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200 – Fuel Cell and Exhaust System

Version 1 2016-01-01

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200 – 1-2 Service Instructions Refuelling Coupling

RFC-88-TN and RFC-88-N

We recommend that the coupling O-rings are coated with “Molykote 1292”

grease after every event. Use the RFC-88-TN service tool to depress the inner

piston down until the 2 O-rings in the housing are visible. Afterwards the O-rings

can be lubricated and / or changed as required. The seals and lubricant are

available as kit (part number RFC-88-TN service kit) from Krontec. In addition,

we recommend that the coupling should be completely rebuilt after a complete

season or 10,000 km by Krontec (replace all seals, etc.).

Image 7: Refuelling Coupling and Molykote 1292 Grease

Содержание R8 LMS 2018

Страница 1: ...Handbook Audi R8 LMS MODIFIED TO COVER 2018...

Страница 2: ...aust System 30 200 1 Fuel Cell 30 200 1 1 Refuelling Valve Service Instructions 30 200 1 2 Service Instructions Refuelling Coupling 33 300 Gearbox Drive Shafts and Ancillary Components 36 400 Front Ax...

Страница 3: ...801 1 Aero Set Up Sheet 83 900 Electric and Data Acquisition 87 900 1 Software 87 900 2 Diagnosis 95 901 Engine Warm Up Procedure Engine Start 98 901 1 Preparation before Engine Start 98 901 1 1 Chec...

Страница 4: ...ad 39 Image 13 Adjustable Preload 39 Image 14 Push Rod Thread With Groove Marking 51 Image 15 Lower Damper Eye in Maximum Permitted Position 51 Image 16 Characteristic Curve Front Damper 4SA 412 019 B...

Страница 5: ...mage 32 Brake Pedal Plate Height Adjustment 76 Image 33 Brake Pedal Plate Angle Adjustment 76 Image 34 Audi Safety Seat PS1 77 Image 35 Shoulder Strap Mounting Below Roll Cage Tube 82 Image 36 Shoulde...

Страница 6: ...Throttle pedal ath butterfly cam Camshaft DDU Digital Display Unit ECU Electronic Control Unit FIA F d ration Internationale de l Automobile KL Design Position PDM Product Detail Assembly Instruction...

Страница 7: ...on date 01 05 2015 The specification corresponds with the current version of the regulations at the time of delivery The car including its components and add on parts is manufactured exclusively for t...

Страница 8: ...Car Views Version 1 2016 01 01 8 113 Car Views...

Страница 9: ...Car Views Version 1 2016 01 01 9 113...

Страница 10: ...Car Views Version 1 2016 01 01 10 113...

Страница 11: ...air jack should never be pressurised without lifting the car or alternatively the pressure must be increased very slowly and in a controlled manner Recommended operating pressure 40 bar Never use cle...

Страница 12: ...tact Krontec for service and maintenance see chapter 902 Service and Maintenance Contacts Please refer to the manufacturer s product description Krontec for additional safety guidelines Car lift syste...

Страница 13: ...n the flat bottom In this case it is necessary to lift the car on the points intended for this purpose see red marks Front axle only at the rear mounting point of the front splitter Rear axle only at...

Страница 14: ...ed with an FIA homologated fire extinguisher system The extinguishant is Aerosol The fine particulate powder used is extremely efficient and thanks to a special nozzle system is distributed evenly in...

Страница 15: ...race track The following components must be checked Extinguishant reservoir Operating pressure must not be less than 32 5 bar or exceed 41 5 bar The next inspection date must not be exceeded see serv...

Страница 16: ...ing out the pip pin emergency fire extinguisher switch located in the front cover cowling When the racecar is no longer in operation the fire extinguisher system should be deactivated Set the toggle s...

Страница 17: ...ntacts for contact information for Kidde Deugra regarding servicing Detonator The detonator has a service life of 3 years after fitting to the extinguishant reservoir and a maximum of 5 years after th...

