil seal for power steering pump drive Special tools and workshop equipment required Thrust piece T40193 Oil seal extracto...

Page 117: ...actor again and pull out remaining part of oil seal Clamp hexagon flats of oil seal extractor in vice and use pliers to remove oil seal Clean contact surface and sealing surface Drive oil seal for power steering pump drive in onto stop with thrust piece T40193 Install power steering pump Rep gr 48 1 15 Removing and installing spur gear drive Special tools and workshop equipment required Sealant El...

Page 118: ... AG Remove hose clip on dust cap arrow for air conditioner com pressor drive Remove drive chain for auxiliary drives page 103 Remove bolts 1 6 Release spur gear drive from bonded joint Up to engine number BSM 006 225 Remove spring 2 be tween spur gear drive 1 and drive shaft 3 for oil pump Remove drive shaft arrow for oil pump Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve...

Page 119: ...ee of oil and grease Insert drive shaft arrow for oil pump into guide sleeve at oil pump Note To ensure that drive shaft engages correctly in oil pump insert drive shaft separately into oil pump NOT together with spur gear drive Note Note the use by date of the sealant Cut off tube nozzle at front marking diameter of nozzle ap prox 1 5 mm Apply beads of sealant arrows onto clean sealing surfaces o...

Page 120: ...ft 3 in spur gear drive 1 Note Secure with correct type of hose clip same as original equipment Electronic parts catalogue The new hose clip 1 must be guided through the hole in the retaining frame and over the dust cap 3 onto the air condi tioner compressor drive shaft 2 while the spur gear drive is still removed Fit spur gear drive and tighten bolts 1 6 in diagonal se quence and in stages Audi A...

Page 121: ...o spur gear for power steering pump drive Remaining installation steps are carried out in reverse sequence note the following Install timing chain cover bottom page 82 Install crankshaft oil seal gearbox end page 64 Install oil filter housing page 177 Install intake manifold Rep gr 24 Install timing chain covers left and right page 80 Install drive plate page 63 After installing engine fill up wit...

Page 122: ... Renew 3 Bearing cover rear For balance shaft 4 Seals For bearing cover rear for balance shaft Renew 5 O rings Renew 6 Bearing cover front For balance shaft 7 5 Nm turn 90 further Renew 8 Cover For balance shaft 9 5 Nm 10 O ring Renew 1 17 Removing and installing balance shaft Removing Remove drive chain for auxiliary drives page 103 Unscrew bolts arrows and detach bearing cover rear for balance s...

Page 123: ...er note the following Note Renew seals and O rings Caution Take care not to damage the oil spray jets when inserting the balance shaft Carefully insert balance shaft into cylinder block Secure bearing cover rear for balance shaft arrows Insert balance shaft into bearing cover rear Install bearing cover front arrow for balance shaft Note The bolts securing bearing cover front for balance shaft are ...

Page 124: ...g page 125 Checking for distortion page 120 Machining limit page 120 If renewed change coolant and engine oil 3 Gasket for cylinder head cover Renew if damaged or leaking 4 Cylinder head cover Removing and instal ling left side page 120 right side page 123 5 Seal For filler cap Renew if damaged or leaking 6 Filler cap 7 Ignition coil Remove using puller T40039 8 Bolt Renew if seal is damaged Cylin...

Page 125: ...e Cylinder bank 1 right side exhaust camshaft control valve 1 N318 Cylinder bank left side exhaust camshaft control valve 2 N319 16 O ring Renew 17 Bolt Renew Note correct sequence when loosening page 128 Tightening torque and sequence page 120 Cylinder head cover left side tightening torque and sequence Tighten bolts in the sequence 1 16 to 9 Nm Cylinder head cover right side tightening torque an...

Page 126: ...m 2 1 12 60 Nm 3 1 12 Turn 90 further 4 1 12 Turn 90 further 5 Arrows A B 11 Nm 6 Arrows A Turn 90 further Checking cylinder head for distortion Use straight edge 500 mm VAS 6075 and feeler gauge to measure cylinder head for distortion at several points Max permissible distortion 0 1 mm Cylinder head machining limit Machining of the cylinder head surface grinding is only permis sible down to the m...

Page 127: ...f information in this document Copyright by AUDI AG Puller T40039 Removing Pull off engine cover panels at front 1 and at rear 2 arrows Detach electrical connector 2 for air mass meter 2 G246 Remove air hose 1 from intake manifold Unscrew bolts arrows and remove top section of air cleaner left side Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 10 2013 2 ...

Page 128: ... and detach vacuum hose for air flap Remove bottom section of air cleaner left side Detach crankcase breather hose from oil separator 6 and from cylinder head cover 5 Pull dipstick 3 out of guide tube Unplug electrical connectors 1 and 7 Remove bolts 2 and 4 Unplug electrical connectors for ignition coils Move wiring harness clear unbolt bracket for wiring harness Pull ignition coils out with pull...

Page 129: ...er if damaged or leaking Renew cylinder head cover bolts if gasket is damaged Clean sealing surfaces they must be free of oil and grease Tighten cylinder head cover bolts page 119 Install wiring guide for ignition coils Rep gr 28 Install air cleaner housing left side Rep gr 24 Tightening torques Fig Cylinder head cover left side tightening torque and sequence page 119 2 3 Removing and installing c...

Page 130: ... and move air hose 4 to one side Caution Do not open hose connection 3 on USA models All vehicles Unscrew bolts arrows and remove top section of air cleaner right side Remove front section of front right wheel housing liner Rep gr 66 Disconnect air hose arrow at bottom of bottom section of air cleaner right side Disconnect both vacuum hoses 1 Remove air duct 2 Remove bolts arrows Turn over bottom ...

Page 131: ... and remove bolts Remove cylinder head cover Installing Installation is carried out in the reverse order note the following Note Renew gasket for cylinder head cover if damaged or leaking Renew cylinder head cover bolts if gasket is damaged Clean sealing surfaces they must be free of oil and grease Tighten bolts for cylinder head cover page 119 Install wiring guide for ignition coils Rep gr 28 Ins...

Page 132: ...ed and in position on scissor type assembly platform VAS 6131 A with gearbox attached Note All cable ties which are released or cut open when removing must be fitted in the same position when installing The following description shows the removal and installation of the cylinder head left side The procedure for the other side is identical Remove exhaust pipes left side page 230 right side page 233...

Page 133: ... 89 Unscrew bolts 1 and 2 and remove chain tensioner left side Unplug electrical connectors arrows at injectors Unscrew high pressure pipe 2 at connection on fuel rail Unscrew high pressure pipe 1 at connection on fuel rail To do so counterhold at hexagon flats with an open end spanner and slacken union nut Note Do not attempt to bend high pressure pipes to a different shape Remove screw plug arro...

