Audi 2003 A8 Instruction manual

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.
Workshop Manual
Audi A8 2003 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-
valve), mechanics
Engine ID BSM
Edition 10.2013
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.
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
26 - Exhaust system
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 © 2013 Audi AG, Ingolstadt A0051128920

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
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Procedure before opening high-pressure section of injection system . . . . . . . . . . . . . . . . 4
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Rules for cleanliness when working on fuel supply system and injection system . . . . . . . . 5
4.2 Checking for leaks in the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.5 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.6 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.7 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1 Assembly mountings - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2 Removing and installing engine mounting (left and right) . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3 Removing, installing and adjusting mounting for torque reaction support . . . . . . . . . . . . . . 50
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.1 Poly V-belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.3 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.4 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.1 Drive plate - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.3 Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.1 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.2 Allocation of main bearing shells for new crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.3 Allocation of main bearing shells on used and machined crankshafts . . . . . . . . . . . . . . . . 70
3.4 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.5 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.6 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.1 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.1 Timing chain covers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.2 Removing and installing timing chain covers (left and right) . . . . . . . . . . . . . . . . . . . . . . . . 78
1.3 Removing and installing timing chain cover (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Audi A8 2003 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve), mechanics - Edition 10.2013
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.
1.4 Camshaft timing chain - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.5 Removing timing chain from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.6 Removing and installing camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.7 Removing and installing chain tensioner for camshaft timing chain . . . . . . . . . . . . . . . . . . 98
1.8 Drive chain for valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.9 Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.10 Drive chain for auxiliary drives - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.11 Removing and installing drive chain for auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.12 Auxiliary drives - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.13 Renewing oil seal for air conditioner compressor drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.14 Renewing oil seal for power steering pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.15 Removing and installing spur gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.16 Balance shaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.17 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.1 Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.2 Removing and installing cylinder head cover (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.3 Removing and installing cylinder head cover (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.2 Measuring axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.4 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.5 Renewing valve stem oil seals (cylinder head installed) . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.6 Renewing valve stem oil seals (cylinder head removed) . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3.7 Checking hydraulic valve compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3.8 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.9 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.10 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.1 Oil pump, sump (bottom section) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 158
1.3 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.5 Sump (top section) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.6 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.7 Oil retention valve and spray nozzle valve - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 173
1.8 Removing and installing oil retention valve and spray nozzle valve . . . . . . . . . . . . . . . . . . 174
1.9 Removing and installing hose for crankcase breather system . . . . . . . . . . . . . . . . . . . . . . 175
1.10 Oil filter housing - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.11 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.12 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.13 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.14 Checking oil pressure and oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.15 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.16 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.1 Connection diagram for coolant hoses - vehicles without auxiliary heater . . . . . . . . . . . . . . 182
1.2 Connection diagram for coolant hoses - vehicles with auxiliary heater . . . . . . . . . . . . . . . . 184
Audi A8 2003 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve), mechanics - Edition 10.2013
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.
1.3 Connection diagram for coolant hoses - vehicles for hot countries without auxiliary heater
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.4 Connection diagram for coolant hoses - vehicles for hot countries with auxiliary heater . . 186
1.5 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.6 Coolant pump and thermostat - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.8 Removing and installing thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.9 Thermostat opening values 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1.10 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 198
1.11 Removing and installing continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . 200
1.12 Coolant pipes - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
1.13 Removing and installing coolant pipe (bottom front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1.14 Removing and installing coolant pipe (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.15 Removing and installing coolant pipe (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.16 Removing and installing coolant pipe (bottom left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
1.17 Removing and installing coolant pipe (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
1.18 Removing and installing coolant pipe (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
1.19 Radiator and radiator fans - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
1.20 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
1.21 Removing and installing auxiliary radiator (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1.22 Removing and installing auxiliary radiator (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.23 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
1.24 Removing and installing radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.25 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
1 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
1.1 Exhaust system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
1.2 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1.3 Removing and installing exhaust pipes (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
1.4 Removing and installing exhaust pipes (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.5 Removing and installing Y-pipe (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.6 Removing and installing Y-pipe (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.7 Removing and installing front silencer (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.8 Removing and installing front silencer (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.9 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2 Servicing secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.1 Principle and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.2 Secondary air system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.3 Checking combination valves for secondary air system for correct operation and leakage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.4 Removing and installing combination valves for secondary air system . . . . . . . . . . . . . . . . 244
2.5 Removing and installing secondary air pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
3 Exhaust flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
3.1 Checking vacuum unit for exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Audi A8 2003 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve), mechanics - Edition 10.2013
Contents iii

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iv Contents

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00 – Technical data
1 Engine number
(ARL003517; Edition 10.2013)
– Pull off engine cover panel (front) -1- -arrows-.
The engine number (“engine code” and “serial number”) can be
found on top of the cylinder block at the front -arrow-.
Note
The engine code is also included on the vehicle data sticker.
Audi A8 2003 ➤
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1. Engine number 1