Страница 18: ...4 Direction of rotation Anticlockwise when looking at the clutch 5 Weight Approx 220 kg 6 Firing order 1 6 5 10 2 7 3 8 4 9 cylinder 1 is front right in direction of travel b Filling Quantities 1 Engi...

Страница 19: ...r service description The engine must be delivered in a transport box flight case with the following ancillary components Flywheel Induction system including butterflies Injectors wiring loom Engine m...

Страница 20: ...l EDGE FORMULA RS 10W 60 or Castrol EDGE TITANIUM FST 10W 60 Part number V31 748 009 5 litre bundle b Oil Level Measurement 1 Position the car on a level flat surface 2 Run the engine until the engine...

Страница 21: ...2 Checking Engine Oil Level and add oil if necessary d Adding Oil during an Endurance Race 1 litre of engine oil should be added after every 8 hours of running in the race The engine consumes approx...

Страница 22: ...e Races After filling the oil fill bottle with engine oil maximum 1 8 litres pressurise the bottle to 6 bar This is made using a standard tyre valve on the bottom of the oil fill bottle The bottle is...

Страница 23: ...lease coupling is part of the endurance homologation VO VO Variant Option When using a system which is homologated together with other systems in a single VO the full extent of the homologated compone...

Страница 24: ...ler is cleaned and the cooling fins lamella are realigned Scheme Diagram Image 2 Scheme of Cooling System Thermostat The R8 LMS engine is equipped with a thermostat The thermostat starts to open at 85...

Страница 25: ...nd increases the cooling fluid s boiling point After reaching operating temperature the expansion reservoir cap must not be opened The system pressure to increase the coolant boiling point would reduc...

Страница 26: ...ill the VAS 6096 coolant reservoir with approx 20 litres of premixed coolant in the desired ratio Screw the adapter for the V A G 1274 8 cooling system tester onto the coolant reservoir Fit the coolin...

Страница 27: ...ve pressure in the cooling system the dial indicator needle must remain in the green range Close valve B The dial indicator needle must remain in the green range if so the negative pressure in the sys...

Страница 28: ...he coolant must be level with the MAX mark When the engine is at operating temperature the coolant level can be above the MAX mark Image 3 Expansion Reservoir If air is still in the system after bleed...

Страница 29: ...n the clutch actuator half full with brake fluid spec DOT 3 DOT 4 DOT 4 plus super DOT 4 plus DOT 5 1 3 Minimum litre extra brake fluid available 4 Open the bleed nipple 5 Pull and release the clutch...

Страница 30: ...he following procedure The seals the lubricant and an O ring mounting tool are available as kit part number RFC 88 K service kit from Krontec The O rings supplied with the kit should be replaced after...

Страница 31: ...1 113 Instructions Image 5 Using Service Tool Refuelling Coupling in Service Position When the service tool is fitted the valve is pushed downwards The O rings are now accessible and can be lubricated...

Страница 32: ...ool RFC 88 K Service Tool Service kit RFC 88 K Service KIT Complete refuelling coupling service after 10 000 km or 1 x per season RFC 88 K FL service dump churn version RFC 88 K SL service refuelling...

Страница 33: ...ervice tool to depress the inner piston down until the 2 O rings in the housing are visible Afterwards the O rings can be lubricated and or changed as required The seals and lubricant are available as...

Страница 34: ...ctions Image 8 Service Tool Decoupled and Unlocked Image 9 Service Tool Fitted Locked and Open After fitting the locking ring rotate clockwise to lock the service tool Afterwards the valve can be depr...

Страница 35: ...1 35 113 Order Number Service tool RFC 88 TN Service Tool Service kit RFC 88 TN Service KIT Complete refuelling coupling service after 10 000 km or 1 x per season RFC 88 TN Service Please return the r...

Страница 36: ...ed Image 10 Gearbox FIA Homolagated Gear Ratios b Gearbox Oil Castrol SAF XJ 75W 140 or Castrol Syntrax Longlife 75W 140 previously known as SAF XJ Part number V31 748 005 01L 1 litre bundle It is rec...

Страница 37: ...ck wipe dry with a clean cloth Afterwards screw the oil dipstick by hand to the final position then remove and check the oil level 3 After the warming up procedure tgear 60 C the oil level should be i...