Page 134: ...will lead to leaks Cylinder heads which have cracks between the valve seats or between a valve seat insert and the spark plug thread can be re installed without reducing service life provided the cracks are only slight and do not exceed a maximum of 0 3 mm in width and no more than the first 4 turns of the spark plug threads are cracked When installing an exchange cylinder head with fitted cam sha...

Page 135: ...ads and tightened to 25 Nm arrows The locking pin 3242 must be screwed in Fit cylinder head gasket Pay attention to dowel sleeves arrows in cylinder block Note installation position of cylinder head gasket the word oben top or the part number should face towards the cyl inder head Fit cylinder head Insert new cylinder head bolts and tighten hand tight Tighten cylinder head bolts page 120 Note Cyli...

Page 136: ... chain tensioner for camshaft timing chain is locked with locking pin T40071 Note Note the correct installation position if the tensioning element has been removed from the chain tensioner drilling in base of housing faces chain tensioner and piston faces tensioner rail Disregard arrow If necessary clean oil strainer 2 of chain tensioner Fit new gasket 3 to rear of chain tensioner 1 Audi A8 2003 1...

Page 137: ...iming chains page 97 Install timing chain covers left and right page 80 Install cylinder head cover left side page 120 right side page 123 Install intake manifold and high pressure pipes Rep gr 24 Install connection for secondary air page 242 Install exhaust pipes left side page 230 right side page 233 After installing engine change engine oil Maintenance Booklet 404 Fill cooling system with fresh...

Page 138: ...ools and workshop equipment required Spark plug socket and ex tension 3122 B Compression tester V A G 1763 Puller T40039 Procedure Engine oil temperature at least 30 Battery voltage at least 12 5 V Switch off ignition Vehicles with auxiliary heater remove bolts arrows securing exhaust pipe for auxiliary additional heater to noise insulation Audi A8 2003 10 cylinder direct petrol injection engine 5...

Page 139: ...to the correctness of information in this document Copyright by AUDI AG Open quick release fasteners 1 and remove noise insulation front Unplug electrical connector at engine speed sender G28 arrow at bottom of gearbox Pull off engine cover panels at front 1 and at rear 2 arrows Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 10 2013 2 Cylinder head 133 ...

Page 140: ... to one side Rest of world vehicles Detach vacuum line 2 at air intake hose Disconnect hose 1 for crankcase breather system from air hose by pressing release tabs Open hose clips arrows and disconnect air intake hose USA models Detach vacuum line 2 from air hose Open hose clips arrows and move air intake hose to one side Caution Do not open hose connection 1 on USA models All vehicles Remove bolts...

Page 141: ...own the accelerator pedal com pletely and simultaneously operate the starter until the pres sure no longer increases on the tester display Repeat procedure on each cylinder Compression pressure bar When new 10 0 14 0 Wear limit 9 0 Difference between cylinders 3 0 maximum Assembling Installation is carried out in the reverse order note the following Install spark plugs Maintenance Booklet 404 Inst...

Page 142: ...st 2 rotations by hand to ensure that none of the valves make contact when the starter is operated 3 1 Valve gear exploded view Note The diagram shows the cylinder head on cylinder bank 2 left side 1 Sealing plugs Apply sealant when in stalling refer to Elec tronic parts catalogue for sealant 2 Valve stem oil seal Renewing cylinder head installed page 145 Renewing cylinder head removed page 149 3 ...

Page 143: ... retaining frame for camshafts refer to tightening torque and sequence page 144 13 9 Nm 14 Hall sender for inlet camshaft Cylinder bank 1 right side Hall sender G40 Cylinder bank 2 left side Hall sender 2 G163 15 O ring Renew 16 O ring Renew 17 Hall sender for exhaust camshaft Cylinder bank 1 right side Hall sender 3 G300 Cylinder bank 2 left side Hall sender 4 G301 18 9 Nm 19 Exhaust camshaft Rem...

Page 144: ... with specified tightening angle Caution Risk of damage to retaining frame for camshafts It is important to tighten the bolts securing the retaining frame as described below Tighten bolts in 4 stages in the sequence shown Stage Bolts Tightening torque angle specification 1 1 28 Screw in by hand until bolt heads make contact with retaining frame 2 1 28 Continue tightening 1 turn at a time in severa...

Page 145: ... dial gauge by hand Set dial gauge to 0 Press camshaft away from dial gauge and read off value Axial clearance 0 100 0 191 mm 3 3 Measuring radial clearance of cam shafts Special tools and workshop equipment required Plastigage Procedure Remove roller rocker fingers 3 4 Removing and installing camshafts page 140 Clean bearings and bearing journals Place a length of Plastigage corresponding to the ...

Page 146: ... bearing diameter 0 024 0 066 mm 36 mm bearing diameter 0 100 0 325 mm When carrying out final assembly renew bolts 3 4 Removing and installing camshafts Special tools and workshop equipment required Locking pin 3242 Impact extractor attachment T10133 3 from tool set for FSI engines T10133 Locating pins T40116 Electric drill with plastic brush attachment Safety goggles Sealant Electronic parts cat...

Page 147: ...form VAS 6131 A with gearbox attached Remove camshaft timing chains from camshafts page 89 Unscrew earth wire 1 from retaining frame Unplug electrical connectors 2 and 3 Remove high pressure pump Rep gr 24 Slacken retaining frame bolts in the sequence 28 1 Note Perform the same procedure laterally reversed on retaining frame right side Carefully release retaining frame from bonded joint and set it...

Page 148: ...ion with locking pin 3242 WARNING Wear safety goggles Caution Make sure that no sealant residue gets into the cylinder head or the bearings Remove sealant residue from cylinder head and retaining frame using a rotating plastic brush or similar Clean sealing surfaces they must be free of oil and grease Lubricate running surfaces of camshafts Insert camshafts into retaining frame Camshafts must be i...

Page 149: ...on and tighten bolts to 25 Nm Note Note the use by date of the sealant Cut off tube nozzle at front marking diameter of nozzle ap prox 2 mm Turn retaining frame back up Fit new gasket 2 in grooves on retaining frame Note The sealant beads must not be thicker than specified otherwise excess sealant could enter the camshaft bearings Apply the beads of sealant 1 3 4 onto the clean sealing sur faces o...

Page 150: ...o dry Renew bolts securing retaining frame for camshafts Caution Risk of damage to retaining frame for camshafts It is important to tighten the bolts securing the retaining frame as described Tighten bolts securing retaining frame for camshafts page 138 Clean bores for sealing plugs in cylinder head they must be free of oil and grease Coat outer circumference of sealing plugs arrows with seal ant ...

