Audi A8 2003 Workshop Manual
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Audi A8 2003 Workshop Manual

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See also: Repair Manual , Workshop Manual
Service
Workshop Manual
Audi A8 2003 ➤
8-cylinder TDI engine (4.2 ltr. 4-valve common rail),
mechanics
Engine ID
Edition 12.2013
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.
Service Department. Technical Information
BVN BMC

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  • Page 1 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 2 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 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 Installing engine ............
  • 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 Oil cooler, pressure control valve, oil filter housing and spray nozzle valve - exploded view with respect to the correctness of information in this document.
  • Page 5 Removing and installing starter catalytic converter (right-side) ..... . 301 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 1.12 Removing and installing exhaust pipe (left-side) .
  • Page 6 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 7: Technical Data

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  • Page 8: Engine Data

    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 9: Safety Precautions

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Safety precautions when working on the 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 10: Safety Precautions When Using Testers And Measuring Instruments During A Road Test

    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 filler cap must engage positively and audibly when it with respect to the correctness of information in this document.

  • Page 11: General Repair Instructions

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  • Page 12: Foreign Particles In Engine

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ♦ We recommend the use of Audi accessories. 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 13 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 14: Removing And Installing Engine

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not or -VAS 6622A- 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 15 ♦ Tensioning strap - T10038- 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 ♦ Tool set for wiper arms - T10369- with respect to the correctness of information in this document.
  • Page 16 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 17 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 18 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Unscrew bolts -arrows- and detach top section of air cleaner permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability housing (left-side).
  • Page 19 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 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 with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 21 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 – Extract hydraulic fluid for power steering from reservoir using with respect to the correctness of information in this document.
  • Page 22 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 23 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 24 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 26 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Note 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 27 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not (left-side) -arrow-. 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 28 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 29 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Detach retaining bracket above main fuse box. 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 30 -arrows-. 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 – Move electrical wiring harness clear. with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 31 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 – Loosen union nut -1- and unclip pressure pipe at main catalytic with respect to the correctness of information in this document.
  • Page 32 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 33 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 34 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 35 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not lustration. 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 36 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 37: Separating Engine And Gearbox

    – Screw down spindles of support elements -2- (left and right) 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 38 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 39 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 40 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 41 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 42 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Insert guide pin of adapter - T40058- with the larger-diameter permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability section -arrow 1- facing towards the engine. The smaller-di‐...
  • Page 43 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 44: Securing Engine To Assembly Stand

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  • Page 45: Protected By Copyright. Copying For Private Or Commercial Purposes, In Part Or In Whole, Is Not

    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 – Using bracket -VAS 6095/1-3- , secure engine to engine and with respect to the correctness of information in this document.

  • Page 46: Installing Engine

    Secure all hose connections with the correct type of hose clips ♦ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability (same as original equipment) ⇒ Electronic parts catalogue . with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 47: With Respect To The Correctness Of Information In This Document. Copyright By Audi Ag

    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 48: With Respect To The Correctness Of Information In This Document. Copyright By Audi Ag

    /10-1 /10-2 /10-5 /10-8 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 /10-1 /10-4 /10-5 /10-9 with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 49: With Respect To The Correctness Of Information In This Document. Copyright By Audi Ag

    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 50: With Respect To The Correctness Of Information In This Document. Copyright By Audi Ag

    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 body brace ⇒ Rep. gr. 47 .

  • Page 51: With Respect To The Correctness Of Information In This Document. Copyright By Audi Ag

    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 52: Assembly Mountings

    4 - 23 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 5 - Bracket for torque reaction with respect to the correctness of information in this document.

  • Page 53: Removing And Installing Engine Mounting (Left-Side)

    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 bolts -arrows- and detach engine support with engine with respect to the correctness of information in this document.

  • Page 54: Removing And Installing Mounting For Torque Reaction Support

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Remove bolts -arrows- and detach top section of air cleaner permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability housing (right-side).
  • Page 55 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 bolts -1 and 2- on bracket for torque reaction support.
  • 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 with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 57 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Install bumper cover (front) ⇒ Rep. gr. 63 . 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 58: Crankshaft Group

    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 59 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 60 Supports are marked for left and right side of vehicle. 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 •...
  • Page 61 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Remove bolts -arrows- and detach bracket for charge air cool‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability er (left-side).
  • Page 62 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 63 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 64 Tighten bolts for subframe to final setting after performing 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 wheel alignment check.

