Audi R8 LMS 2018 User manual

Handbook
Audi R8 LMS
MODIFIED TO COVER 2018

Contents
Version 1 2016-01-01 2 / 113
Contents
List of Images ........................................................................................ 4
List of Abbreviations............................................................................... 6
Miscellaneous ........................................................................................ 7
Car Views .............................................................................................. 8
000 –Air Jack and Fire Extinguisher........................................................ 11
000 - 1 Air Jack System ............................................................................ 11
000 - 2 Fire Extinguisher System 596........................................................ 14
100 –Engine Ancillaries, Oil Tank and Water Cooler ................................. 18
100 - 1 Drivetrain .................................................................................... 18
100 - 1.1 Engine................................................................................... 18
100 –1.2 Engine Lubrication ................................................................. 20
100 –1.3 Engine Cooling System ........................................................... 24
100 - 1.3 Clutch - Flywheel.................................................................... 29
200 –Fuel Cell and Exhaust System........................................................ 30
200 - 1 Fuel Cell ...................................................................................... 30
200 –1.1 Refuelling Valve Service Instructions....................................... 30
200 –1-2 Service Instructions Refuelling Coupling.................................. 33
300 –Gearbox, Drive Shafts and Ancillary Components ............................ 36
400 –Front Axle, Anti-Roll Bar, Dampers and Steering ............................. 40
400 –1 Filling / Bleeding Steering System................................................. 40
400 –2 Miscellaneous.............................................................................. 42
400 –2.1 Suspension Geometry Curves .................................................. 44
400 –2.2 Springs ................................................................................. 46
400 –2.3 Anti-roll Bars ......................................................................... 47
400 –2.4 Damper / Ride Height Adjustment........................................... 49
400 –2.5 Camber Adjustment ............................................................... 54
400 –2.6 Toe Rods / Toe Adjustment ..................................................... 56
400 –2.7 Brake discs ............................................................................ 57
500- Rear Axle, Anti-roll Bar and Dampers .............................................. 63
600- Brake Pipes, Brake Cooling Ducts, Wheels and Tyres ......................... 64

Contents
Version 1 2016-01-01 3 / 113
700- Pneumatic Gearshift and Pedals ..................................................... 65
700 - 1 Pedals ......................................................................................... 65
700 - 1.1 Longitudinal Adjustment Pedal Unit ........................................ 65
700 - 1.2 Throttle Pedal ........................................................................ 69
700 - 1.3 Brake Pedal............................................................................ 74
800- Bodywork, Chassis Parts, Seat and Air Conditioning.......................... 77
800 - 1 Seat ............................................................................................ 77
800 - 1.1 Homologation........................................................................ 77
800 - 1.2 Seat Sizes .............................................................................. 79
800 - 1.3 Cushions................................................................................ 80
800 - 1.4 Additional Inserts................................................................... 81
800 - 1.5 Shoulder Strap Mounting ........................................................ 82
801- Aerodynamics .............................................................................. 83
801 - 1 Aero Set-Up Sheet ........................................................................ 83
900- Electric and Data Acquisition.......................................................... 87
900 - 1 Software...................................................................................... 87
900 - 2 Diagnosis..................................................................................... 95
901- Engine Warm-Up Procedure / Engine Start ...................................... 98
901 - 1 Preparation before Engine Start .................................................... 98
901 - 1.1 Checking / Adjusting Gearbox Potentiometer............................ 98
901 - 1.2 Checking Engine Oil Level...................................................... 100
901 - 1.3 Checking Gearbox Oil Level.................................................... 101
901 - 1.4 Fuel, Coolant and Coolant Additive, Steering Oil and Brake Fluid
................................................................................................ 102
901 - 1.5 Preparation Warm Up Procedure / ‘Warm up’ ......................... 104
901 - 2 Warming up / Cooling down the Engine and Gearbox .................... 105
901 - 2.1 Warm up Procedure.............................................................. 105
901 - 2.2 Cooling Down Procedure ....................................................... 106
902 –Service and Maintenance Contacts ............................................... 107

