4.2l v8 5v Engine Mechanical, Engine Code(s): Bfm Audi A8 D3 рестайлинг

Scheme 1

The engine number ("engine code" and "serial number") are stamped on left side of cylinder block.

In addition, a sticker with "engine code" and "serial number" is affixed to timing belt cover.

The engine code is also included on vehicle data plate.

Engine data

*In exceptional circumstances 95 RON, however with reduced performance

Scheme 2

Special tools, testers and auxiliary items required

1. Pry Lever - Rmv Outside Mirror 80-200
2. Old oil collecting and extracting device V.A.G 1782
3. Hose clamp pliers V.A.G 1921
4. Spring-type clip pliers V.A.S 5024 A

1. Step ladder VAS 5085
2. Scissor lift table VAS 6131

Scheme 3

1. Locking Pin T10060 A

Scheme 4

1. Tensioning Strap T10038 qty. 2

Scheme 5

1. Lifting Eyebolt 3368 qty. 2

Removing

Note. Engine is removed downward with transmission and subframe. Obtain radio anti-theft code. All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine. Battery is located at right in luggage compartment. Drained coolant must be stored in a clean container for disposal or reuse.

Note. Before raising the vehicle on a hoist (wheels off the ground), first activate the vehicle jack mode --> 43 - SELF LEVELING SUSPENSION .

Scheme 6

1. Remove rubber seal for plenum chamber cover - 1 -.
2. Remove plenum chamber cover - 2 - and - 3 -.
3. Switch ignition on.
4. Carry out flick wipe function and let wiper motor run to rest position.

1. Turn ignition and remove ignition key.

Scheme 7

1. Pry off cover cap at wiper arms using a screwdriver - arrows - and remove hex nut.
2. Pull off wiper arms from wiper axles.

Scheme 8

1. Remove wind deflector - 1 - by removing bolts on left and right - arrows - if present.

Scheme 9

1. Remove dust and pollen filter, to do so open quick-release screws - arrows -.

Scheme 10

1. Remove right luggage compartment side trim cover.

Scheme 11

1. Remove cover - 1 - above battery.

Note. Disregard - 2 -.

Scheme 12

1. Disconnect Ground (GND) strap - arrow - at battery.

For vehicles with auxiliary heater

Scheme 13

1. Remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

All

1. Remove left and right front wheels.

Scheme 14

1. Remove noise insulation, items - 1 through 4 -.
2. Remove front and rear parts of wheel housing liner at right front --> «66 - EXTERIOR EQUIPMENT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Remove front part of left front wheelhouse liner --> «66 - EXTERIOR EQUIPMENT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Remove front bumper --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 15

1. Disconnect intake air duct - 1 - at Secondary Air Injection (AIR) Pump Motor V101.

Scheme 16

1. Remove engine cover - 1 - and - 2 - upward.
2. Carefully open cap on coolant expansion tank (release pressure), then close again.

Scheme 17

1. Remove clips - 1 - using Pry Lever - Rmv Outside Mirror 80 - 200.
2. Remove bolt - 2 - and remove cover.

Note. Note clips when installing - arrows -.

Scheme 18

1. Remove hose - 1 -.

Scheme 19

1. Disconnect hose - 1 -.
2. Unclip hose - 2 -.
3. Remove air intake tube - arrows -.

Scheme 20

1. Disconnect electrical connector - 1 - from mass air flow (MAF) sensor.
2. Remove air filter box - arrows -.
3. Remove right headlight --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment) .

Scheme 21

1. Depress locking mechanisms - arrows - and remove air guide at right front from lock carrier.

Scheme 22

1. Remove bolts - arrows - and remove air guide.
2. Pull lock carrier toward front --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior)

Scheme 23

1. Unclip cable - arrows -.
2. Remove bolts - 1 - for torque support.

Scheme 24

1. Separate torque support - arrow - from torque support valve N382 and remove.

Scheme 25

1. Disconnect connector - 1 - of heated oxygen sensor before catalytic converter (black).
2. Disconnect connector - 2 - of oxygen sensor behind catalytic converter (brown).
3. Disconnect connector - 3 - from solenoid valve and lay wiring harness to engine aside.
4. Disconnect hose - 4 - from solenoid valve and lay hose aside.