  • Page 65: Servicing Work On Pulley End

    ❑ Removing and installing 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 ⇒ Rep. gr. 87 with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 66: Removing And Installing Poly V-Belt

    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 67 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 68: Removing And Installing Tensioner For Poly V-Belt

    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 bolts -arrows- and take off tensioner for poly V-belt.

  • Page 69: Removing And Installing Vibration Damper

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Before removing, mark direction of rotation of poly V-belt with permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability chalk or felt-tip pen. If the belt runs in the opposite direction when with respect to the correctness of information in this document.

  • Page 70: Oil Seal And Sealing Flange (Pulley End) - Exploded View

    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 71: Renewing Crankshaft Oil Seal (Pulley End)

    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 72 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 – To slacken poly V-belt, pivot belt tensioner in direction of with respect to the correctness of information in this document.
  • Page 73 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 – Apply press sleeve -T40048/3- to crankshaft using M8×55 mm with respect to the correctness of information in this document.

  • Page 74: Removing And Installing Sealing Flange (Front)

    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 75 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Note the use-by date of the sealant. 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 76 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 77: Servicing Work On Timing Chain End

    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 78: Renewing Crankshaft Oil Seal (Timing Chain End)

    ♦ Counterhold tool - 10 - 201- Removing 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 • Engine/gearbox removed.
  • Page 79 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 80: Renewing Oil Seal For Toothed Belt Drive Sprocket

    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 81 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 82 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 83 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ted. 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 84 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not er (left-side). 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 85 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 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 with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 87 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 88 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 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.
  • Page 90 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Remove circlip -2-. 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 91 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 92: Vacuum Pump - Exploded View

    – Install mounting for torque reaction support ⇒ page 48 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. – Install engine cross member and engine mounting ⇒...

  • Page 93: Removing And Installing

    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 94: Removing And Installing Vacuum Pump

    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 95 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 96 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 97 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 98: Removing And Installing Crankshaft

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 7 - Dowel sleeve for oil pump 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 99 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 – Check that dowel sleeves -arrows- are inserted in retaining with respect to the correctness of information in this document.

  • Page 100: Allocation Of Main Bearing Shells For New Crankshafts

    Coloured dot marking 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 Yellow Yellow with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 101: Allocation Of Crankshaft Bearing Shells For Retaining Frame Without Visible Colour Coding

    64.965 … 64.958 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 Crankshaft dimensions with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 102: Measuring Radial Clearance

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ♦ Dial gauge - VAS 6079- 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 103 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 104: Dismantling And Assembling Pistons And Conrods

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  • Page 105 Dimensions in mm 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 1st compression ring 0.28 … 0.41 0.70...
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  • Page 108: Piston And Cylinder Dimensions

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  • Page 144: Drive Chain For Valve Gear - Exploded View

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  • Page 150: Auxiliary Drives - Exploded View

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  • Page 158: Removing And Installing Cylinder Head

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  • Page 167: Checking Compression

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  • Page 170: Servicing Valve Gear

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  • Page 188: Lubrication

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  • Page 201: Removing And Installing Oil Pump

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  • Page 203: Sump (Top Section) - Exploded View

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  • Page 208: Oil Cooler, Pressure Control Valve, Oil Filter Housing And Spray Nozzle Valve - Exploded View

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  • Page 214: Removing And Installing Mounting Plate For Oil Cooler, Pressure Control Valve And Oil Filter

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  • Page 215 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Install exhaust gas recirculation cooler with change-over flap permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ⇒ page 320 with respect to the correctness of information in this document.

  • Page 216: Removing And Installing Oil Pressure Switch F1

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  • Page 217: Checking Oil Pressure

    Oil pressure at 2000 rpm: at least 2.5 bar. 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 Assembling with respect to the correctness of information in this document.

  • Page 218: Engine Oil

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  • Page 219: Cooling

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  • Page 220 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not with fresh coolant 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 221: Draining And Filling Cooling System

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  • Page 222 Filling 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. Copyright by AUDI AG.
  • Page 223 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 Because of its high boiling point, the coolant improves engine ♦...
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  • Page 226: Coolant Pump And Thermostat - Exploded View

    • The coolant level must be at the MAX marking when the en‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability gine is cold. with respect to the correctness of information in this document. Copyright by AUDI AG.
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  • Page 228: Removing And Installing Coolant Pump

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  • Page 230 Secure all hose connections with the correct type of hose clips ♦ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability (same as original equipment) ⇒ Electronic parts catalogue . with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 231: Removing And Installing Thermostat

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Thermostat housing to coolant pump housing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Retaining clip for hydraulic line to sump with respect to the correctness of information in this document.
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  • Page 233: Checking Thermostat

