Audi 2003 A8 Guide

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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.
Maintenance
Audi A8 2003 ➤
Edition 06.2014
Service
Service Department. Technical Information

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.
Maintenance
Heading
1. General information
2. Preparations
3. Maintenance
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2014 Audi AG, Ingolstadt A0051015020

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.
Contents
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 --- Change history --- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Overview of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Vehicle: raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Engine cover panel: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Noise insulation: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Window regulators: activating automatic open/close function . . . . . . . . . . . . . . . . . . . . . . 14
2.5 Vehicle diagnostic tester: connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Diesel particulate filter: reading out ash deposit volume . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Event memory: reading out and erasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 Navigation system (MMI high): releasing eject button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.4 Navigation system (MMI basic): releasing eject button and running CD for languages . . . . 20
3.5 Service interval display: resetting service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.6 Transport mode: deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.7 Shipping mode: deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.8 Battery: reading out status and sending diagnostic log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.9 Battery: checking that battery and battery cables are securely fitted . . . . . . . . . . . . . . . . . . 23
3.10 Battery: checking electrolyte level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.11 Brake fluid: changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.12 Brake fluid: checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.13 Brake system: checking condition of brake hoses, and checking that caps are fitted on bleeder
screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.14 Brake pads: checking thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.15 Tyres: checking condition and wear pattern, and checking and recording tread depth . . . . 33
3.16 Tyres: checking tyre pressures and adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . . . 34
3.17 Tyre Pressure Loss Indicator: storing changed tyre pressures . . . . . . . . . . . . . . . . . . . . . . 35
3.18 Tyre repair kit: checking that set is complete, and checking and recording expiry date . . 36
3.19 Wheel bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.20 Components of front and rear axles: checking play, secure attachment and protective
boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.21 Engine, gearbox, final drive and steering: checking for leaks and damage . . . . . . . . . . . . 41
3.22 Underbody: checking trim, wheel housing liners, side members and pipes/wiring for damage,
and checking that they are properly secured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.23 Roof insert: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.24 Roof insert - sliding/tilting sunroof: cleaning and lubricating . . . . . . . . . . . . . . . . . . . . . . . . 42
3.25 Rear lid hinges: lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.26 Bonnet arrester hook: lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.27 Door hinges with arresters and locking cylinders: lubricating . . . . . . . . . . . . . . . . . . . . . . . . 45
3.28 Windscreen washer system: checking spray pattern and adjusting if necessary . . . . . . . . 46
3.29 Wiper blades: checking for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.30 Headlight washer system: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.31 Headlights: checking for correct adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.32 Headlights and reversing lights, side lights, number plate lights, turn signals, hazard warning
lights: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.33 Luggage compartment lighting: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.34 Glove box light, interior lighting and reading light: checking operation . . . . . . . . . . . . . . . . 50
3.35 Horn: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.36 Front passenger's airbag: checking key switch on / off and setting to "on" . . . . . . . . . . . . 51
3.37 Vehicle keys: checking operation and recording number of keys given to customer . . . . . . 51
Audi A8 2003 ➤
Maintenance - Edition 06.2014
Contents i