Page 151: ...stall high pressure pump Rep gr 24 Position timing chains on camshafts page 92 Install timing chain covers left and right page 80 Install cylinder head cover left side page 120 right side page 123 Note After working on the valve gear turn the engine carefully at least 2 rotations by hand to ensure that none of the valves make contact when the starter is operated Tightening torques Fig Retaining fr...

Page 152: ...nd installation device for valve cotters VAS 5161 with guide plate VAS 5161 19B Adapters T40012 Removing Engine removed and in position on scissor type assembly platform VAS 6131 A with gearbox attached Remove camshafts page 140 Mark original positions of roller rocker fingers and hydraulic compensation elements for reinstallation Remove roller rocker fingers together with hydraulic compen sation ...

Page 153: ...ar Screw snap in device VAS 5161 6 with engaging fork VAS 5161 5 into guide plate Insert assembly cartridge VAS 5161 8 into guide plate Attach pressure fork VAS 5161 2 to snap in device and push assembly cartridge down At the same time turn knurled screw of assembly cartridge clockwise until tips engage in valve cotters Move knurled screw back and forth slightly the valve cotters are thus forced a...

Page 154: ... oil seal B Lightly lubricate sealing lip of valve stem oil seal Slip valve stem oil seal over plastic sleeve Carefully press the valve stem oil seal onto valve guide using fitting tool 3365 Remove plastic sleeve If valve cotters have been removed from assembly cartridge they need to be put into insertion device VAS 5161 18 first Larger diameter of valve cotters faces upwards Install valve spring ...

Page 155: ...urled screw still in pulled posi tion Repeat procedure for each valve Assembling Installation is carried out in the reverse order note the following Ensure that all roller rocker fingers contact the ends of the valve stems correctly and are clipped onto their respective hy draulic compensation elements Install camshafts page 140 Install spark plugs Maintenance Booklet 404 Note After working on the...

Page 156: ...mshafts page 140 Mark original positions of roller rocker fingers and hydraulic compensation elements for reinstallation Remove roller rocker fingers together with hydraulic compen sation elements and put down on a clean surface Insert cylinder head tensioning device VAS 6419 into engine and gearbox support VAS 6095 Secure cylinder head in cylinder head tensioning device as illustrated Connect cyl...

Page 157: ...ng fork VAS 5161 5 into guide plate Insert assembly cartridge VAS 5161 8 into guide plate Attach pressure fork VAS 5161 2 to snap in device and push assembly cartridge down At the same time turn knurled screw of assembly cartridge clockwise until tips engage in valve cotters Move knurled screw back and forth slightly the valve cotters are thus forced apart and taken up by the assembly cartridge Re...

Page 158: ... be put into insertion device VAS 5161 18 first Larger diameter of valve cotters faces upwards Install valve spring and valve spring plate The closely spaced spring coils arrow face the cylinder head Screw guide plate back onto cylinder head Insert assembly cartridge into guide plate Push pressure fork down and pull knurled screw upwards while turning to left and right this will insert the valve c...

Page 159: ...t it run until the radiator fan has switched on once Increase engine speed to approx 2500 rpm for 2 minutes perform road test if necessary Note If the irregular valve noise disappears but repeatedly re occurs when travelling short distances renew the oil retention valve page 174 If the hydraulic compensation elements are still noisy locate the defective element as follows Remove cylinder head cove...

Page 160: ...ylinder head cover left side page 120 right side page 123 3 8 Valve dimensions Note Inlet and exhaust valves must not be machined Only grinding in is permitted Dimension Inlet valve Exhaust valve a mm 33 85 0 10 28 0 0 1 b mm 5 980 0 007 5 965 0 007 c mm 103 97 0 20 101 87 0 20 α 45 45 WARNING Care must be taken when disposing of old sodium cooled exhaust valves The valves must be sawn in two with...

Page 161: ... into exhaust valve guide as the stem diameters are different End of valve stem must be flush with valve guide Determine amount of sideways play Wear limit 0 8 mm Note If the valve has to be renewed as part of a repair use a new valve for the measurement If the wear limit is exceeded repeat the measurement with new valves Renew cylinder head if wear limit is still exceeded 3 10 Checking valves Vis...

Page 162: ...later The oil level must not be above max mark on dipstick danger of damage to catalytic converter Refer to Maintenance tables for engine oil capacity oil specifications and viscosity grades 1 1 Oil pump sump bottom section exploded view 1 Sump bottom section With oil level and oil temperature sender G266 Removing and installing sump bottom section page 158 Removing and installing oil level and oi...

Page 163: ...enew 19 Dowel sleeve 2x 20 Drive shaft for coolant pump 21 Gasket Renew 22 Oil pump Do not dismantle With pressure control valve approx 5 5 bar Removing and installing page 163 23 Oil pump drive shaft 24 8 Nm turn 90 further Renew 25 Gasket Renew 26 9 Nm 27 Intake connecting pipe For oil pump 28 Oil strainer Clean 29 Baffle plate 30 5 Nm turn 45 further Renew 31 Rubber buffer 32 9 Nm 33 Seal Renew...

Page 164: ...ure sender G266 item 2 to 9 Nm 1 2 Removing and installing oil level and oil temperature sender G266 Removing Drain off engine oil Maintenance Booklet 404 Unplug electrical connector 3 Remove nuts 1 and detach oil level and oil temperature sender G266 item 4 Installing Installation is carried out in the reverse order note the following Note Renew seal 2 Fill with engine oil and check oil level Mai...

Page 165: ...right by AUDI AG Adapters 10 222 A 21 Electric drill with plastic brush attachment Safety goggles Sealant Electronic parts catalogue Removing Remove cover above coolant expansion tank arrows Pull off rubber seal 1 and remove plenum chamber covers 2 and 3 Unbolt bracket left side for refrigerant line from suspension turret arrow Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valv...

Page 166: ...are marked for left and right side of vehicle The centre support point 2 of the adapters is located on front bolts for cross piece for suspension strut The adapters are attached by means of the rear securing bolts 3 for the cross piece for suspension strut The knurled screw 1 must be screwed down until support plate rests on suspension turret Secure spindles of support bracket 10 222 A to rear eng...

Page 167: ...UDI AG Release quick release fasteners 1 and 2 and take off noise insulation panels Unscrew bolts 2 on retaining clamps left and right for anti roll bar and move anti roll bar 1 downwards Remove bolts 1 2 3 on left and right and detach engine cross member Remove nut 1 and bolt 6 at coolant pipe bottom left Note Disregard items marked 2 5 Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ...