Страница 38: ...Rebuilds and training courses are implemented and coordinated in conjunction with Audi Sport customer racing Please contact Kurt Gr fenstein Kurt1 graefenstein audi de 49 0 151 421 340 05 g Differenti...

Страница 39: ...able Differential Preload Image 13 Adjustable Preload Attention The preload is approx 100 150 Nm at delivery and with new gearbox It should be noted that the preload changes significantly before a cer...

Страница 40: ...thout engine running 2 Steer lock to lock 10 times while refilling oil level and until the oil level remains constant 3 Start engine idle speed and run until the oil level sinks in the reservoir after...

Страница 41: ...l level at room temperature between MAX 20 and MAX 20 3 mm Oil level immediately after turning off engine at operating temperature between MAX 80 3 mm and MIN 80 Attention It is highly recommended tha...

Страница 42: ...eight KL 1 55 mm 75 mm Max Compression 50 mm 50 mm From design level Max Droop 30 mm 30 mm From design level Ratio damper to wheel 0 835 0 808 Damper travel wheel displacement Damper length at design...

Страница 43: ...mechanical stop Max steering angle at wheel turning out 18 4 Left wheel to left Max steering angle at wheel turning in 17 7 Right wheel to right 1 The front or rear standard height or ride height is...

Страница 44: ...15 20 25 30 35 40 45 50 Toe angle in toe out toe in Heave in mm rebound bump 0 20 40 60 80 100 120 140 160 180 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 Roll center height in mm Heave in mm rebo...

Страница 45: ...bump 0 25 0 20 0 15 0 10 0 05 0 00 0 05 0 10 0 15 0 20 0 25 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 Toe angle in toe out toe in Heave in mm rebound bump 0 20 40 60 80 100 120 140 160 180 30 2...

Страница 46: ...ng free length in mm Spring block length coil bound in mm 160 0 835 112 2 705 143 71 190 132 3 213 139 73 220 153 3 720 136 69 250 174 4 227 134 72 265 185 4 481 133 69 280 195 4 734 132 71 Rear sprin...

Страница 47: ...Anti roll Bars The following images show the correct lengths of the anti roll bar drop links Front Rear Anti roll Bar Adjustment Front anti roll bar Position 1 soft 2 middle 3 hard Alignment ARB rate...

Страница 48: ...2 middle 3 hard Alignment ARB rate at the wheel 1 49 N mm 60 N mm 69 N mm Axle roll stiffness 2 385 Nm 2 920 Nm 3 360 Nm 1 Anti roll bar rate at the wheel to add to the main spring rate at the wheel t...

Страница 49: ...he piston rod thoroughly with iso propanol 2 Clamp the piston rod using aluminium clamp blocks V03 862 342 AB hlins part number 00727 05 sold in pairs 3 Before removing the push rod heat it with a hot...

Страница 50: ...ear Listed in the following table are the maximum and minimum adjusted damper lengths as well as the default setting for the ride heights at design level Front Rear Extended length minimum adjustable...

Страница 51: ...tion see Image 14 The groove must remain within the lower damper eye Image 14 Push Rod Thread With Groove Marking Image 15 Lower Damper Eye in Maximum Permitted Position The maximum droop travel can b...

Страница 52: ...tform on the damper body or on the push rod Damper Adjustment The compression setting is adjusted on the gold wheel marked with COMP The rebound setting is adjusted on the black wheel marked with REB...

Страница 53: ...4SA 512 019 C 3000 2500 2000 1500 1000 500 0 500 1000 1500 2000 2500 3000 0 50 100 150 200 250 300 Force in N bump rebound Speed in mm s Front Damper 4SA 412 019 B R1 R5 R9 R13 R17 R21 B1 B5 B9 B13 B...

Страница 54: ...nt shim Toe rod length correction in mm Toe rod length correction in flats 0 25 15 blank metallic 1 0 mm 0 4 mm 1 5 flats 0 50 30 Black 2 0 mm 0 8 mm 3 0 flats 1 00 60 Gold 4 0 mm 1 6 mm 6 5 flats 1 F...