List of Images
Version 1 2016-01-01 4 / 113
List of Images
Image 1: Adding Engine Oil during Endurance Races ..................................... 22
Image 2: Scheme of Cooling System ............................................................ 24
Image 3: Expansion Reservoir...................................................................... 28
Image 4: Refuelling Coupling, Service Tool and Molykote 1292 Grease........... 30
Image 5: Using Service Tool, Refuelling Coupling in Service Position .............. 31
Image 6: Using Service Tool, Lubricating O-rings........................................... 31
Image 7: Refuelling Coupling and Molykote 1292 Grease .............................. 33
Image 8: Service Tool Decoupled and Unlocked............................................. 34
Image 9: Service Tool Fitted, Locked and Open ............................................. 34
Image 10: Gearbox –FIA Homolagated Gear Ratios ...................................... 36
Image 11: Gearbox –Clutch Bleed Nipple, Oil Level Check, Inspection Openings
................................................................................................ 38
Image 12: Screw Plug, Adjustable Differential Preload.................................. 39
Image 13: Adjustable Preload ..................................................................... 39
Image 14: Push Rod Thread With Groove Marking......................................... 51
Image 15: Lower Damper Eye in Maximum Permitted Position....................... 51
Image 16: Characteristic Curve Front Damper 4SA 412 019 B ........................ 53
Image 17: Characteristic Curve Rear Damper 4SA 512 019 C ......................... 53
Image 18: Front Axle Brake Cooling Duct Without Blanking........................... 61
Image 19: Front Axle Brake Cooling Duct With Blanking................................ 61
Image 20: Rails with Ratchet and Detent Mechanism .................................... 65
Image 21: Centre Console with Button to Disengage Pedal Unit and Main Switch
to Activate Compressor .............................................................. 66
Image 22: Push Surface on the Pedal Unit Cover ........................................... 67
Image 23: The Two Possible Throttle Pedal Plate Positions............................ 69
Image 24: Nut to Adjust Spring Preload on Throttle Pedal............................. 70
Image 25: Standard Setting and Adjustment Direction for Spring Preload on
Throttle Pedal............................................................................ 70
Image 26: Pedal Assembly –Throttle Pedal Damper...................................... 71
Image 27: Adjusting the Throttle Pedal Damper ........................................... 73

List of Images
Version 1 2016-01-01 5 / 113
Image 28: Basic Setting: Brake Pedal Plate 10 mm in Font of Throttle Pedal
Plate......................................................................................... 74
Image 29: Setting Brake Pedal Plate 20 mm in Front of Throttle Pedal Plate .. 74
Image 30: Brake Pedal Plate Long Side Left.................................................. 75
Image 31: Brake Pedal Plate Long Side Right................................................ 75
Image 32: Brake Pedal Plate Height Adjustment........................................... 76
Image 33: Brake Pedal Plate Angle Adjustment ............................................ 76
Image 34: Audi Safety Seat PS1................................................................... 77
Image 35: Shoulder Strap Mounting Below Roll-Cage Tube............................ 82
Image 36: Shoulder Strap Mounting Above Roll-Cage Tube ........................... 82
Image 37: Rear Wing Adjustment Range...................................................... 83
Image 38: Shift Barrel in Neutral (N) Position............................................... 99
Image 39: Adjusting the Gearbox Potentiometer .......................................... 99
Image 40: Gearbox –Clutch Bleed Nipple, Oil Level Check, Inspection Openings
.............................................................................................. 101
Image 41: Coolant Expansion Reservoir ..................................................... 102

List of Abbreviations
Version 1 2016-01-01 6 / 113
List of Abbreviations
ARB anti-roll bar
aps Throttle pedal
ath butterfly
cam Camshaft
DDU Digital Display Unit
ECU Electronic Control Unit
FIA Fédération Internationale de l’Automobile
KL Design Position
PDM Product Detail Assembly Instructions
POM Polyoxymethylene
RP Reference Page
TC Traction Control
VO Variant Option
WP Work page

Miscellaneous
Version 1 2016-01-01 7 / 113
Miscellaneous
The Audi R8 LMS race car was designed and built in accordance with the FIA
technical regulations for GT3 category cars and in accordance with the FIA
homologation.
Homologation number: GT3-038
Homologation date: 01.05.2015
The specification corresponds with the current version of the regulations at the
time of delivery.
The car, including its components and add-on parts, is manufactured exclusively
for the defined purpose in motorsport and must not be used for other purposes
–especially not on public roads.
Information about the handbook
This handbook is for the R8 LMS Generation II and describes the possibilities for
adjustment and certain maintenance work.