Page 168: ... 404 Unbolt sump bottom section 1 and carefully release it from bonded joint Note There will still be some oil in the sump bottom section Installing Note Renew seals WARNING Wear safety goggles Remove sealant residue from bottom and top sections of sump with rotating plastic brush or similar Clean sealing surfaces they must be free of oil and grease Note Note the use by date of the sealant Cut off...

Page 169: ...olts hand tight Tighten bolts for sump bottom section 1 page 158 Remaining installation steps are carried out in reverse sequence note the following Install engine cross member Rep gr 40 Install anti roll bar Rep gr 40 Fill with engine oil and check oil level Maintenance Booklet 404 Tightening torques Fig Sump bottom section tightening torque and se quence oil level and oil temperature sender G266...

Page 170: ...he oil pump Remove sump bottom section page 158 Position used oil collection and extraction unit V A G 1782 below engine Unscrew bolts arrows and remove oil pipe Note Some oil will come out when oil pipe is removed Unscrew bolts arrows and remove intake connecting pipe with baffle plate Unscrew bolts arrows and remove oil pipe together with housing for oil cooler bypass valve Note Some oil will co...

Page 171: ...t 1 for oil pump against spring pressure and remove oil pump Installing Note Renew the bolts tightened with specified tightening angle Renew seals and O rings Check whether the two dowel sleeves are fitted in the cylinder block install if necessary Press back drive shaft 1 for oil pump using water pump pliers and fit oil pump on cylinder block Release water pump pliers and let drive shaft 1 slide ...

Page 172: ...all coolant pump page 196 Fill with engine oil and check oil level Maintenance Booklet 404 Fill cooling system page 190 Tightening torques 1 1 Oil pump sump bottom section exploded view page 156 1 4 2 Removing and installing oil pump from engine number BSM 006 226 onwards Special tools and workshop equipment required Used oil collection and extraction unit V A G 1782 Removing Engine separated from...

Page 173: ...collection and extraction unit V A G 1782 below engine Unscrew bolts arrows and remove oil pipe Note Some oil will come out when oil pipe is removed Unscrew bolts arrows and remove intake connecting pipe with baffle plate Unscrew bolts arrows and remove oil pipe together with housing for oil cooler bypass valve Note Some oil will come out when oil pipe is removed Audi A8 2003 10 cylinder direct pe...

Page 174: ...new the bolts tightened with specified tightening angle Renew seals and O rings Check whether the two dowel sleeves are fitted in the cylinder block install if necessary Install sump bottom section page 162 Install coolant pump page 196 Install spur gear drive page 111 After installing engine fill up with engine oil and check oil level Maintenance Booklet 404 Tightening torques 1 1 Oil pump sump b...

Page 175: ...emoving and installing page 170 Fitting location of dowel sleeves page 169 2 Seals Renew 3 O ring Renew 4 Bolt Renew Tightening torque and sequence page 170 5 Seal Renew 6 Screw plug 35 Nm Fitting location of dowel sleeves for sump top section Check whether dowel sleeves arrows for centring sump top section are fitted in retaining frame insert missing dowel sleeves Audi A8 2003 10 cylinder direct ...

Page 176: ...moving and installing sump top sec tion Removing Engine separated from gearbox page 27 engine secured to engine and gearbox support page 36 Engine oil drained Maintenance Booklet 404 Remove drive plate page 63 Remove timing chain covers left and right page 78 Remove intake manifold Rep gr 24 Remove oil filter housing page 177 Remove timing chain cover bottom page 82 Remove alternator Electrical sy...

Page 177: ... pry sump off dowel pins on cylinder block Installing Note Renew bolts which are tightened to a specified angle as well as seals and O rings WARNING Wear safety goggles Remove sealant residue from sump top section and cylinder block with rotating plastic brush or similar Clean sealing surfaces they must be free of oil and grease Note Note the use by date of the sealant Cut off tube nozzle at front...

Page 178: ...s on cylinder block Apply bead of sealant arrow onto clean sealing surface of sump top section as illustrated Width of beads of sealant 2 5 mm Note The bead of sealant must not be thicker than specified other wise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe The sump top section must be installed within 5 minutes after applying sealant Audi A8 2003 10 cylinder...

Page 179: ... note the following Install oil pump page 163 Install sump bottom section page 162 Install coolant pump page 196 Install coolant pipe front page 205 Install alternator Electrical system Rep gr 27 Install timing chain cover bottom page 82 Install crankshaft oil seal gearbox end page 64 Install oil filter housing page 177 Install intake manifold Rep gr 24 Install timing chain covers left and right p...

Page 180: ...ing page 174 10 O ring Renew 1 8 Removing and installing oil retention valve and spray nozzle valve Note In the event of irregular valve noise which disappears after a lengthy drive but repeatedly re occurs when travelling short dis tances the oil retention valve must be renewed Removing Remove intake manifold Rep gr 24 Remove bolts 2 and 3 Detach high pressure pipe 1 from fuel rail Unscrew high p...

Page 181: ...d O rings Install high pressure pipes Rep gr 24 Removing and installing injectors Install intake manifold Rep gr 24 Tightening torques 1 7 Oil retention valve and spray nozzle valve exploded view page 173 1 9 Removing and installing hose for crank case breather system Removing Remove intake manifold Rep gr 24 Remove bolt arrow and pull out crankcase breather hose 1 from cover 2 Installing Installa...

Page 182: ... 4 22 Nm 5 O ring Part of oil filter element 6 Oil filter element Removing and installing Maintenance Book let 404 7 O ring Renew 8 Sealing cap 25 Nm 9 Not fitted 10 Not fitted 11 Screw plug 50 Nm 12 Screw plug 9 Nm 13 Seal Renew 14 O ring Renew Engine oil cooler tightening torque and sequence Note Renew gaskets 3 for engine oil cooler 2 Tighten bolts in 2 stages as follows Stage Bolts Tightening ...

Page 183: ...Note Place a cloth around the oil filter housing to catch any escaping oil Unscrew bolts arrows and remove oil filter housing Installing Installation is carried out in the reverse order note the following Note Renew seals and O rings Install intake manifold Rep gr 24 Check oil level Maintenance Booklet 404 Tightening torques 1 10 Oil filter housing exploded view page 175 1 12 Removing and installi...

Page 184: ...ection and extraction unit V A G 1782 below engine Remove bolts 1 3 4 5 6 and detach engine oil cooler Installing Installation is carried out in the reverse order note the following Note Renew O rings Secure all hose connections with the correct type of hose clips same as original equipment Electronic parts catalogue Install bracket for alternator page 55 Install alternator Electrical system Rep g...