Страница 55: ...55 113 Camber change in degrees Camber change in minutes Adjustment shim colour Thickness of adjustment shim on wishbone Thickness of adjustment shim toe rod 0 25 15 blank metallic 1 3 mm 0 4 mm 0 50...

Страница 56: ...lengths for zero toe at design level ride height and static camber Front Rear Toe Adjustment Toe rod front axle Turns Change in length Toe change in degrees Toe change in minutes 1 flat 0 25 mm 0 11...

Страница 57: ...inly useful for the preparation of the disc rather than the pad material For ideal bedding we suggest a phase with a progression of constant pressure stops 35 40 at increasing speed avoiding as much a...

Страница 58: ...al of 35 40 stops or alternatively 35 40 km of mileage with gradually increasing of the initial speed and total brake energy These brakings must be made well below the tyres adhesion limit 50 60 of th...

Страница 59: ...ightly shiny layer must cover the rubbing surfaces of the discs the observation of the external surface is enough Darker stains are allowed and close to the fixing of the disc there may be visible pur...

Страница 60: ...correctly bedded set of disc pads sx compared to a new one Blanking Attention Due to thermally induced mechanical stresses cracks can develop despite perfectly bedded brake discs and pads A critical v...

Страница 61: ...e Brake Cooling Duct With Blanking IR temperature sensors can provide information about the critical minimum temperatures when in operation Brake disc temperature paint can provide information about t...

Страница 62: ...eep long straight and continuous cracks on the edges of the brake discs Uncritical cracks thin short and branched distributed evenly over the entire surface no cracks on the edges of the brake discs A...

Страница 63: ...500 Rear Axle Anti roll Bar and Dampers Version 1 2016 01 01 63 113 500 Rear Axle Anti roll Bar and Dampers For current information see chapter 400 Front Axle Anti Roll Bar Dampers and Steering...

Страница 64: ...600 Brake Pipes Brake Cooling Ducts Wheels and Tyres Version 1 2016 01 01 64 113 600 Brake Pipes Brake Cooling Ducts Wheels and Tyres No current information...

Страница 65: ...bilities are described below in details 700 1 1 Longitudinal Adjustment Pedal Unit The seat is bolted firmly to the chassis The pedal unit is mounted to a sledge adjustable longitudinally The adjustme...

Страница 66: ...centre console must be switch on The compressor will start to run As soon as it switches off automatically there is sufficient pressure stored in the reservoir to disengage the pedal unit The pneumat...

Страница 67: ...can cause the unit to jam Image 22 Push Surface on the Pedal Unit Cover When the button is released two independent springs push the lock into the detents If the lock is between two detents the next...

Страница 68: ...wait until the compressor switches off Press the button valve in the centre console Move the sledge to the desired position by pushing below the throttle pedal plate with the heel of the right foot R...

Страница 69: ...Plate There are two positions The pedal in the left hand image shows the standard position The plate can be moved 10 mm to the right to create more space between the throttle and brake pedal Image 23...

Страница 70: ...threaded stud is moved and the spring preload changed The basic setting is shown in the following image The pin in the slot shows the actual setting The pin at the top means the minimum spring preloa...

Страница 71: ...ge 26 Pedal Assembly Throttle Pedal Damper The damping is adjustable The standard setting is completely soft Changing the damping is made by rotating the cylinder relative to the piston rod When fitte...

Страница 72: ...e adjustment Attention Do not use force to rotate otherwise the adjuster segment in the damper can be damaged Attention The driver s foot can get tired if the damper is set too hard Remount the damper...

Страница 73: ...700 Pneumatic Gearshift and Pedals Version 1 2016 01 01 73 113 Image 27 Adjusting the Throttle Pedal Damper...

Страница 74: ...angle of pedal plate a X Position In the standard position the brake pedal plate is on the same plane as the left footrest and compared to the throttle pedal plate 10 mm closer to the driver If requi...