Car Views
Version 1 2016-01-01 8 / 113
Car Views

Car Views
Version 1 2016-01-01 9 / 113

Car Views
Version 1 2016-01-01 10 / 113

000 –Air Jack and Fire Extinguisher
Version 1 2016-01-01 11 / 113
000 –Air Jack and Fire Extinguisher
000 - 1 Air Jack System
- When driving, the bleed valve must be open (pulled out) in order to
ensure the air jack piston is fully retracted.
- Working under the car supported only by the air jacks without the chocks
(safeties) is forbidden.
- To prevent damage to the end stops on the piston rods, the air jack should
never be pressurised without lifting the car or alternatively the pressure
must be increased very slowly and in a controlled manner.
- Recommended operating pressure: 40 bar
- Never use cleaning products containing mineral oil.
- Do not dismantle the air jack –the system is pressurised even when
retracted!
- The tightening torque for the grooved nut (to secure the air jack) must
always be checked during a normal car check (spanner check).
- Tightening procedure grooved nut: see PDM 4SA 011 001
- If a loose or incorrectly mounted air jack is identified it must be replaced
immediately.

000 –Air Jack and Fire Extinguisher
Version 1 2016-01-01 12 / 113
- If a new pressure line is fitted to the car, the insertion depth of the tube
must be marked before tightening the union nut.
- Recommended air jack service interval: see PDM 4SA 011 001
- Contact Krontec for service and maintenance (see chapter 902 –Service
and Maintenance Contacts)
- Please refer to the manufacturer’s product description (Krontec) for
additional safety guidelines.
Car lift system
- Car lifting systems can be bought directly from the product manufacturer
Krontec (for contact details see chapter 902 –Service and Maintenance
Contacts).
- ONLY use original parts otherwise damage can occur to the air jack’s
bottom cover or piston rod.

000 –Air Jack and Fire Extinguisher
Version 1 2016-01-01 13 / 113
Lifting the car
- It is recommended to lift the car to the desired level for working using
ONLY a Car lift System.
- Only in exceptional circumstances such as during a race should the car be
lifted on the flat bottom.
In this case, it is necessary to lift the car on the points intended for this purpose
(see red marks).
Front axle: only at the rear mounting point of the front splitter
Rear axle: only at the areas marked yellow on the rear diffusor
Please ensure that a lifting device with a sufficiently large plate is used!
Lifting the car using a vehicle hoist
-The car can be lifted using a vehicle hoist with the arms positioned as
shown in the above picture.

000 –Air Jack and Fire Extinguisher
Version 1 2016-01-01 14 / 113
000 - 2 Fire Extinguisher System 596
The car is equipped with an FIA homologated fire extinguisher system. The
extinguishant is Aerosol. The fine particulate powder used is extremely efficient
and thanks to a special nozzle system is distributed evenly in the car. The
extinguishant is discharged via three nozzles –2 in the engine bay as well as one
nozzle in the cockpit.

000 –Air Jack and Fire Extinguisher
Version 1 2016-01-01 15 / 113
Technical Data
-Extinguishant: Aerosol KD-A96
-Filling pressure: 36.5 bar / 20 °C
-Operating pressure: Min. 32.5 bar
Max. 41.5 bar
-Net extinguishant weight: 0.5 kg
-Operating temperature range: - 10 to + 60 °C
-Discharge time: Approx. 5 seconds
-Homologation number: EX.014.03 04/03
Checking the Extinguishing System
The fire extinguishing system must be checked and armed each time before an
event where the car is driven on the race track.
The following components must be checked:
-Extinguishant reservoir:
Operating pressure must not be less than 32.5 bar or exceed 41.5
bar
The next inspection date must not be exceeded (see service interval
extinguishing system)
-Control unit:
Set the toggle switch on the control unit to the ‘TEST’ position
The four LEDs should illuminate afterwards
Small green LED --> System active
BATTERY LED --> Battery ok (charged)
FIRE LED --> Electric circuit to trigger ok
EXTING LED --> Electric circuit to detonator ok
If the BATTERY LED does not glow, the two batteries must be
changed (see ‘Changing Batteries’).
If one of the three remaining LEDs does not glow, the wiring loom
must be checked.