Page 185: ...Move lock carrier to service position Rep gr 50 Unplug electrical connector 2 at oil pressure switch F1 item 1 Unscrew oil pressure switch Installing Installation is carried out in the reverse order note the following Note Renew seal Install lock carrier with attachments Rep gr 50 Tightening torques Fig Oil pressure switch F1 tightening torque page 177 1 14 Checking oil pressure and oil pressure s...

Page 186: ...lity with respect to the correctness of information in this document Copyright by AUDI AG Special tools and workshop equipment required Oil pressure tester V A G 1342 with adapter V A G 1342 14 Voltage tester V A G 1527B Auxiliary measuring set V A G 1594C Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 10 2013 180 Rep gr 17 Lubrication ...

Page 187: ... leads from auxiliary measuring set V A G 1594C to oil pressure switch and battery positive LED should not light up If the LED lights up Renew oil pressure switch Start engine Note Observe tester and LED while starting as switching point of oil pressure switch may already be exceeded when starting LED should light up at 1 2 1 6 bar If LED does not light up Renew oil pressure switch Checking oil pr...

Page 188: ...ote The cooling system is under pressure when the engine is hot If necessary relieve pressure before commencing repair work Secure all hose connections with the correct type of hose clips same as original equipment Electronic parts catalogue Renew gaskets seals and O rings The arrow markings on coolant pipes and on ends of hoses must align Fit all heat shields and heat insulation sleeves in the or...

Page 189: ...renewed refill system with fresh coolant 6 Bleeder screw 7 Thermostat For gear oil cooler and ATF cooler 8 Gear oil cooler 9 ATF cooler 10 Coolant temperature sender G62 11 Coolant expansion tank Checking pressure re lief valve in filler cap page 223 12 Cylinder head cylinder block If renewed refill system with fresh coolant 13 Coolant pump Removing and installing page 196 14 Continued coolant cir...

Page 190: ...mp V55 6 Auxiliary heater 7 Bleeder screw 8 Heat exchanger for heater If renewed refill system with fresh coolant 9 Bleeder screw 10 Thermostat For gear oil cooler and ATF cooler 11 Gear oil cooler 12 ATF cooler 13 Coolant temperature sender G62 14 Coolant expansion tank Checking pressure re lief valve in filler cap page 223 15 Cylinder head cylinder block If renewed refill system with fresh coola...

Page 191: ...nd installing page 177 If renewed refill system with fresh coolant 6 Bleeder screw 7 Heat exchanger for heater If renewed refill system with fresh coolant 8 Bleeder screw 9 Thermostat For gear oil cooler and ATF cooler 10 Gear oil cooler 11 ATF cooler 12 Coolant temperature sender G62 13 Coolant expansion tank Checking pressure relief valve in filler cap page 223 14 Cylinder head cylinder block If...

Page 192: ...r Removing and installing page 177 If renewed refill system with fresh coolant 6 Heater coolant shut off valve N279 7 Circulation pump V55 8 Auxiliary heater 9 Bleeder screw 10 Heat exchanger for heater If renewed refill system with fresh coolant 11 Bleeder screw 12 Thermostat For gear oil cooler and ATF cooler 13 Gear oil cooler 14 ATF cooler 15 Coolant temperature sender G62 16 Coolant expansion...

Page 193: ...iliary radiator left side Removing and installing page 217 If renewed refill system with fresh coolant 1 5 Draining and filling cooling system Special tools and workshop equipment required Adapter for cooling system tester V A G 1274 8 Cooling system charge unit VAS 6096 Drip tray for workshop hoist VAS 6208 Hose clip pliers VAS 6362 Refractometer T10007 Audi A8 2003 10 cylinder direct petrol inje...

Page 194: ...r disposal Remove cover above coolant expansion tank arrows WARNING Hot steam or hot coolant can escape when coolant expansion tank is opened cover filler cap with cloth and open carefully Open filler cap on coolant expansion tank Vehicles with auxiliary heater remove bolts arrows securing exhaust pipe for auxiliary additional heater to noise insulation Open quick release fasteners 1 and remove no...

Page 195: ...espect to the correctness of information in this document Copyright by AUDI AG Place drip tray for workshop hoist VAS 6208 under engine Unscrew drain plug arrow at thermostat housing and drain off coolant Remove drain plug arrow at front coolant pipe and drain off coolant Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 10 2013 1 Cooling system 189 ...

Page 196: ...this document Copyright by AUDI AG Disconnect coolant hose bottom 2 from auxiliary radiator right side and drain off remaining coolant Note Disregard item 1 Filling Ignition off Caution Always use cooling system charge unit VAS 6096 when filling the cooling system Otherwise the automatic gearbox could malfunction Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edi...

Page 197: ...additive Because of its high boiling point the coolant improves engine reliability under heavy loads particularly in countries with trop ical climates Frost protection is required down to about 25 in countries with arctic climate down to about 36 The coolant concentration must not be reduced by adding wa ter even in warmer seasons and in warmer countries The antifreeze concentration must be at lea...

Page 198: ...ect to the correctness of information in this document Copyright by AUDI AG Procedure Fit drain plug arrow with new O ring on thermostat housing Install drain plug arrow with new seal on front coolant pipe Attach coolant hose bottom 2 at auxiliary radiator right side arrow Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 10 2013 192 Rep gr 19 Cooling ...

Page 199: ...of flow Connect hose 3 to compressed air Pressure 6 10 bar Open valve B by setting lever in direction of flow The suction jet pump generates a partial vacuum in the cooling system The needle on the gauge should move into the green zone Also briefly open valve A turn lever in direction of flow so that hose on reservoir for cooling system charge unit VAS 6096 can fill with coolant Close valve A agai...

Page 200: ... off again Start engine Set temperature to HI in all zones Switch off air conditioner compressor press ECON button Run the engine for 3 minutes at 2000 rpm Allow the engine to run at idling speed until the two large cool ant hoses at main radiator become warm Run the engine for 1 minute at 2000 rpm Switch off ignition and allow engine to cool down Check coolant level The coolant level must be at t...

Page 201: ... torque Item 4 page 203 4 Coolant pipe front Removing and installing page 205 5 O ring Renew 6 Seal Renew 7 Coolant pump Removing and installing page 196 8 O ring Renew 9 9 Nm 10 Drive shaft for coolant pump 11 O ring Renew 12 Thermostat housing Removing and installing page 197 Thermostat opening values page 198 13 O ring Renew 14 Drain plug 4 Nm 15 9 Nm Continued coolant circulation pump V51 tigh...

