Foreign Particles In Engine; Contact Corrosion; Routing And Attachment Of Pipes, Hoses And Wiring; Installing Radiators, Condensers And Charge Air Coolers - Audi A8 2003 Workshop Manual

Audi A8 2003 ➤
8-cylinder TDI engine (4.2 ltr. 4-valve common rail), mechanics - Edition 12.2013
– Then check high-pressure part of fuel system again for leak‐
age.
4.3

Foreign particles in engine

♦ When performing assembly work on the engine, all open pas‐
sages in the intake and exhaust systems must be sealed with
suitable plugs (e.g. from engine bung set - VAS 6122- ) to
prevent foreign particles from entering the engine.
♦ In the event of mechanical damage to one of the cylinder
banks, the intake and exhaust systems and combustion cham‐
bers of the opposite cylinder bank must always be examined
to prevent further damage occurring later.
Note
If the turbocharger has suffered mechanical damage
⇒ page 252
4.4

Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
used.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Note the following:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of Audi accessories.
♦ Damage caused by contact corrosion is not covered under
warranty.
4.5 Routing and attachment of pipes, hoses
and wiring
♦ Mark fuel lines, hydraulic lines, vacuum lines and electrical
wiring etc. before removal so they can be re-installed in the
original positions and correctly connected. Make sketches or
take photographs if necessary.
♦ To prevent damaging pipes, hoses and wiring, ensure suffi‐
cient clearance from all moving or hot components in engine
compartment (little space in engine compartment).
4.6 Installing radiators, condensers and
charge air coolers
Even when the radiator, condenser and charge air cooler are cor‐
rectly installed, slight impressions may be visible on the fins of
these components. This does not mean that the components are
damaged. If the fins are only very slightly distorted, this does not
justify renewal of the radiator, charge air cooler or condenser.
4.7

Checking vacuum system

Special tools and workshop equipment required
6
Rep. gr.00 - Technical data
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