10-Service Manual 8-cylinder TDI engine (4 2 ltr 4-valve common rail BVN & BMC) mechanics, Audi - A8 (D3)(1)
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//-->ServiceWorkshop ManualAudi A8 2003 ➤Engine ID8-cylinder TDI engine (4.2 ltr. 4-valve common rail),mechanicsBVN BMCEdition 12.2013Protected by copyright. Copying for private or commercial purposes, in part or in whole, is notpermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liabilitywith respect to the correctness of information in this document. Copyright by AUDI AG.Service Department. Technical InformationServiceList of Workshop Manual Repair GroupsList of Workshop ManualRepair GroupsList of Workshop Manual Repair GroupsRepair Group00 - Technical data10 - Removing and installing engine13 - Crankshaft group15 - Cylinder head, valve gear17 - Lubrication19 - Cooling21 - Turbocharging/supercharging26 - Exhaust systemProtected by copyright. Copying for private or commercial purposes, in part or in whole, is notpermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liabilitywith respect to the correctness of information in this document. Copyright by AUDI AG.Technical information should always be available to the foremen and mechanics, because theircareful and constant adherence to the instructions is essential to ensure vehicle road-worthiness andsafety. In addition, the normal basic safety precautions for working on motor vehicles must, as amatter of course, be observed.All rights reserved.No reproduction without prior agreement from publisher.Copyright © 2014 Audi AG, IngolstadtA0051122920Audi A8 2003 ➤8-cylinder TDI engine (4.2 ltr. 4-valve common rail), mechanics - Edition 12.2013Contents00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1233.13.23.344.14.24.34.44.54.64.7123455.15.25.35.4122.12.22.32.42.52.62.733.13.23.33.43.53.644.14.24.34.44.54.6Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . .Safety precautions when using testers and measuring instruments during a road test . . . .Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . .General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking for leaks in the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing radiators, condensers and charge air coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Protected by copyright.to assemblyor commercial. . . . .in. . .whole,. . .Securing engineCopying for privatestand . .purposes,. .part.or in. . . .is not. . . . . . . . . . . . . . . . . . . . . .permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liabilityInstalling engine . . . . .of information in. . .document.. . . . . .by AUDI. . . . . . . . . . . . . . . . . . . . . . . . . . .with respect to the correctness. . . . . . . .this. . . . .Copyright. . . .AG.Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly mountings - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing engine mounting (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing engine mounting (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing mounting for torque reaction support . . . . . . . . . . . . . . . . . . . . . .Lowering subframe for repair and assembly work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servicing work on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Poly V-belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil seal and sealing flange (pulley end) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . .Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing sealing flange (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servicing work on timing chain end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive plate - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Renewing crankshaft oil seal (timing chain end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Renewing oil seal for toothed belt drive sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vacuum pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Allocation of main bearing shells for new crankshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . .Allocation of crankshaft bearing shells for retaining frame without visible colour coding . .Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Measuring axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Measuring radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Contents11233445556666610 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .883138404646474748525959606263646568717171727486889292949595959613 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52iAudi A8 2003 ➤8-cylinder TDI engine (4.2 ltr. 4-valve common rail), mechanics - Edition 12.201355.15.25.35.45.55.611.11.21.31.41.51.61.71.81.91.101.111.1222.12.22.32.42.533.13.23.33.43.53.63.73.83.93.103.1111.11.21.31.41.51.61.71.81.91.101.11Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Allocation of conrod bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Timing chain covers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Camshaft timing chains - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Detaching camshaft timing chains from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive chain for valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chain for auxiliary drives - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing chain for auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary drives - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Renewing oil seal for power steering pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing spur gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder head cover - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Measuring axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Renewing valve stem oil seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . .Renewing valve stem oil seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . .Checking hydraulic valve compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .989810110210210310310610610811611812913814014114214414514815215215415515616116416416616716717317617918018018018115 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10617 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182Oil pump, sump (bottom section), sump (centre section) - exploded view . . . . . . . . . . . . . . 182Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 184Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184Removing and installing sump (centre section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195Sump (top section) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Protected by copyright. Copying for private or commercial purposes, in partRemoving and installing sump (top section)authorised.by.AUDI.AG..AUDI.AG.does.not.guarantee or.or.in whole,liability. . . . . . . . . . . . . . . . . . . .accept any.is.not....198permitted unlessOil cooler, pressure control valve,withfilter housing andof information in thisvalve - explodedAUDI AG.oilrespect to the correctnessspray nozzledocument. Copyright byview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205Removing and installing pressure control valve for crankcase breather system . . . . . . . . 206iiContentsAudi A8 2003 ➤8-cylinder TDI engine (4.2 ltr. 4-valve common rail), mechanics - Edition 12.20131.121.131.141.151.161.1711.11.21.31.41.51.61.71.81.91.101.111.121.131.141.151.1611.11.21.31.41.51.61.711.11.21.31.41.51.61.71.81.91.101.111.121.131.141.151.161.17Removing and installing mounting plate for oil cooler, pressure control valve and oil filterhousing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing oil temperature sender G8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Coolant pump and thermostat - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing coolant pipes (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing coolant pipe (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing coolant pipe (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing coolant pipe (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . .Radiator and radiator fans - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servicing charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing turbocharger (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing turbocharger (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Charge air cooling - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing charge air cooler (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing charge air cooler (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Emission control - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . .Removing and installing exhaust gas temperature sender 1 for bank 2 G236 . . . . . . . . . .Removing and installing exhaust gas temperature sender 2 G448 . . . . . . . . . . . . . . . . . .Removing and installing exhaust gas temperature sender 2 for bank 2 G449 . . . . . . . . . .Removing and installing temperature sender 2 before particulate filter G498 . . . . . . . . . .Removing and installing temperature sender before particulate filter G506 . . . . . . . . . . . .Separating Y-pipe and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing starter catalytic converter (left-side) . . . . . . . . . . . . . . . . . . . . . .Protected by copyright. Copying for private or commercial purposes, in part or in whole, is notRemoving and installing starterunless authorised by AUDI AG. AUDI AG does not.guarantee or.accept any. . . . . . . .permittedcatalytic converter (right-side) . . . . . . . . . . . .liabilitywith respect to the correctnessRemoving and installing exhaust pipe (left-side)of information.in.this.document..Copyright.by AUDI AG.. . . . . ...... . ..... .... ......Removing and installing exhaust pipe (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing particulate filter/main catalytic converter (left-side) . . . . . . . . . . . .Removing and installing particulate filter/main catalytic converter (right-side) . . . . . . . . . .Exhaust manifold - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and installing exhaust manifold (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Contents20821021021121221221321321522022222522722723223723724024024224624724825025025225826626827027127327327728028128228428829129429530130630730931031031219 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21321 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25026 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273iii
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