Страница 75: ...and the system can stick in the depressed position b Y Position To increase the distance to the left footrest or the throttle pedal plate to the right the brake pedal plate can be turned through 180 I...

Страница 76: ...700 Pneumatic Gearshift and Pedals Version 1 2016 01 01 76 113 Image 32 Brake Pedal Plate Height Adjustment Image 33 Brake Pedal Plate Angle Adjustment...

Страница 77: ...77 113 800 Bodywork Chassis Parts Seat and Air Conditioning 800 1 Seat Audi PS1 Image 34 Audi Safety Seat PS1 800 1 1 Homologation The Audi PS1 is homologated under the number AS 031 13 M and AS 032...

Страница 78: ...800 Bodywork Chassis Parts Seat and Air Conditioning Version 1 2016 01 01 78 113...

Страница 79: ...is Parts Seat and Air Conditioning Version 1 2016 01 01 79 113 800 1 2 Seat Sizes The Audi PS1 is available in two sizes Audi PS1 M 42A 881 023 D Audi PS1 L 42A 881 023 E The width of the M and L seat...

Страница 80: ...equipped with different thickness Confor CF45 cushions which comply with the regulations Attention The cushions are an integral component of the safety concept and are important to absorb energy duri...

Страница 81: ...rts Seat and Air Conditioning Version 1 2016 01 01 81 113 800 1 4 Additional Inserts If additional seat inserts must be made to fit the driver one of the following FIA homologated foams must be used F...

Страница 82: ...idelines To fulfil these guidelines the shoulder strap mounting must be adapted to suit the size of the driver Two possible options can be selected subject to the size of the driver Version A Below th...

Страница 83: ...Ride height Measured under the axles Balance Total Total front rear wing front axle downforce drag mm mm Pos High Downforce 55 80 6 steep 0 1 6 8 4 5 Medium Downforce 55 75 4 Low Downforce 58 5 75 1 f...

Страница 84: ...ndard downforce 55 75 4 Increased FRH 57 75 4 1 8 1 8 0 0 Increased RRH 55 77 4 0 9 1 2 0 2 Balance Rear Wing Table Rear wing set up Ride height Measured under the axles Balance Total Total front rear...

Страница 85: ...s 65 5 mm 128 mm Rear wing position see chapter 800 1 1 Homologation Ensure that the Gurney flap uppermost edge of the rear wing is within the homologated dimension at all times The position of the Gu...

Страница 86: ...801 Aerodynamics Version 1 2016 01 01 86 113...

Страница 87: ...rottle pedal camshafts The R8 LMS is delivered with a ready to race RaceCon configuration Adapting the display pages and additional functions is not necessary If changes are desired and teams are stil...

Страница 88: ...stem tree Three green status LEDs indicate that the computer configuration matches the car Changes made offline for example a modified display view are highlighted with the yellow status LED A message...

Страница 89: ...is yellow after connecting to the car this indicates that changes were made offline whereby the parameters between computer and ECU differ Afterwards a message asks whether an UPLOAD or DOWNLOAD is d...

Страница 90: ...900 Electric and Data Acquisition Version 1 2016 01 01 90 113 b Adapting the lap trigger c Resetting the outing and lap counters...

Страница 91: ...Throttle pedal aps via CWAPSADJ also if throttle pedal changed Butterflies ath via CWTHRADJ also if one or both throttles changed Camshaft cam via CWCAMADAP also if a camshaft sensor changed Other va...

Страница 92: ...le speed toil 65 C Start camshaft adaptation when calibrating condition 15 is written in the calibration channel CWCAMADAP and confirmed by pressing enter Wait until the adaptation status cam_adapt_sa...

Страница 93: ...tatus to calibration inactive Pull left clutch paddle to mechanical stop activate status calibrate full pulled paddle Do not pull clutch paddle activate status calibrate release paddle Reset status to...

Страница 94: ...aight ahead positon activate status cal middle offset Reset status to off 9 Adjusting pit speed Change the pit speed to the desired value Copy work page WP to reference page RP Special case pit speed...