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2 Engine data
Code letters BSM
Capacity ltr. 5.204
Power output kW at rpm 331/7000
Torque Nm at rpm 540/3500
Bore ∅ mm 84.5
Stroke mm 92.8
Compression ratio 12.5
RON 98 1)
Injection/ignition system Bosch Motronic
Firing order 1-6-5-10-2-7-3-8-4-9
Exhaust gas recirculation no
Turbocharging/supercharging no
Knock control 4 sensors
Lambda control 2 probes before catalyt‐
ic converter
2 probes after catalytic
converter
Variable valve timing Inlet
Exhaust
Intake manifold change-over yes
Secondary air system yes
Valves per cylinder 4
•1) Unleaded premium RON 95 can also be used, but results
in reduced power
Audi A8 2003 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve), mechanics - Edition 10.2013
2 Rep. gr.00 - Technical data

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3 Safety precautions
When working on the fuel system note the following warnings:
WARNING
The fuel system operates at extremely high pressure. This can
cause injury.
♦ The fuel pressure in the high-pressure section of the in‐
jection system must be reduced to a residual pressure
prior to opening the system.
– Procedure before opening high-pressure section of injection
system ⇒ Rep. gr. 24 .
Observe the following to prevent injuries to persons and damage
to the injection and ignition system:
♦ Always switch off the ignition before connecting or discon‐
necting electrical wiring for the injection or ignition system or
tester cables.
♦ Always switch off ignition before washing engine.
♦ Erase any entries in event memory resulting from testing or
installation ⇒ Vehicle diagnostic tester, Interrogate event
memory, then Generate readiness code .
Caution
To prevent irreparable damage to the electronic components
when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .
When working on the cooling system note the following warnings:
WARNING
Hot steam/hot coolant can escape - risk of scalding.
♦ The cooling system is under pressure when the engine is
hot.
♦ To allow pressure to dissipate, cover filler cap on coolant
expansion tank with cloth and open carefully.
Audi A8 2003 ➤
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3. Safety precautions 3

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Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
Accidents can be caused if the driver is distracted by test
equipment while road-testing, or if test equipment is not prop‐
erly secured.
Persons sitting in the front passenger's seat could be injured if
the airbag is triggered in an accident.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Test equipment must always be secured on the rear seat
with a strap and operated from the rear seat by a second
person.
3.1 Procedure before opening high-pres‐
sure section of injection system
WARNING
♦ The injection system consists of a high-pressure section
(maximum approx. 120 bar) and a low-pressure section
(approx. 6 bar).
♦ The fuel pressure in the high-pressure section must be
reduced to a residual pressure of approx. 6 bar prior to
opening the system. Procedure ⇒ Rep. gr. 24
Audi A8 2003 ➤
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4 Rep. gr.00 - Technical data

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4 General repair instructions
4.1 Rules for cleanliness when working on
fuel supply system and injection system
Even small amounts of dirt can cause malfunctions. When work‐
ing on the fuel supply system and injection system, it is therefore
important to observe the following basic rules:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal off open pipes/lines and connections immediately with
clean plugs, e.g. from engine bung set - VAS 6122- .
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use fluffy cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open: Do not work with compressed air.
Do not move the vehicle unless absolutely necessary.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
4.2 Checking for leaks in the fuel system
– Allow engine to run for several minutes at moderate rpm.
– Switch off ignition.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Road-test vehicle and accelerate with full throttle at least once.
– Then inspect high-pressure section of fuel system again for
leaks.
4.3 Foreign particles in engine
♦ When working on the engine, all open inlet and exhaust ports
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.
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.
Audi A8 2003 ➤
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4. General repair instructions 5

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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 hydraulic lines, vacuum lines and electrical wiring before
removal so they can be re-installed in the original positions and
correctly connected. Make sketches or take photographs if nec‐
essary.
4.6 Installing radiators and condensers
Even when the radiator and condenser are correctly 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 or the condenser.
4.7 Checking vacuum system
Special tools and workshop equipment required
♦ Hand vacuum pump - VAS 6213-
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ Lines porous or leaking
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If a fault is stored in the event memory, check the vacuum lines
leading to the corresponding component and also check the
remaining vacuum lines in the system.
– If it is not possible to build up a vacuum with the hand vacuum
pump - VAS 6213- or if the vacuum pressure drops again im‐
Audi A8 2003 ➤
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6 Rep. gr.00 - Technical data

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mediately, check the hand vacuum pump and connecting
hoses for leaks.
Audi A8 2003 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve), mechanics - Edition 10.2013
4. General repair instructions 7