Page 202: ...adiator outlet coolant temperature sender G83 Detach coolant hose 2 bottom from thermostat housing Remove bolts arrows Remove thermostat housing and detach coolant hose 1 top from thermostat housing Slacken hose clip 1 on coolant hose Remove bolts arrows Pull off coolant pump housing forwards note the drive shaft for coolant pump Note The coolant hose can only be disconnected when the coolant pump...

Page 203: ...section Note To fit the drive flange onto the hexagon flats of the drive shaft use your finger to turn the impeller access through the bottom pipe connection of coolant pump until the coolant pump can be pressed on all the way Remaining installation steps are carried out in reverse sequence note the following Install thermostat housing page 197 Install coolant pipe front page 205 Fill cooling syst...

Page 204: ... hose connections with the correct type of hose clips same as original equipment Electronic parts catalogue Fill cooling system page 190 Tightening torque 1 6 Coolant pump and thermostat exploded view page 194 1 9 Thermostat opening values 1 Starts to open Fully open Opening travel Voltage meas ured at ther mostat approx 105 approx 117 at least 8 mm 0 V approx 105 at least 8 mm 14 V 1 Cannot be te...

Page 205: ...emove air hose left side arrows Rest of world vehicles Detach vacuum line 2 at air intake hose Disconnect hose 1 for crankcase breather system from air hose by pressing release tabs Open hose clips arrows and disconnect air intake hose USA models Detach vacuum line 2 from air hose Open hose clips arrows and move air intake hose to one side Caution Do not open hose connection 1 on USA models Audi A...

Page 206: ... coolant Detach retaining clip 3 and remove coolant temperature sender G62 Installing Installation is carried out in the reverse order note the following Note To avoid loss of coolant insert new coolant temperature send er G62 immediately and secure with retaining clip Renew O ring Secure all hose connections with the correct type of hose clips same as original equipment Electronic parts catalogue...

Page 207: ...yright by AUDI AG Hose clip pliers VAS 6340 Hose clip pliers VAS 6362 Removing Drain off coolant page 187 Place drip tray for workshop hoist VAS 6208 under contin ued coolant circulation pump V51 Disconnect coolant hoses 1 2 3 and drain off coolant Remove nut 1 and bolt 6 at coolant pipe bottom left Note Disregard items marked 2 5 Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 v...

Page 208: ...ulation pump V51 and detach pump from coolant hose 3 Installing Installation is carried out in the reverse order note the following Note Secure all hose connections with the correct type of hose clips same as original equipment Electronic parts catalogue Install coolant pipe bottom left page 208 Fill cooling system page 190 Tightening torques Fig Continued coolant circulation pump V51 tightening t...

Page 209: ... Coolant pipe right side Removing and installing page 211 7 9 Nm 8 Coolant hose 9 O ring Renew 10 Coolant hose To intake manifold 11 9 Nm 12 Coolant temperature sender G62 Removing and installing page 198 13 Retaining clip 14 O ring Renew 15 Coolant pipe rear Removing and installing page 212 16 9 Nm 17 Coolant hose 18 O ring Renew 19 9 Nm 20 Coolant pipe left side Removing and installing page 207 ...

Page 210: ...eal Renew 1 13 Removing and installing coolant pipe bottom front Special tools and workshop equipment required Drip tray for workshop hoist VAS 6208 Hose clip pliers VAS 6362 Removing Remove cover above coolant expansion tank arrows WARNING Hot steam or hot coolant can escape when coolant expansion tank is opened cover filler cap with cloth and open carefully Open filler cap on coolant expansion t...

Page 211: ... VAS 6208 under coolant pipe bottom front Unscrew bolts 2 and 3 and detach coolant pipe bottom front from coolant hoses 1 and 4 Installing Installation is carried out in the reverse order note the following Note Secure all hose connections with the correct type of hose clips same as original equipment Electronic parts catalogue Fit all cable ties in the original positions when installing Fill cool...

Page 212: ...I AG Drip tray for workshop hoist VAS 6208 Hose clip pliers VAS 6362 Removing Drain off coolant page 187 Remove alternator Electrical system Rep gr 27 Remove bolts arrows and detach bracket for alternator Note Lay a cloth under the connection to catch escaping oil Detach coolant hoses 2 and 7 Remove bolts 1 3 4 5 6 and detach engine oil cooler Audi A8 2003 10 cylinder direct petrol injection engin...

Page 213: ...e front Installing Installation is carried out in the reverse order note the following Note Renew seals and O rings Install engine oil cooler page 177 Install bracket for alternator page 55 Install alternator Electrical system Rep gr 27 Fill cooling system page 190 Tightening torques 1 12 Coolant pipes exploded view page 202 1 15 Removing and installing coolant pipe left side Special tools and wor...

Page 214: ...ach coolant pipe left side from coolant hoses Installing Installation is carried out in the reverse order note the following Note Renew O ring Secure all hose connections with the correct type of hose clips same as original equipment Electronic parts catalogue Renew O ring on guide tube for oil dipstick and insert guide tube into hole in top section of sump Tightening torques 1 12 Coolant pipes ex...

Page 215: ...to the correctness of information in this document Copyright by AUDI AG Hose clip pliers VAS 6340 Hose clip pliers VAS 6362 Removing Drain off coolant page 187 Remove bolts for engine mountings arrows on both sides Pull off rubber seal 1 and remove plenum chamber covers 2 and 3 Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 10 2013 1 Cooling system 209 ...

Page 216: ...ut Attach support bracket 10 222 A with adapters 10 222 A 21 onto suspension turrets Supports are marked for left and right side of vehicle The centre bracing point 2 of the supports is positioned on front bolts for cross piece for suspension strut The adapters 10 222 A 21 are attached by means of the rear securing bolts 3 for the cross piece for suspension strut The knurled screw 1 must be screwe...

Page 217: ...1 12 Coolant pipes exploded view page 202 5 1 Assembly mountings exploded view page 45 1 17 Removing and installing coolant pipe right side Special tools and workshop equipment required Hose clip pliers VAS 6362 Removing Engine removed and in position on scissor type assembly platform VAS 6131 A with gearbox attached Remove bolts 2 and 3 Loosen hose clips 1 4 5 and detach coolant pipe right side f...

Page 218: ... coolant pipe right side page 211 Unscrew nuts 2 and 4 and detach bracket for electrical connectors on coolant pipe rear Release engine wiring harness at coolant pipe rear Unplug electrical connector 3 at coolant temperature sender G62 Detach coolant hose 5 from coolant pipe rear Remove bolts 1 and 6 and detach coolant pipe rear Installing Installation is carried out in the reverse order note the ...