Страница 95: ...ontrolled or received by the ECU Ideally every error entry displays FALSE which means that there are no errors Occasionally error entries can indicate TRUE when for example the corresponding sensor is...

Страница 96: ...component the following page view also allows every component to be checked that requires the engine to be running Another option that provides an excellent monitoring function during the engine start...

Страница 97: ...previous page views the pressures and temperatures are listed separately which provides improved performance when monitoring the most important values In addition the combustion process in the cylind...

Страница 98: ...cribed below Checking gearbox potentiometer voltage 1 Turn on the main and ignition switches 2 Select neutral N gear value in display must be N rear wheels can be easily turned by hand 3 Selected disp...

Страница 99: ...2016 01 01 99 113 Image 38 Shift Barrel in Neutral N Position Adjustment 1 Loosen the bolts 2 Rotate the gearbox potentiometer until the value gearbox in the display shows 1 2 V 3 Retighten the bolts...

Страница 100: ...n the car on a level flat surface 2 Run the engine until the engine oil temperature reaches 100 C 110 C see chapter 901 Engine Warm Up Procedure Engine Start 3 Run the engine at idle speed for approx...

Страница 101: ...oil dipstick wipe dry with a clean cloth Afterwards screw the oil dipstick by hand to the final position then remove and check the oil level 3 After the warming up procedure tgear 60 C the oil level s...

Страница 102: ...tion about fuel quality b Coolant and coolant additive See chapter 100 1 3 Engine Cooling System for information about quality and coolant levels c Checking coolant level 1 When the engine is cold the...

Страница 103: ...rew in the filler cap hand and then remove again 4 Check oil level 5 Oil level at room temperature between MAX 20 and MAX 20 3mm Oil level immediately after turning off engine at operating temperature...

Страница 104: ...must be charged to check the function of the battery and alternator the battery charger should be disconnected during the engine warm up procedure Fit the engine start wheel hub adapters on the rear a...

Страница 105: ...sixth gear by pulling the right hand shift paddle during this procedure the engine speed should be kept at a constant 3 000 rpm 7 Heat up the engine and gearbox oil in sixth gear at 3 000 rpm 8 Monit...

Страница 106: ...ox 2 minutes after check engine oil level see chapter 100 1 2 Engine Lubrication or chapter 901 1 2 Checking Engine Oil Level 10 Check all fluid levels 11 Check the engine for leakage damage electrica...

Страница 107: ...llastrasse 19 93083 Obertraubling Germany Contact Mrs Eugenia Lonski Tel 49 0 9401 5253 0 Fax 49 0 9401 5253 10 Tel 49 0 9401 5253 25 Web www krontec de Email e lonski krontec de info krontec de USA R...

Страница 108: ...880 Ratingen Germany Delivery address Harkortstr 1 40880 Ratingen Germany Tel 49 0 2102 405 141 Fax 49 0 2102 405 129 Web www kidde deugra com Email info kidde deugra utas utc com Contact engine rebui...

Страница 109: ...l r grabenbauer hoer technologie de Contact damper service hlins Racing AB Web www ohlins com http www ohlins com contact distributors Please contact your nearest hlins service partner as listed on th...

Страница 110: ...motorsport com Contact brake caliper service BREMBO S p A Web www brembo com http www brembo com en car racing professionals distributors Please contact your nearest BREMBO service partner as listed o...

Страница 111: ...ntacts Version 1 2016 01 01 111 113 Contact gear shift system service MEGA Line RACING ELECTRONIC GmbH Haunersdorfer Str 3 93342 Saal Germany Tel 49 0 9441 6866 0 Fax 49 0 9441 6866 11 Web www mega li...

Страница 112: ...8 4299 Web www zf com Email technical service zre zf com Australia Triple Eight Race Engineering 40 Depot St 4014 Banyo QLD Australia Tel 61 0 736 35 7000 Web www tripleeight com au Email info triplee...

Страница 113: ...and Maintenance Contacts Version 1 2016 01 01 113 113 Japan Web www enable apg jp China As this service is not provided in China ZF Race Engineering recommends that Enable OSCN Inc in Japan carry out...

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