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Page 3: Table Of Contents
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Contact corrosion! ............
Page 4 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 19 - Cooling ............182 with respect to the correctness of information in this document.
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Page 7: Technical Data
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Page 8: Engine Data
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Page 9: Safety Precautions
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Page 10: Procedure Before Opening High-Pressure Section Of Injection System
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Page 11: General Repair Instructions
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Page 12: Routing And Attachment Of Pipes, Hoses And Wiring
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Page 14: Removing And Installing Engine
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Page 20 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability – Pull bonnet seal away from lock carrier and wing panels.
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Page 31 Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability The electrical connectors remain attached. with respect to the correctness of information in this document. Copyright by AUDI AG.
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Page 33: Separating Engine And Gearbox
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Page 38 – Position support elements from -VAS 6131/10- at left of en‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability gine/gearbox assembly, as shown in illustration.
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Page 40 • The larger-diameter section -arrow 2- faces the adapter. 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. Rep. gr.10 - Removing and installing engine...
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Page 42: Securing Engine To Engine And Gearbox Support
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Page 44: Installing Engine
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Page 47 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability – Fit wiring harness and coolant hoses to engine/gearbox as‐...
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Page 51: Assembly Mountings
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Page 52: Removing And Installing Engine Mounting (Left And Right)
Special tools and workshop equipment required Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ♦ Support bracket - 10 - 222 A- with respect to the correctness of information in this document.
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Page 54 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Secure spindles of support bracket - 10 - 222 A- to rear engine permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability lifting eyes.
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Page 56: Removing, Installing And Adjusting Mounting For Torque Reaction Support
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Page 57 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability – Open hose clips and move air hose -4- to one side.
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Page 61: Crankshaft Group
7 - Dowel sleeve Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ❑ For bracket for alterna‐...
Page 62: Removing And Installing Poly V-Belt
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Page 65: Removing And Installing Vibration Damper
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Page 66: Renewing Crankshaft Oil Seal (Pulley End)
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Page 68 ⇒ page 56 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability – Install radiator cowl ⇒ page 220 with respect to the correctness of information in this document.
Page 69: Cylinder Block (Gearbox End)
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Page 70: Renewing Crankshaft Oil Seal (Gearbox End)
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Page 72: Crankshaft
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Page 75: Allocation Of Main Bearing Shells For New Crankshaft
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Page 76: Allocation Of Main Bearing Shells On Used And Machined Crankshafts
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Page 77: Crankshaft Dimensions
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Page 78: Measuring Radial Clearance Of Crankshaft
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Page 79: Pistons And Conrods
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Page 82: Piston And Cylinder Dimensions
♦ Plastigage Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Procedure with respect to the correctness of information in this document. Copyright by AUDI AG.
Page 83: Cylinder Head, Valve Gear
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Page 84: Removing And Installing Timing Chain Covers (Left And Right)
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Page 86 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Caution with respect to the correctness of information in this document.
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Page 88: Removing And Installing Timing Chain Cover (Bottom)
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Page 89 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is 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.
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Page 91: Camshaft Timing Chain - Exploded View
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Page 92 ❑ Removing from camshafts ⇒ page 89 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. ❑ Removing and installing ⇒...
Page 93 2 - 42 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 3 - Camshaft adjuster for ex‐...
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Page 95: Removing Timing Chain From Camshafts
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ♦ Camshaft clamp - T40070- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability (2x) with respect to the correctness of information in this document. Copyright by AUDI AG.
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Page 100 ⇒ Item 2 (page 86) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Tighten on inlet camshaft to final tight‐...
Page 101 30° and set to “TDC” again. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability • The threaded holes -arrows- in the camshafts must face up‐...
Page 102: Removing And Installing Camshaft Timing Chains
⇒ page 123 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability – Remove timing chain covers (left and right) ⇒...
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Page 104: Removing And Installing Chain Tensioner For Camshaft Timing Chain
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Page 106: Drive Chain For Valve Gear - Exploded View
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Page 107: Removing And Installing Drive Chain For Valve Gear
⇒ page 27 , engine attached permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability to scissor-type assembly platform - VAS 6131 A- or secured with respect to the correctness of information in this document. Copyright by AUDI AG.
Page 108 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Unscrew bolts -1- and remove guide rail. 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.
Page 109: Drive Chain For Auxiliary Drives - Exploded View
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 7 - Bearing cap 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.
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Page 111 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Using adapter - T40058- turn the crankshaft in the normal di‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability rection of rotation -arrow- to “TDC”.
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Page 113: Auxiliary Drives - Exploded View
– Install timing chain covers (left and right) ⇒ page 80 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.
Page 114: Renewing Oil Seal For Air Conditioner Compressor Drive
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Page 116: Renewing Oil Seal For Power Steering Pump Drive
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Page 117: Removing And Installing Spur Gear Drive
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Page 121: Balance Shaft - Exploded View
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Page 122: Removing And Installing Balance Shaft
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Page 124: Cylinder Head
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Page 126: Removing And Installing Cylinder Head Cover (Left-Side)
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Page 129: Removing And Installing Cylinder Head Cover (Right-Side)