1. free up electrical wires of oxygen sensors.

Scheme 26

1. Disconnect fuel supply line - 1 -.
2. Disconnect fuel return line - 2 -.
3. Remove right trim for A-pillar --> «70 - INTERIOR TRIM»(/audi/a8/d3-2005-2007/remont/gauges-instrument-panels/#body-interior) .
4. Fold floor covering back.

1. Remove protective cover from above main fuse holder.

Scheme 27

1. Fold cap - 2 - aside.
2. Remove nut - 4 -.
3. Remove terminal 30 wire to starter.

Note. Ignore - 1 - and - 3 -.

Scheme 28

1. Remove harness clamp - 1 - in right front wheel housing.
2. Pull wiring harness out from interior - arrow -.

Scheme 29

1. Disconnect electrical harness connectors - 1 - and - 3 -.
2. Remove Ground (GND) wire - 2 - on long member.
3. Remove bracket for wiring harness on longitudinal member - arrows - and lay wiring harness aside.
4. Place drip tray for workshop crane VAS 6208 under engine.

Scheme 30

1. Disconnect coolant hose - 1 - to drain coolant.
2. Disconnect coolant hose - 2 -.
3. Open drain plug - 3 - and drain coolant from oil filter bracket.

Scheme 31

1. Open drain plug - arrow - and drain coolant from engine.

Scheme 32

1. Disconnect coolant hoses - 1 and 2 -.

Note. Before removing toothed belt, mark running direction with chalk or felt tip marker. A reversed turning direction can cause damage to the belt under operating conditions. Note previously marked direction of belt rotation and be sure that it is seated correctly on pulley.

Scheme 33

1. To loosen ribbed belt, turn tensioner clockwise in direction of - arrow - using box wrench until two holes are aligned; counter hold in position using locking pin T10060 A.
2. Remove ribbed belt.

Scheme 34

1. Disconnect vacuum hose - 1 - to variable-tract intake manifold.

Note. For the sake of illustration, compressor is removed.

Scheme 35

1. Disconnect electrical connector - 1 - from A/C compressor and free up electrical wire.
2. Remove A/C compressor - arrows - and hang at side.

Note. Lines remain connected. Lines must not be bent. Pay attention to centering sleeves for guiding A/C compressor at retainer.

1. Place drip tray VAS 6208 underneath vehicle to collect hydraulic fluid.

Scheme 36

1. Loosen clamp - 4 - , pull off intake line - 3 - and lay aside.
2. Remove banjo fitting - 2 - for expansion hose - 1 - and lay expansion hose aside.
3. Seal connections of power steering pump using sealing plugs.

For vehicles without auxiliary/additional heater

Scheme 37

1. Disconnect supply and return line to heater core - arrows -.

For vehicles with auxiliary/additional heater

Scheme 38

1. Disconnect coolant hose - arrow - from coolant pipe.

All

Scheme 39

1. Disconnect hose - arrow - from coolant pipe.

Scheme 40

1. Remove insulation mat from dome brace - arrows -.

Scheme 41

1. Remove dome brace bolts - 1 through 4 -.

Note. Note spacer sleeves for - 2 -.

Scheme 42

1. Remove engine control module - arrows - and lay aside.

Note. The anti-theft device is not removed, the control module remains attached.

Scheme 43

1. Disconnect electrical connector - 1 -.
2. Remove E-Box cover - arrows -.

Scheme 44

1. Disconnect electrical connectors - arrows - and expose wiring harness with control module up to engine.

Scheme 45

1. Disconnect hose - arrow - for secondary air injection.

Scheme 46

1. Disconnect hose - arrow - to brake booster.

Scheme 47

1. Disconnect hose - 1 - for permanent ventilation from coolant expansion tank.
2. Disconnect hose - 2 - for permanent ventilation from coolant expansion tank.
3. Remove coolant reservoir - arrows -.
4. Disconnect electrical connector for coolant level indicator.

