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 ➤
8-cylinder TDI engine (4.0 ltr. 4-valve common rail),
mechanics
Engine ID ASE
Edition 12.2013
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
21 - Turbocharging/supercharging
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 © 2014 Audi AG, Ingolstadt A0051006420

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 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when using testers and measuring instruments during a road test . . . . 3
2.3 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Checking for leaks in the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.6 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.7 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Moving lock carrier into service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Lowering subframe for repair and assembly work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2 Servicing work on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.1 Poly V-belt drive for alternator and air conditioner - exploded view of components . . . . . . 54
2.2 Poly V-belt drive for alternator and air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . 55
2.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.5 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.6 Removing and installing sealing flange (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3 Servicing work on timing chain end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.1 Drive plate - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3 Renewing crankshaft oil seal (timing chain end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.4 Vacuum pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.5 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.1 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2 Allocation of main bearing shells for new crankshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.3 Allocation of crankshaft bearing shells for retaining frame without visible colour coding . . 73
4.4 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.5 Measuring axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.6 Measuring radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.1 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Audi A8 2003 ➤
8-cylinder TDI engine (4.0 ltr. 4-valve common rail), mechanics - Edition 12.2013
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.
5.4 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.5 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1 Timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.1 Timing chain covers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.2 Removing and installing oil seal for toothed belt sprocket on high-pressure pump . . . . . . 84
1.3 Removing and installing all timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2 Drive chains for camshafts and valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.1 Camshaft timing chain (left-side) - exploded view of components . . . . . . . . . . . . . . . . . . . . 97
2.2 Camshaft timing chain (right-side) - exploded view of components . . . . . . . . . . . . . . . . . . 98
2.3 Removing and installing camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.4 Detaching camshaft timing chains from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.5 Drive chain for valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.6 Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.7 Checking drive chains for camshafts and valve gear for elongation . . . . . . . . . . . . . . . . . . 120
3 Auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.1 Chain for auxiliary drives - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.2 Removing and installing chain for auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.3 Auxiliary drives - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.4 Renewing oil seal for power steering pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.5 Removing and installing spur gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.1 Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.2 Cylinder head cover - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.3 Removing and installing cylinder head cover (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.4 Removing and installing cylinder head cover (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.5 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.2 Checking axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.3 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.4 Renewing valve stem oil seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . 163
5.5 Renewing valve stem oil seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . 166
5.6 Checking hydraulic valve compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.7 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.8 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.9 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.10 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.1 Oil pump, sump (bottom section), sump (centre section) - exploded view . . . . . . . . . . . . . . 173
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 175
1.3 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.4 Removing and installing sump (centre section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.6 Sump (top section) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.7 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.8 Oil cooler, pressure control valve, oil filter housing and spray nozzle valve - exploded view
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
1.9 Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
1.10 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.11 Removing and installing pressure control valve for crankcase breather system . . . . . . . . 198
Audi A8 2003 ➤
8-cylinder TDI engine (4.0 ltr. 4-valve common rail), mechanics - Edition 12.2013
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.
1.12 Removing and installing mounting plate for oil cooler, pressure control valve and oil filter
housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1.13 Removing and installing spray nozzle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.14 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.15 Removing and installing oil temperature sender G8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1.16 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.17 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.18 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.1 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.2 Coolant pump and thermostat - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1.4 Removing, installing and checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
1.5 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.6 Removing and installing coolant pipes (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
1.7 Removing and installing coolant pipe (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.8 Removing and installing coolant pipe (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1.9 Removing and installing coolant pipe (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1.10 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 233
1.11 Radiator and radiator fans - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . 233
1.12 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
1.13 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.14 Removing and installing radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
1.15 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1 Servicing charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1.1 Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1.2 Removing and installing turbocharger (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
1.3 Removing and installing turbocharger (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.4 Charge air cooling - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
1.5 Removing and installing charge air cooler (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
1.6 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1.7 Removing and installing charge air cooler (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
1.1 Exhaust system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
1.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 279
1.3 Removing and installing exhaust gas temperature sender 1 for bank 2 G236 . . . . . . . . . . 280
1.4 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1.5 Removing and installing main catalytic converter (left-side) . . . . . . . . . . . . . . . . . . . . . . . . 282
1.6 Removing and installing main catalytic converter (right-side) . . . . . . . . . . . . . . . . . . . . . . 284
1.7 Removing and installing front exhaust pipe (left-side) with starter catalytic converter . . . . 286
1.8 Removing and installing front exhaust pipe (right-side) with starter catalytic converter . . . . 289
1.9 Exhaust manifold - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
1.10 Removing and installing exhaust manifold (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
1.11 Removing and installing exhaust manifold (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
1.12 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
1.13 Aligning tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
1.14 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
2.1 Exhaust gas recirculation system - exploded view of components . . . . . . . . . . . . . . . . . . 295
2.2 Removing and installing mechanical exhaust gas recirculation valve (left-side) . . . . . . . . 296
Audi A8 2003 ➤
8-cylinder TDI engine (4.0 ltr. 4-valve common rail), mechanics - Edition 12.2013
Contents iii