Page 219: ... hose To detach release re taining clip Connecting to radiator page 214 5 Radiator Removing and installing page 214 If renewed change coolant in entire system 6 6 Nm 7 Mounting for radiator 8 O ring Renew 9 Coolant hose To detach release re taining clip Connecting to radiator page 214 10 Radiator fan 2 V177 With radiator fan control unit 2 J671 Removing and installing page 221 11 Retaining pin 12 ...

Page 220: ...r Remove old O ring 2 from coolant hose 3 Lubricate new O ring with coolant additive and fit O ring in coolant hose Press coolant hose onto connection 1 until it engages audi bly Press coolant hose in again and then pull to check that plug in connector is correctly engaged 1 20 Removing and installing radiator Removing Note If there are slight impressions on the fins refer to page 6 Vehicles with ...

Page 221: ... Rep gr 63 Drain off coolant page 187 Remove coolant pipe bottom front page 204 Detach coolant hoses 1 and 2 from radiator Detach electrical connector 1 for air mass meter G70 Detach vacuum hoses 2 and 3 from air intake hose USA models Detach vacuum line 2 from air hose Caution Do not open vacuum hose 3 on USA models All vehicles Remove air hose 4 from intake manifold Unscrew bolts arrows and remo...

Page 222: ...rew bolt 1 and detach air duct for auxiliary radiator with auxiliary radiator fan Detach ambient temperature sensor G17 item 4 Unplug electrical connectors 1 2 3 Move electrical wiring harness clear Note Disregard item 5 Unscrew bolts arrows and remove bumper together with struts Detach electrical connector from adaptive cruise control unit J428 if fitted Note Disregard items 1 and 2 WARNING The a...

Page 223: ...k carrier Installing Installation is carried out in the reverse order note the following Connect coolant hoses to radiator page 214 Install condenser Rep gr 87 Install bumper and bumper cover front Rep gr 63 Fill cooling system page 190 Note The coolant in the entire system must be changed if the radiator is renewed Tightening torques 1 19 Radiator and radiator fans exploded view page 212 Fig Air ...

Page 224: ...ary radiator from bracket and remove Installing Installation is carried out in the reverse order note the following Note Secure all hose connections with the correct type of hose clips same as original equipment Electronic parts catalogue Install reservoir for air conditioning system Rep gr 87 Install front section of front left wheel housing liner Rep gr 66 Fill cooling system page 190 Note The c...

Page 225: ...ove coolant expansion tank arrows WARNING Hot steam or hot coolant can escape when coolant expansion tank is opened cover filler cap with cloth and open carefully Open filler cap on coolant expansion tank Unplug electrical connector 2 and move wiring clear Unscrew bolt 1 and detach air duct for auxiliary radiator with auxiliary radiator fan Place drip tray for workshop hoist VAS 6208 under engine ...

Page 226: ... type of hose clips same as original equipment Electronic parts catalogue Install bumper cover front Rep gr 63 Fill cooling system page 190 Note The coolant in the entire system must be changed if the radiator is renewed Tightening torques Fig Auxiliary radiator tightening torques page 214 Fig Air duct for auxiliary radiator tightening torque page 214 1 23 Removing and installing radiator cowl Rem...

Page 227: ...der note the following Install radiator page 214 Fill cooling system page 190 1 24 Removing and installing radiator fans Removing Drain off coolant page 187 Remove radiator page 214 Remove radiator cowl page 220 Remove bolts arrows Unclip electrical connectors and lay wiring aside Remove radiator fans Installing Installation is carried out in the reverse order note the following Install radiator c...

Page 228: ... tester V A G 1274 B Adapter for cooling system tester V A G 1274 8 Adapter for cooling system tester V A G 1274 9 Procedure Engine must be warm Remove cover above coolant expansion tank arrows WARNING Hot steam or hot coolant can escape when coolant expansion tank is opened cover filler cap with cloth and open carefully Open filler cap on coolant expansion tank Audi A8 2003 10 cylinder direct pet...

Page 229: ...nd pump on cooling system tester to create a pressure of approx 1 0 bar If the pressure drops Locate leak and eliminate fault Checking pressure relief valve in filler cap Attach cooling system tester V A G 1274 B with adapter V A G 1274 9 to filler cap Use hand pump on cooling system tester to create pressure The pressure relief valve should open at a pressure of 1 4 1 6 bar If the pressure relief...

Page 230: ...points and the mountings are evenly loaded 1 1 Exhaust system exploded view Exhaust system front Note The illustration shows the exhaust system front for cylinder bank 1 right side 1 Nut Renew Tightening torque and sequence left side page 225 right side page 226 2 Gasket Renew 3 23 Nm Renew 4 Gasket Renew 5 Nut Renew Tightening torque and sequence left side page 226 right side page 226 6 Gasket Re...

Page 231: ...nt more than 10 otherwise it can be damaged Removing and installing left side page 236 right side page 238 Align exhaust system so it is free of stress page 240 14 23 Nm Renew 15 Lambda probe after catalytic converter G130 For exhaust bank I cylinders 1 2 3 Removing and installing Rep gr 24 16 Gasket Renew 17 Exhaust manifold front with catalytic converter For exhaust bank I cylinders 1 2 3 Protec...

Page 232: ...with exhaust manifold 2 1 6 10 Nm 3 1 6 25 Nm Exhaust manifold front right tightening torque and sequence Tighten nuts in 3 stages in the sequence shown Stag e Nuts Tightening torque 1 1 9 Screw in by hand until nuts make con tact with exhaust manifold 2 1 9 10 Nm 3 1 9 25 Nm Exhaust manifold rear right tightening torque and sequence Tighten nuts in 3 stages in the sequence shown Stag e Nuts Tight...

Page 233: ...tress page 240 4 23 Nm 5 Clamp rear For separate replace ment of centre and rear silencers Installation position page 229 Before tightening align exhaust system so it is free of stress page 240 Tighten bolt connec tions evenly 6 Connecting bracket 7 Rubber mounting Renew if damaged 8 23 Nm 9 Bolt 10 Rear silencer With exhaust flap Checking vacuum unit for exhaust flap page 246 Combined in one unit...

Page 234: ...ponents 1 23 Nm 2 Washer 3 Compression spring 4 Spacer sleeve 5 Bracket 6 Buffer 7 Spacer sleeve 8 Sleeve 9 23 Nm 10 Bracket 11 23 Nm 12 Spacer sleeve 13 Buffer 14 Bracket 15 Compression spring 16 Washer 17 23 Nm 18 Spacer sleeve Installation position of front clamps Fit clamps so that ends of bolts do not protrude beyond bottom of clamp Bolt connections face outwards Audi A8 2003 10 cylinder dire...