1. Remove coolant hose beneath coolant reservoir.

Note. Wheel bearing housing must be supported to prevent upper control arm joints from being damaged.

Note. Ensure Lifting Eyebolt 3368 thread does not protrude too far toward top.

Scheme 48

1. Position Lifting Eyebolt 3368 into hole at suspension strut dome and secure with washer - 1 - and nut - 2 -.
2. Tie up wheel bearing housing using tensioning strap T10038 as shown in illustration.

Scheme 49

1. Have a second technician press brake pedal.

1. Remove collar bolt - 2 - at left and right drive axles - 1 -.

Scheme 50

1. Remove bolts - arrows - uniformly at left and right.
2. Remove stabilizer.

Scheme 51

1. Remove cross member - arrows - for noise insulation at subframe.

Scheme 52

1. Disconnect electrical harness connector - 2 - at left level control system sensor.
2. Remove coupling rod - 1 - at left and right control arms.

Scheme 53

1. Remove air spring damper from control arm - arrow -.

Scheme 54

1. Remove guide control link - 1 - and control link - 2 - on subframe.

Scheme 55

1. Pivot guide control link - 1 - and control link - 2 - outward.

1. Repeat work procedure on opposite side of vehicle.

Scheme 56

1. Remove shielding plate - arrows - of drive axles.

Note. The left shielding plate consists of 2 parts.

1. Remove drive shaft from transmission flange.

1. Pivot wheel bearing housing outward and remove drive axle.
2. Repeat work procedure on opposite side of vehicle.

Scheme 57

1. Loosen double clamps - 1 - and - 2 - and slide toward front.
2. Remove front cross member - arrows -.

Scheme 58

1. Remove drive shaft heat shield - A - - arrows -.
2. Remove bolts at transmission/drive shaft flange.
3. Push drive shaft together with rear final drive. The constant velocity (CV) joints can move axially.
4. Tie up drive shaft to side at body.

Scheme 59

1. Pry off selector lever cable - 2 - from ball head using Pry Lever - Rmv Outside Mirror 80 - 200.
2. Remove securing device from bracket - 1 - and expose selector lever cable.

Prepare scissor lift platform

Scheme 60

1. Equip scissor lift table VAS 6131 with support set VAS 6131/10 and supplementary set, Audi A8 VAS 6131/11 as follows

1. Install attachments on scissor lift table by hand first.
2. Place scissor lift platform VAS 6131 in horizontal position.
3. Note bubble level (sight glass) on support platform
4. Drive scissor lift platform VAS 6131 under engine/transmission subassembly.

Scheme 61

1. Place Support Set VAS 6131/10 and Supplementary Set, Audi A8 VAS 6131/11 attachments on front of engine as shown in illustration.
2. Make sure threaded spindles are installed completely.

Scheme 62

1. Position attachments of support set VAS 6131/10 at left and right on engine carrier and subframe, as shown in illustration.

Scheme 63

1. Place Support Set VAS 6131/10 and Supplementary Set, Audi A8 VAS 6131/11 attachments on rear of transmission as shown in illustration.
2. Twist all spindles of support elements upward far enough until all support pins make contact at support points.
3. When all attachments are positioned, lift scissor lift table far enough until engine and transmission mount are free of tension.
4. Tighten base plates for attachments to 20 Nm onto scissor lift table VAS 6131.

Scheme 64

1. Remove bolts - arrows - at tunnel cross member.

Scheme 65

1. Mark installation position of subframe on long member using a felt tip pen.
2. Remove bolts - 1 - and - 4 -.
3. Remove bolts - 2 - and - 3 - in diagonal sequence and in stages.

Note. Verify that all hoses and lines between engine, transmission, subframe and body have been disconnected. While lowering, carefully guide engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.