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10 – Removing and installing engine
1 Removing engine
Note
♦ The engine is removed from underneath together with the
gearbox and subframe (with lock carrier installed).
♦ Collect drained coolant in a clean container for re-use or dis‐
posal.
♦ Fit all heat shields and heat insulation sleeves in the original
positions when installing.
♦ All cable ties which are released or cut open when removing
must be fitted in the same position when installing.
Special tools and workshop
equipment required
♦ Removal lever - 80 - 200-
♦ Eye-head bolt - 3368-
♦ Used oil collection and ex‐
traction unit - V.A.G 1782-
♦ Spark plug connector pliers
- V.A.G 1922-
♦ Hose clip pliers - VAS
6340-
♦ Hose clip pliers - VAS
6362-
Audi A8 2003 ➤
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8 Rep. gr.10 - Removing and installing engine

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♦ Stepladder - VAS 5085-
♦ Scissor-type assembly
platform - VAS 6131 A- with
support set for Audi - VAS
6131/10-
♦ Drip tray for workshop hoist
- VAS 6208-
♦ Tensioning strap - T10038-
(2x)
♦ Puller - T40039-
♦ Engine bung set - VAS 6122-
Procedure
Caution
Observe notes on procedure for disconnecting the battery ⇒
Electrical system; Rep. gr. 27 .
Audi A8 2003 ➤
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1. Removing engine 9

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Note
♦ To make sure you can still move the front wheels when the
battery has been disconnected, only disconnect the battery
with the ignition key inserted.
♦ The electromechanical parking brake must be released before
disconnecting the battery so that the propshaft can be turned
during removal.
– With ignition switched off, disconnect earth cable -arrow- at
battery ⇒ Electrical system; Rep. gr. 27 .
– Discharge the refrigerant system ⇒ Air conditioner system -
with refrigerant R134a .
– Pull off engine cover panels at front -1- and at rear -2-
-arrows-.
– Remove cover above coolant expansion tank -arrows-.
WARNING
Hot steam or hot coolant can escape when coolant expansion
tank is opened; cover filler cap with cloth and open carefully.
– Open filler cap on coolant expansion tank.
Audi A8 2003 ➤
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10 Rep. gr.10 - Removing and installing engine

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– Remove both front wheels ⇒ Rep. gr. 44 .
– Vehicles with auxiliary heater: remove bolts -arrows- securing
exhaust pipe for auxiliary/additional heater to noise insulation.
– Release quick-release fasteners -1- and -2- and take off noise
insulation panels.
– Remove front and rear sections of front wheel housing liners
(left and right) ⇒ Rep. gr. 66 .
– Place drip tray for workshop hoist - VAS 6208- under engine.
– Unscrew drain plug -arrow- at thermostat housing and drain
off coolant.
– Remove drain plug -arrow- at front coolant pipe and drain off
coolant.
Audi A8 2003 ➤
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1. Removing engine 11

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– Disconnect coolant hoses -1 ... 3- and drain off coolant.
– Disconnect coolant hose next to drive shaft (left-side) from
coolant pipe -arrow- and drain off coolant.
– Remove bolts -2- and -3-.
– Detach bottom front coolant pipe from hoses -1- and -4-.
– Disconnect hoses -1- and -2- from connecting pipes for sec‐
ondary air.
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12 Rep. gr.10 - Removing and installing engine

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– Disconnect coolant hoses -1- and -2- from auxiliary radiator
(right-side) and drain off remaining coolant.
– Unscrew nut -1- and remove coolant hose -2- from auxiliary
radiator (right-side).
– Unplug electrical connector -1- at activated charcoal filter sol‐
enoid valve 1 - N80- and detach vacuum hose -2-.
– Detach activated charcoal filter solenoid valve 1 - N80- from
bracket and move it clear to the side with hose still attached.
– Detach coolant hose -arrow- leading from coolant pipe to cool‐
ant expansion tank.
Audi A8 2003 ➤
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1. Removing engine 13

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– Detach electrical connector -2- for air mass meter 2 - G246- .
– Remove air hose -1- from intake manifold.
– Unscrew bolts -arrows- and remove top section of air cleaner
(left-side).
– Remove air duct -1-.
– Remove bolts -arrows-.
– Turn over bottom section of air cleaner and detach vacuum
hose for air flap.
– Remove bottom section of air cleaner (left-side).
– Extract hydraulic fluid for power steering from reservoir using
used oil collection and extraction unit - V.A.G 1782- .
Note
Lay a cloth under the separating point to catch escaping hydraulic
fluid.
– Disconnect hydraulic pressure line for power steering
-arrow- at front left of engine.
– Seal off open pipes/lines and connections with clean plugs
from engine bung set - VAS 6122- .
– Pull bonnet seal away from lock carrier and wing panels.
– Detach vacuum hoses -1- and -2- and move clear.
Audi A8 2003 ➤
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14 Rep. gr.10 - Removing and installing engine