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Page 131: Removing And Installing Cylinder Head
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Page 137: Checking Compression
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Page 142: Valve Gear
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Page 144: Measuring Axial Clearance Of Camshafts
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Page 145: Measuring Radial Clearance Of Camshafts
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Page 146: Removing And Installing Camshafts
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Page 151: Renewing Valve Stem Oil Seals (Cylinder Head Installed)
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Page 155: Renewing Valve Stem Oil Seals (Cylinder Head Removed)
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Page 159: Checking Hydraulic Valve Compensation Elements
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Page 160: Valve Dimensions
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Page 161: Checking Valves
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Page 162: Lubrication
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Page 164: Removing And Installing Oil Level And Oil Temperature Sender G266
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Page 169: Removing And Installing Oil Pump
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Page 174: Sump (Top Section) - Exploded View
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Page 176: Removing And Installing Sump (Top Section)
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Page 179: Oil Retention Valve And Spray Nozzle Valve - Exploded View
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Page 180: Removing And Installing Oil Retention Valve And Spray Nozzle Valve
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Page 181: Removing And Installing Hose For Crankcase Breather System
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Page 183: Removing And Installing Oil Filter Housing
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Page 185: Removing And Installing Oil Pressure Switch F1
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Page 187: Engine Oil
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Page 188: Cooling
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Page 190: Connection Diagram For Coolant Hoses - Vehicles With Auxiliary Heater
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Page 191: Connection Diagram For Coolant Hoses - Vehicles For Hot Countries Without Auxiliary Heater
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Page 192: Connection Diagram For Coolant Hoses - Vehicles For Hot Countries With Auxiliary Heater
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Page 193: Draining And Filling Cooling System
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Page 194 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Open filler cap on coolant expansion tank. 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.
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Page 197 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability The refractometer - T10007 A- must be used to determine the ♦...
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Page 200: Coolant Pump And Thermostat - Exploded View
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Page 202: Removing And Installing Coolant Pump
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Page 203: Removing And Installing Thermostat Housing
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Page 204: Thermostat Opening Values 1)
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Page 206: Removing And Installing Continued Coolant Circulation Pump V51
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Page 208: Coolant Pipes - Exploded View
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Page 210: Removing And Installing Coolant Pipe (Bottom Front)
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Page 211: Removing And Installing Coolant Pipe (Front)
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Page 213: Removing And Installing Coolant Pipe (Left-Side)
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Page 214: Removing And Installing Coolant Pipe (Bottom Left)
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Page 217: Removing And Installing Coolant Pipe (Right-Side)
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Page 218: Removing And Installing Coolant Pipe (Rear)
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Page 220: Removing And Installing Radiator
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Page 223: Removing And Installing Auxiliary Radiator (Left-Side)
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Page 224: Removing And Installing Auxiliary Radiator (Right-Side)
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Page 226: Removing And Installing Radiator Cowl
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Page 227: Removing And Installing Radiator Fans
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Page 228 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Hot steam or hot coolant can escape when coolant expansion permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability tank is opened; cover filler cap with cloth and open carefully.
Page 229 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is 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.
Page 230: Exhaust System
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not inders 4, 5) 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.
Page 231 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ❑ Renew 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.
Page 232 -1 … 9- 10 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability -1 … 9- 25 Nm with respect to the correctness of information in this document.
Page 233 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ❑ Tighten bolt connec‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability tions evenly with respect to the correctness of information in this document. Copyright by AUDI AG.
Page 234 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is 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.
Page 235: Separating Centre And Rear Silencers
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Page 236: Removing And Installing Exhaust Pipes (Left-Side)
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Page 237 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is 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.
Page 238 – Install coolant pipe (left-side) ⇒ page 202 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. – Align exhaust system free of stress after installing engine ⇒...
Page 239: Removing And Installing Exhaust Pipes (Right-Side)
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Page 240 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is 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.
Page 241 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is 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.
Page 242: Removing And Installing Y-Pipe (Left-Side)
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Page 243 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is 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.
Page 244: Removing And Installing Y-Pipe (Right-Side)
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Page 245: Removing And Installing Front Silencer (Left-Side)
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Page 246: Stress-Free Alignment Of Exhaust System
Tightening torques Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ♦ ⇒ “1.1 Exhaust system - exploded view”, page 224 with respect to the correctness of information in this document.
Page 247 Tightening torques Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ♦ ⇒ “1.1 Exhaust system - exploded view”, page 224 with respect to the correctness of information in this document.
Page 248: Servicing Secondary Air System
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Page 249: Checking Combination Valves For Secondary Air System For Correct Operation And Leakage
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Page 250: Removing And Installing Combination Valves For Secondary Air System
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Page 251: Removing And Installing Secondary Air Pump
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Page 252: Exhaust Flaps
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Audi A8 2003 Workshop Manual

Technical Data

Removing and Installing Engine

Crankshaft Group

Cylinder Head, Valve Gear

Lubrication

Cooling

Exhaust System

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Summary of Contents for Audi A8 2003

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