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.
3.38 Turbocharger: greasing rod linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.39 Engine oil: draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.40 Engine oil: extracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.41 Engine oil: renewing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.42 Engine oil: filling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.43 Engine oil: checking oil level and correcting if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.44 Poly V-belts for ancillaries: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.45 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.46 Hydraulic system: checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.47 Cooling system: checking anti-freeze protection and coolant level, and correcting if
necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.48 Air cleaner: renewing filter element and cleaning housing . . . . . . . . . . . . . . . . . . . . . . . . 90
3.49 Plenum chamber and water drains: checking for dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.50 Snow screen: cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.51 Dust and pollen filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.52 Fuel filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.53 Fuel tank: adding fuel additive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.54 Body: checking vehicle paint for damage and corrosion with bonnet, rear lid and doors
open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.55 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.56 Display instruments: setting language, time and date . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.57 Automatic gearbox (multitronic): changing ATF fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.58 Poly V-belts for ancillaries: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.59 Poly V-belts for ancillaries and all pulleys: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.60 Poly V-belts for ancillaries and pulleys for coolant pump and power steering pump:
renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.61 Poly V-belts for ancillaries and idler rollers: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.62 Instrument cluster: resetting driver information system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.63 Toothed belt for camshaft drive: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.64 Toothed belt for camshaft drive and tensioning roller: renewing . . . . . . . . . . . . . . . . . . . . 108
Audi A8 2003 ➤
Maintenance - Edition 06.2014
ii 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
with respect to the correctness of information in this document. Copyright by AUDI AG.
1 General information
(AIGG000565; Edition 06.2014)
Change history ⇒ page 1
Overview of engines ⇒ page 1
Engine number ⇒ page 2
Vehicle identification number ⇒ page 5
Vehicle data sticker ⇒ page 5
1.1 --- Change history ---
N
o.
Date Chapter Changes made
2 28.05.2014 Headlights: checking for correct adjustment
⇒ page 48
Chapter added
1 20.05.2014 All Completely revised
Note
For greater clarity, only the last three updates to the document
are listed.
1.2 Overview of engines
Petrol engines ⇒ page 1
Diesel engines ⇒ page 2
1.2.1 Petrol engines
Engine
code
Engine
type/
number
of cylin‐
ders
Capaci‐
ty [ltr.]
Injection
system
Power out‐
put [kW]
(rpm)
Torque
[Nm]
(rpm)
Cam‐
shaft
drive
Stroke
[mm]
Bore
[mm]
Com‐
pression
ratio
[:1]
ASN V6 3.0 MPI 162 300 Toothed
belt
92.8 82.5 10.3
(6300) (3200)
BBJ V6 3.0 MPI 160 290 Toothed
belt
92.8 82.5 10.3
(6300) (3200)
BDX V6 2.8 FSI 154 280 Timing
chain
82.4 84.5 12.0
(6000) (
3000-50
00)
BFL V8 3.7 MPI 206 360 Timing
chain
82.4 84.5 11.0
(6000) (3750)
BFM V8 4.2 MPI 246 430 Timing
chain
93.0 84.5 11.0
(6500) (3500)
BGK V8 4.2 MPI 246 430 Timing
chain
93.0 84.5 11.0
(6000) (3500)
BHT W12 6.0 MPI 331 580 Timing
chain
90.2 84.0 10.75
(6200) (
4000-47
00)
Audi A8 2003 ➤
Maintenance - Edition 06.2014
1. General information 1

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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.
Engine
code
Engine
type/
number
of cylin‐
ders
Capaci‐
ty [ltr.]
Injection
system
Power out‐
put [kW]
(rpm)
Torque
[Nm]
(rpm)
Cam‐
shaft
drive
Stroke
[mm]
Bore
[mm]
Com‐
pression
ratio
[:1]
BPK V6 3.2 FSI 191 330 Timing
chain
92.8 84.5 12.5
(6500) (3250)
BSB W12 6.0 MPI 331 580 Timing
chain
90.2 84.0 10.75
(6200) (
4000-47
00)
BSM V10 5.2 FSI 331 540 Timing
chain
92.8 84.5 12.5
(7000) (
3000-40
00)
BTE W12 6.0 MPI 331 580 Timing
chain
90.2 84.0 10.75
(6200) (
4000-45
00)
BVJ V8 4.2 FSI 257 440 Timing
chain
92.8 84.5 11.5
(6500) (3500)
CJBA V6 2.8 FSI 170 280 Timing
chain
82.4 84.5 12.0
(6000) (
3000-50
00)
1.2.2 Diesel engines
Engine
code
Engine
type/
number
of cylin‐
ders
Capaci‐
ty [ltr.]
Injection
system
Power out‐
put [kW]
(rpm)
Torque
[Nm]
(rpm)
Cam‐
shaft
drive
Stroke
[mm]
Bore
[mm]
Com‐
pression
ratio
[:1]
ASB V6 3.0 TDI
common
rail
171 450 Timing
chain
91.4 83.0 19.5
(4000) (1500)
ASE V8 4.0 TDI
common
rail
202 650 Timing
chain
95.5 81.0 19.5
(3750) (1800)
BNG V6 3.0 TDI
common
rail
155 450 Timing
chain
91.4 83.0 17.0
(4000) (1400)
BVN V8 4.2 TDI
common
rail
240 650 Timing
chain
95.5 83.0 16.5
(3750) (
1600-35
00)
1.3 Engine number
Note
The engine number consists of the engine code letters (3 or 4
characters) and the serial number.
Audi A8 2003 ➤
Maintenance - Edition 06.2014
2 1. General information