Page 235: ...ther 1 2 Separating centre and rear silencers The connecting pipe can be cut through at the cutting point in order to renew the centre and rear silencers separately The cutting point is marked by an indentation on the circum ference of the exhaust pipe Special tools and workshop equipment required Chain pipe cutter VAS 6254 Procedure Cut through exhaust pipes at a right angle at cutting points arr...

Page 236: ...1 A with gearbox attached Note Fit all heat shields and heat insulation sleeves in the original positions when installing All cable ties which are released or cut open when removing must be fitted in the same position when installing Take electrical connector 1 for Lambda probe 3 after catalytic converter G287 out of bracket and unplug it Note Ignore items marked 2 and arrows Remove bracket for el...

Page 237: ... this document Copyright by AUDI AG Remove bolts 2 and 3 Pull the guide tube for oil dipstick out upwards arrow Note Disregard items 1 and 4 Unscrew bolt arrow at bracket for exhaust pipes left side Unscrew nuts arrows Unscrew nuts in the sequence 9 1 and remove front left exhaust manifold with catalytic converter Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Ed...

Page 238: ...ose clips same as original equipment Electronic parts catalogue Fit all heat shields and heat insulation sleeves in the original positions when installing Fit all cable ties in the original positions when installing Fit exhaust manifold rear left with catalytic converter to cyl inder head and tighten nuts page 226 Fit exhaust manifold front left with catalytic converter to cyl inder head and tight...

Page 239: ... positions when installing All cable ties which are released or cut open when removing must be fitted in the same position when installing Take electrical connector 2 for Lambda probe 3 after catalytic converter G130 out of bracket and unplug it Note Ignore items marked 1 and arrows Remove bracket for electrical connectors 1 4 for Lambda probes from subframe arrow Take electrical connectors 3 for ...

Page 240: ...information in this document Copyright by AUDI AG Unscrew bolts 1 5 and remove bracket for torque reaction support Remove bolts 2 and 3 Loosen hose clips 1 4 5 and detach coolant pipe right side from coolant hoses Unscrew bolt arrow at bracket for exhaust pipes right side Unscrew nuts arrows Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edition 10 2013 234 Rep g...

Page 241: ...n the sequence 6 1 and remove rear right exhaust manifold with catalytic converter Installing Installation is carried out in the reverse order note the following Note Renew gaskets and self locking nuts Secure all hose connections with the correct type of hose clips same as original equipment Electronic parts catalogue Fit all heat shields and heat insulation sleeves in the original positions when...

Page 242: ...ngine page 240 Tightening torques 1 1 Exhaust system exploded view page 224 Fig Exhaust manifold front right tightening torque and sequence page 226 Fig Exhaust manifold rear right tightening torque and sequence page 226 1 5 Removing and installing Y pipe left side Removing Open quick release fasteners 2 and remove rear noise in sulation Remove bracket for electrical connectors 1 4 for Lambda prob...

Page 243: ...in this document Copyright by AUDI AG Unbolt cross piece front arrows Note The flexible joint in the front silencer must not be bent more than 10 damage can otherwise occur Slacken clamp 2 Unscrew bolt arrow at bracket for exhaust pipes left side Remove nuts 1 and 2 and detach Y pipe together with front silencer Audi A8 2003 10 cylinder direct petrol injection engine 5 2 ltr 4 valve mechanics Edit...

Page 244: ...40 Tightening torques 1 1 Exhaust system exploded view page 224 1 6 Removing and installing Y pipe right side Removing Engine removed and in position on scissor type assembly platform VAS 6131 A with gearbox attached Remove exhaust pipes right side page 233 Remove nuts arrows and detach front silencer right side from Y pipe Note Shown in illustration when installed Installing Installation is carri...

Page 245: ...oosen clamp left side 2 Remove nuts arrows and detach front silencer left side from Y pipe Installing Installation is carried out in the reverse order note the following Note Renew gaskets and self locking nuts Align exhaust system so it is free of stress page 240 Tightening torques 1 1 Exhaust system exploded view page 224 1 8 Removing and installing front silencer right side Removing Note The fl...

Page 246: ...ge 224 1 9 Stress free alignment of exhaust system The exhaust system must be aligned when it is cool Loosen bolt connections of all exhaust system clamps Press rear silencer to front arrow until the rubber mountings are pre loaded to the specified dimensions Rubber mounting front a 11 mm Rubber mounting rear a 14 mm Align rear silencer horizontally Position clamps so that they align with centre o...

Page 247: ...ing tailpipes Check clearance between tailpipes left and right and bumper cover Dimension x left side dimension x right side If necessary correct dimension x as follows Slacken bolt connection arrow on brace between exhaust pipes Adjust the distance between the rear silencers Tighten connection Tightening torques 1 1 Exhaust system exploded view page 224 Audi A8 2003 10 cylinder direct petrol inje...

Page 248: ... air pump via the secondary air pump relay Air is routed to the secondary air combination valves In parallel to this the secondary air inlet valve is activated and allows vacuum to pass to the secondary air combination valves In this way the combination valve opens a passage for the secondary air system to supply air to the exhaust ports in the cylinder head 2 2 Secondary air system exploded view ...

Page 249: ...l member Removing and installing page 245 Checking in Guided Fault Finding mode Vehicle diagnostic tester 14 9 Nm Fitting location of secondary air pump relay J299 and secondary air pump fuse S130 In electronics box plenum chamber passenger s side 1 Secondary air pump relay J299 B Secondary air pump fuse S130 50 amp 2 3 Checking combination valves for secon dary air system for correct operation an...

Page 250: ...do not use compressed air The combination valve for secondary air system should be closed it should not be possible to blow through the hose Operate hand vacuum pump The combination valve for secondary air system should open it should now be possible to blow through the hose If combination valve for secondary air does not open Renew relevant secondary air combination valve page 244 2 4 Removing an...

Page 251: ...g Installation is carried out in the reverse order note the following Note Renew seals and gaskets Tightening torques 2 2 Secondary air system exploded view page 242 2 5 Removing and installing secondary air pump Removing Remove combination valves for secondary air page 244 Unplug electrical connector 1 Unscrew nuts arrows and remove secondary air pump Installing Installation is carried out in the...

Page 252: ...cial tools and workshop equipment required Hand vacuum pump VAS 6213 Procedure Disconnect hose at vacuum unit for exhaust flap on rear si lencer Connect hand vacuum pump to vacuum unit Use hand vacuum pump to generate vacuum The linkage should move upwards Vent hand vacuum pump Linkage should move downwards If the linkage does not move Check linkage for ease of movement and check vacuum unit for l...

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