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  • Page 234 – Remove radiator cowl ⇒ page 246 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. – Remove bolts -arrows- and detach top section of air cleaner housing (right-side).
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  • Page 236 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not It is not possible to remove crankcase breather pipe from engine permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability compartment at this stage.
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  • Page 238: Removing And Installing Coolant Pipe (Left-Side)

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  • Page 240 – Unplug electrical connectors -1- and -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 – Remove crankcase breather hose -2-.
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  • Page 243: Removing And Installing Coolant Pipe (Right-Side)

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  • Page 246: Removing And Installing Coolant Temperature Sender G62

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  • Page 248: Removing And Installing Radiator

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  • Page 250 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 front sections of front wheel housing liners (left and with respect to the correctness of information in this document.
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  • Page 252: Removing And Installing Radiator Cowl

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  • Page 253: Removing And Installing Radiator Fans

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  • Page 254: Checking Cooling System For Leaks

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  • Page 256: Turbocharging/Supercharging

    271 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 Turbocharger - exploded view with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 257 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 6 - Coolant pipe permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ❑ Tighten union nut to 25 with respect to the correctness of information in this document.

  • Page 258: Removing And Installing Turbocharger (Left-Side)

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  • Page 260 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 – Unscrew securing bolt -2- and securing bolt -4-.
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  • Page 263 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 ♦ Secure all hose connections with the correct type of hose clips with respect to the correctness of information in this document.

  • Page 264: Removing And Installing Turbocharger (Right-Side)

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  • Page 267 – Remove bolts -arrows- and detach bracket for charge air cool‐ 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 272: Charge Air Cooling - Exploded View

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  • Page 274: Removing And Installing Charge Air Cooler (Left-Side)

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  • Page 276: Removing And Installing Charge Pressure Sender G31

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  • Page 277: Removing And Installing Charge Air Cooler (Right-Side)

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  • Page 278 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Air duct to charge air cooler 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 279: Exhaust System

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  • Page 280 14 - 25 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 15 - Gasket with respect to the correctness of information in this document. Copyright by AUDI AG.
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  • Page 283: Emission Control - Exploded View

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  • Page 285 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not for bank 2 - G236- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 2 - Exhaust gas temperature sender 1 for cylinder bank 2 - with respect to the correctness of information in this document.

  • Page 286: Removing And Installing Exhaust Gas Temperature Sender 1 G235

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  • Page 287: Removing And Installing Exhaust Gas Temperature Sender 1 For Bank 2 G236

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  • Page 288: Removing And Installing Exhaust Gas Temperature Sender 2 G448

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ♦ Tool set - T10395 A- 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 290: Removing And Installing Exhaust Gas Temperature Sender 2 For Bank 2 G449

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Installing 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 294: Removing And Installing Temperature Sender 2 Before Particulate Filter G498

    – Install subframe ⇒ Rep. gr. 40 . 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 Tightening torques with respect to the correctness of information in this document.
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  • Page 297: Removing And Installing Temperature Sender Before Particulate Filter G506

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not G498- to starter catalytic converter 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 300: Separating Y-Pipe And Rear Silencers

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  • Page 301: Removing And Installing Starter Catalytic Converter (Left-Side)

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  • Page 305 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Pivot starter catalytic converter and unscrew exhaust gas tem‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability perature sender 2, bank 2 - G449- -item 1-.
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  • Page 307: Removing And Installing Starter Catalytic Converter (Right-Side)

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  • Page 311 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Install subframe ⇒ Rep. gr. 40 . 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 312: Removing And Installing Exhaust Pipe (Left-Side)

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  • Page 313: Removing And Installing Exhaust Pipe (Right-Side)

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  • Page 315: Removing And Installing Particulate Filter/Main Catalytic Converter (Left-Side)

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  • Page 316: Removing And Installing Particulate Filter/Main Catalytic Converter (Right-Side)

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  • Page 317 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ther permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ❑ Renew with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 318: Removing And Installing Exhaust Manifold (Left-Side)

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  • Page 319: Stress-Free Alignment Of Exhaust System

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  • Page 320: Aligning Tailpipes

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  • Page 322: Servicing Exhaust Gas Recirculation System

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  • Page 323: Removing And Installing Exhaust Gas Recirculation Control Motor 2 V339 (Left-Side)

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  • Page 325: Removing And Installing Control Motor For Exhaust Gas Recirculation V338 (Right-Side)

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  • Page 326: Removing And Installing Exhaust Gas Recirculation Cooler With Change-Over Flap

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  • Page 329: Removing And Installing Exhaust Gas Recirculation Cooler

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