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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.
6-cyl. petrol engine 2.8 ltr. FSI/3.0 ltr. MPI/3.2 ltr. FSI
⇒ page 3
8-cyl. petrol engine 3.7 ltr. MPI/4.2 ltr. MPI/4.2 ltr. FSI
⇒ page 3
10-cyl. petrol engine 5.2 ltr. FSI ⇒ page 3
12-cyl. petrol engine 6.0 ltr. MPI ⇒ page 4
6-cyl. diesel engine 3.0 ltr. TDI ⇒ page 4
8-cyl. diesel engine 4.0 ltr. TDI ⇒ page 4
8-cyl. diesel engine 4.2 ltr. TDI ⇒ page 5
1.3.1 6-cyl. petrol engine 2.8 ltr. FSI/3.0 ltr.
MPI/3.2 ltr. FSI
The engine number is stamped on the left side at the joint between
the engine and the gearbox -arrow-.
The engine number is also given on the sticker on the toothed belt
cover (top).
In addition, the engine code letters are given on the vehicle data
sticker ⇒ page 5 .
1.3.2 8-cyl. petrol engine 3.7 ltr. MPI/4.2 ltr.
MPI/4.2 ltr. FSI
The engine number is stamped on the left side at the joint between
the engine and the gearbox -arrow-.
The engine number is also given on the sticker on the toothed belt
cover (top).
In addition, the engine code letters are given on the vehicle data
sticker ⇒ page 5 .
1.3.3 10-cyl. petrol engine 5.2 ltr. FSI
The engine number is stamped on the left side at the joint between
the engine and the gearbox -arrow-.
The engine number is also given on the sticker on the toothed belt
cover (top).
In addition, the engine code letters are given on the vehicle data
sticker ⇒ page 5 .
Audi A8 2003 ➤
Maintenance - Edition 06.2014
1. General information 3

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.
1.3.4 12-cyl. petrol engine 6.0 ltr. MPI
The engine number is stamped on the left side at the joint between
the engine and the gearbox -arrow-.
The engine number is also given on the sticker on the toothed belt
cover (top).
In addition, the engine code letters are given on the vehicle data
sticker ⇒ page 5 .
1.3.5 6-cyl. diesel engine 3.0 ltr. TDI
The engine number is stamped on the left side at the joint between
the engine and the gearbox -arrow-.
The engine number is also listed on the sticker on the toothed belt
cover (top) -arrow-.
In addition, the engine code letters are given on the vehicle data
sticker ⇒ page 5 .
1.3.6 8-cyl. diesel engine 4.0 ltr. TDI
The engine number can be found on the inside left surface below
the intake manifold -arrow- (left-side).
The engine number is also printed on the sticker on the intake
manifold.
In addition, the engine code letters are given on the vehicle data
sticker ⇒ page 5 .
Audi A8 2003 ➤
Maintenance - Edition 06.2014
4 1. General information

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.
1.3.7 8-cyl. diesel engine 4.2 ltr. TDI
The engine number can be found on the inside left surface below
the intake manifold -arrow- (left-side).
The engine number is also printed on the sticker on the intake
manifold.
In addition, the engine code letters are given on the vehicle data
sticker ⇒ page 5 .
1.4 Vehicle identification number
Depending on the equipment and country-specific version, the
vehicle identification number is located:
♦ Optional: In the MMI under »Car systems«
♦ On the suspension turret (right-side)
♦ On the vehicle data sticker ⇒ page 5
The vehicle identification number consists of the following:
WAU ZZZ 4E Z B A / N 000 234
Manufactur‐
er's mark
Filler charac‐
ters
Type Filler charac‐
ters
Model year Production lo‐
cation
Serial number
1.5 Vehicle data sticker
The vehicle data sticker is located:
♦ In the Service Schedule
♦ In the area of the spare wheel well under the floor covering
-arrow-
Audi A8 2003 ➤
Maintenance - Edition 06.2014
1. General information 5

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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.
The vehicle data sticker contains the following vehicle data:
1 - Vehicle identification number
2 - Vehicle model, manufacturer's code, engine type and power
output, production month and year
3 - Engine and gearbox code letters (not specified on some export
models)
4 - Paint number, interior equipment number
5 - Numbers for optional extras
6 - Fuel consumption: urban, extra urban, combined, CO2 (not
specified on some export models)
Audi A8 2003 ➤
Maintenance - Edition 06.2014
6 1. General information