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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.
2.3 Removing and installing mechanical exhaust gas recirculation valve (right-side) . . . . . . . . 297
2.4 Removing and installing exhaust gas recirculation cooler (left-side) . . . . . . . . . . . . . . . . . . 298
2.5 Removing and installing exhaust gas recirculation cooler (right-side) . . . . . . . . . . . . . . . . 300
Audi A8 2003 ➤
8-cylinder TDI engine (4.0 ltr. 4-valve common rail), mechanics - Edition 12.2013
iv Contents

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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00 – Technical data
1 Technical data
(ARL003636; Edition 12.2013)
⇒ “1.1 Engine number”, page 1
⇒ “1.2 Engine data”, page 1
1.1 Engine number
The engine number (including “engine code” and “serial number”)
can be found on the inner part of the block below the intake mani‐
fold (left-side).
There is also a sticker on the intake manifold showing the “engine
code” and “serial number”.
The engine code is also included on the vehicle data sticker.
1.2 Engine data
Code letters ASE
Capacity ltr. 3.936
Power output kW at rpm 202/3750
Torque Nm at rpm 650/1800 … 2500
Bore ∅ mm 81.0
Stroke mm 95.5
Compression ratio 17.5
Fuel According to DIN EN 590
Firing order 1-5-4-8-6-3-7-2
Exhaust gas recirculation yes
Turbocharging/supercharging yes
Self-diagnosis yes
Catalytic converter yes
Charge air cooling yes
Audi A8 2003 ➤
8-cylinder TDI engine (4.0 ltr. 4-valve common rail), mechanics - Edition 12.2013
1. Technical data 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.
2 Safety precautions
⇒ “2.1 Safety precautions when working on the fuel supply sys‐
tem”, page 2
⇒ “2.2 Safety precautions when using testers and measuring in‐
struments during a road test”, page 3
⇒ “2.3 Safety precautions when working on the cooling system”,
page 3
2.1 Safety precautions when working on the
fuel supply system
When working on the fuel system note the following warnings:
WARNING
Risk of injury - fuel system operates under pressure.
♦ Wrap a clean cloth around the connection before opening
the fuel system. Then release pressure by carefully loos‐
ening the connection.
♦ Wear protective gloves.
♦ Wear safety goggles.
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Caution
The high-pressure pump has very close tolerances and must
not be allowed to run without fuel. To prevent this and to enable
the engine to start quickly after parts have been renewed, it is
important to observe the following:
♦ If the high-pressure pump or the components of the fuel
system between the fuel tank and the high-pressure pump
are removed or renewed, the fuel system must be bled ⇒
Rep. gr. 23 ; Bleeding fuel system after installing high-
pressure pump .
Observe the following points to prevent personal injuries and
damage to the injection and glow plug system:
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as
injectors and gas-discharge headlights.
♦ Always switch off the ignition before connecting or discon‐
necting tester cables or electrical wiring for the injection or
glow plug system.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off ignition before washing engine.
Audi A8 2003 ➤
8-cylinder TDI engine (4.0 ltr. 4-valve common rail), mechanics - Edition 12.2013
2 Rep. gr.00 - Technical data

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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.
♦ Erase any entries in event memory resulting from repairs
⇒ Vehicle diagnostic tester, Guided Functions , then In-
terrogate event memory.
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 ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
2.2 Safety precautions when using testers
and measuring instruments during a
road test
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.
2.3 Safety precautions when working on the
cooling system
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.
Caution
Overheating can occur if the filler cap is not fitted properly.
♦ The filler cap must engage positively and audibly when it
is closed.
Audi A8 2003 ➤
8-cylinder TDI engine (4.0 ltr. 4-valve common rail), mechanics - Edition 12.2013
2. Safety precautions 3

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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.
3 General repair instructions
⇒ “3.1 Rules for cleanliness”, page 4
⇒ “3.2 Checking for leaks in the fuel system”, page 4
⇒ “3.3 Foreign particles in engine”, page 5
⇒ “3.4 Contact corrosion”, page 5
⇒ “3.5 Routing and attachment of pipes, hoses and wiring”, page
5
⇒ “3.6 Installing radiators and condensers”, page 5
⇒ “3.7 Checking vacuum system”, page 5
3.1 Rules for cleanliness
Even small amounts of dirt can cause malfunctions. For this rea‐
son, please observe the following rules when working on the fuel
supply system, injection system and turbocharger:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Immediately seal open lines and connections with clean plugs,
for example from engine bung set - VAS 6122- .
♦ Do not remove sealing caps from components until immedi‐
ately prior to installation. Keep components that are to be re-
used in new, sealable plastic bags.
♦ 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 not been stored in the proper packaging (e.g. in tool
boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move the vehicle unless absolutely necessary.
♦ Make sure that no fuel runs onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned again immediately.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
3.2 Checking for leaks in the fuel system
– Start the engine and let it run at medium speed for a few mi‐
nutes.
– Switch off ignition.
– Check the entire 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.
– Then carry out a test drive with at least one full-power accel‐
eration.
Audi A8 2003 ➤
8-cylinder TDI engine (4.0 ltr. 4-valve common rail), mechanics - Edition 12.2013
4 Rep. gr.00 - Technical data