1. Slowly lower engine/transmission subassembly downward.
2. Remove scissor lift table VAS 6131 under vehicle.

Engine and transmission, separating

1. Engine/transmission removed and attached to scissor lift platform VAS 6131.

Scheme 66

1. Rotate spindles of support elements - 2 - at left and right of subframe completely downward.
2. Remove support pins from spindles.
3. Remove subframe - 3 - to side.

Note. A second technician is required to remove subframe.

1. Rotate spindles of support elements - 1 - at left and right of engine carrier - 4 - completely downward.

Scheme 67

1. Remove bolts - arrows - for engine mount at left and right.
2. Remove engine carrier.
3. Remove four base plates of attachments for engine carrier and subframe from scissor lift table VAS 6131.
4. Equip scissor lift table VAS 6131 with support set VAS 6131/10 and supplementary set, Audi A8 VAS 6131/11 as follows

Note. The other attachments remain unchanged.

Scheme 68

1. Place Support Set VAS 6131/10 and Supplementary Set, Audi A8 VAS 6131/11 attachments on left of engine/transmission as shown in illustration.

Scheme 69

1. Position attachments from Support Set VAS 6131/10 at right on engine/transmission, as shown in illustration.
2. Twist spindles of attachments upward far enough until all support pins make contact at support points.
3. Tighten base plates for attachments to 20 Nm onto scissor lift table VAS 6131.
4. Free up Heated Oxygen Sensor (HO2S) 2 G108 electrical wire.

Scheme 70

1. Remove catalytic converter with front muffler from exhaust manifold - arrows -.

Scheme 71

1. Disconnect electrical connector - 3 - (brown) of Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 and free up electrical wire.

Scheme 72

1. Remove bolt - arrow - on bracket for exhaust pipe.

Note. Flex joint in front exhaust pipe must not be bent more than 10° , otherwise it may be damaged.

Scheme 73

1. Remove bolt - 1 - on bracket for exhaust system and remove catalytic converter with front muffler.

Scheme 74

1. Remove water pipe at right - arrows -.

Scheme 75

1. Disconnect water pipe - arrow - and remove.
2. Free up Heated Oxygen Sensor (HO2S) G39 electrical wire.

Scheme 76

1. Remove catalytic converter with front muffler from exhaust manifold - arrows -.

1. Disconnect electrical connector - 2 - (black) of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130.

Scheme 77

1. Remove bolt - 1 - on bracket for exhaust pipe.
2. Remove heat shield - 2 -.
3. Free up Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 electrical wire.

Note. Flex joint in front exhaust pipe must not be bent more than 10° , otherwise it may be damaged.

1. Remove bolt - 2 - on bracket for exhaust system and remove catalytic converter with front muffler.

Scheme 78

1. Disconnect electrical harness connector on transmission, to do this swing twist lock counterclockwise - arrow -.

1. Disconnect electrical connector - 1 - (gray) for Engine Speed (RPM) Sensor G28 and free up electrical wire with heat shield.

Scheme 79

1. Disconnect coolant hoses - arrows -.
2. Disconnect connector from engine mount.

Scheme 80

1. Remove wiring harness from engine mount - 1 -.
2. Remove engine mount - arrows -.

Scheme 81

1. Remove starter with connected wiring harness - 1 and 4
2. When disassembled, rotate engine to Top Dead Center (TDC) and align marking on transmission housing with marking on converter.

Note. Before removing converter from drive plate, mark position of both components toward each other.

Scheme 82

1. Remove torque converter from drive plate, 3 bolts.

Note. To loosen the torque converter bolts counter hold main bolt of crankshaft.

1. Remove engine/transmission connecting bolts.

Scheme 83

1. Loosen side clamping screws - 1 - on scissor lift platform VAS 6131 and pull rear platform top with transmission toward rear - arrow - , simultaneously push torque converter through opening of drive plate while doing this.
2. Secure torque converter in transmission so that it cannot fall out.