000 –Air Jack and Fire Extinguisher
Version 1 2016-01-01 16 / 113
Activating Extinguishing System
-When the toggle switch on the control unit is set to ‘ON’, the
extinguishing system is operational. Only the system active LED glows.
The fire extinguisher is activated and extinguishant is discharged from the
nozzles by pressing the ‘FIRE’ button on the dashboard or by pulling out
the pip pin emergency fire extinguisher switch located in the front
cover cowling.
-When the racecar is no longer in operation, the fire extinguisher system
should be deactivated. Set the toggle switch to the ‘OFF’ position.
Changing the Control Unit Battery
-Attention: The toggle switch mounted on the control unit must be set in
the ‘OFF’ position.
-Remove the control unit cover and replace the battery. Ensure that the
battery polarity is correct.
-Use only original batteries of specification DURACELL PLUS Alkaline MN
1604 6LR61 9 V or Philipps Alkaline 6LR61 9 V.

000 –Air Jack and Fire Extinguisher
Version 1 2016-01-01 17 / 113
Service Interval Extinguisher System
-Extinguishant reservoir:
The next date for servicing the extinguishant reservoir is printed on the
service sticker (see inspection sticker). The date indicates the latest date
for servicing the extinguishant reservoir. The service interval is 2 years.
See chapter 902 –Service and Maintenance Contacts for contact
information for Kidde-Deugra regarding servicing.
-Detonator:
The detonator has a service life of 3 years after fitting to the
extinguishant reservoir, and a maximum of 5 years after the date of
manufacture.
Mounting Instructions
-If a new discharge pipe is fitted in the car, the insertion depth of the pipe
should be marked before tightening the union nut.
-Attention: The position and alignment of the nozzles must not be
changed!
-Additional information about the extinguishing system can be found in
the KD-596 extinguisher system instruction manual.
Date of manufacture:
Script:

100 –Engine Ancillaries, Oil Tank and Water Cooler
Version 1 2016-01-01 18 / 113
100 –Engine Ancillaries, Oil Tank and Water Cooler
100 - 1 Drivetrain
100 - 1.1 Engine
a) Technical Data
1. Type V10 FSI –90 °
2. Displacement 5,204 cc
3. Power Up to 585 hp. Adjustable using air
restrictor
4. Direction of rotation Anticlockwise when looking at the clutch
5. Weight Approx. 220 kg
6. Firing order 1/6/5/10/2/7/3/8/4/9 (cylinder 1 is
front-right in direction of travel)
b) Filling Quantities
1. Engine oil Castrol 10-W60 8,500 ml
2. Coolant Min. 10 % Glycol 13,500 ml
3. Servo oil Castrol 5-W30 1,000 ml
4. Fuel Min. 98 RON
We recommend that the oil levels are checked after every session and refill if
necessary.
Complete exchange of fluids and filters after maximum 6,000 km.

100 –Engine Ancillaries, Oil Tank and Water Cooler
Version 1 2016-01-01 19 / 113
c) Service & Maintenance
1. Please refer to PDM 4SA 100 021 for 902 –Service and
Maintenance Contacts
2. 10,000 km Minor service - description
3. 20,000 km Major service –description
-The engine must be delivered in a transport box (flight case) with the
following ancillary components:
Flywheel
Induction system including butterflies
Injectors wiring loom
Engine mounts
Generator/alternator including complete poly-V-belt system
Oil pump including pressure (supply) and return pipes
Fittings for cooling water supply and return
Do not deliver the clutch, exhaust manifolds or engine wiring loom

100 –Engine Ancillaries, Oil Tank and Water Cooler
Version 1 2016-01-01 20 / 113
100 –1.2 Engine Lubrication
The R8 LMS engine is equipped with a dry sump lubrication system. The oil tank
is located in the engine bay.
Engine cooling is made via an oil-water heat exchanger and an additional oil
cooler mounted in the sill on the left hand side of the car.
a) Engine Oil
Castrol EDGE FORMULA RS 10W-60 or Castrol EDGE TITANIUM FST 10W-60
Part number V31 748 009 --> 5 litre bundle
b) Oil Level Measurement
1. Position the car on a level, flat surface
2. Run the engine until the engine oil temperature reaches 100 °C –
110 °C (see chapter 901- Engine Warm-Up Procedure / Engine Start
3. Run the engine at idle speed for approx. 2 minutes
4. Switch off the engine and after approx. 2 minutes check the oil level
5. Oil level in ‘Fill’ range: add 1 litre oil until oil level reaches ‘Do not
fill’ range
6. The oil level should be in the upper third of the ‘Do not fill’ range