Scheme 84

Special tools, testers and auxiliary items required

1. Adapter set for engine and transmission support VW 540/1 B
2. Engine and transmission holder VAS 6095
3. Shop crane VAS 6100
4. Lifting tackle 3033

1. Shackle 10 - 222 A/12

Work procedure

Scheme 85

1. Engage shackle 10 - 222 A/12 at right front and left rear engine lifting eye.
2. Hook in lifting tackle 3033 at shackles 10 - 222 A/12 and at workshop crane VAS 6100 , as depicted in illustration.

Scheme 86

1. Lift engine by shop crane VAS 6100 far enough so that flywheel center is at height of mounting plate of engine and transmission holder VAS 6095. Then, install with four universal mounting components at cylinder block as depicted.

Installing

Note. During assembly, replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as O-rings and gaskets. Secure all hose connections using hose clamps appropriate for the model type . During installation, all cable ties must be re-installed at the same location. During installation, re-install all heat insulation sleeves and heat shields at the same locations.

1. Install torque converter --> «32 - TORQUE CONVERTER»(/audi/a8/d3-2005-2007/remont/automatic-trans/#6-speed-automatic-transmission-09e-awd) for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE «32 - TORQUE CONVERTER»(ref-289215-S27923605822008062700000) for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE .
2. Make sure alignment sleeves for engine to transmission are installed in cylinder block. Install if necessary.
3. No needle bearing is installed in crankshaft on vehicles with automatic transmission.
4. Before connecting engine and transmission, rotate torque converter and engine drive plate so that holes or threaded holes stands at height of opening of removed starter.

1. To secure torque converter to drive plate, use new original ribbed bolts .

1. Attach torque converter to drive plate, 3 bolts.

Note. To tighten torque converter bolts, counter hold main bolt of crankshaft.

Note. Torque specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not. Do not use any degreased parts. Tolerance for torque specifications ± 15%.

Scheme 87

1. Securing engine/transmission (flange view of transmission)

Installation is in reverse order of removal, note the following

1. Always clean threaded drive shaft bores in transmission flanged shaft of locking fluid residue using a tap before installation.

1. Twist spindles of attachments from support set VAS 6131/10 and supplementary set, Audi A8 VAS 6131/11 downward at left on engine/transmission.

1. Twist spindles of support elements support set VAS 6131/10 downward at right on engine/transmission.
2. Remove four base plates of attachments for engine carrier and subframe from scissor lift table VAS 6131.

Note. The other attachments remain unchanged.

1. Equip scissor lift table VAS 6131 with support set VAS 6131/10 and supplementary set, Audi A8 VAS 6131/11 as follows

1. Position engine carrier on both attachments VAS 6131/10-7.
2. Twist left and right spindle of support elements VAS 6131/10-7 upward.
3. Tighten base plates for attachments to 20 Nm onto scissor lift table VAS 6131.

Note. A second technician is required to position subframe onto support elements.

1. Position subframe on both attachments VAS 6131/10-8.
2. Twist left and right spindle of support elements VAS 6131/10-8 upward.
3. Tighten base plates for attachments to 20 Nm onto scissor lift table VAS 6131.

1. Tighten left and right bolts - arrows - for engine mount.
2. Guide engine/transmission unit with subframe and engine carrier into body from below using scissor lift table VAS 6131.

1. Install subframe --> «40 - FRONT SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
2. Tighten bolts for subframe only to tightening torque, do not tighten further (tighten bolts only after axle alignment) --> «40 - FRONT SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

1. Tighten bolts - 4 - for engine carrier.

1. Tighten bolts - arrows - at tunnel cross member.
2. Install drive shaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a8/d3-2005-2007/remont/differentials-drive-axles/#rear-final-drive-0ar) .
3. Install selector lever cable, adjust if necessary --> «37 - CONTROLS, HOUSING»(/audi/a8/d3-2005-2007/remont/automatic-trans/#6-speed-automatic-transmission-09e-awd) for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-289215-S16746576102008062700000) for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE .
4. Install exhaust system free of stress --> «Exhaust system, installing free of tension»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__exhaust-system-installing-free-of-tension)

1. Install guide control link, control link and stabilizer --> «40 - FRONT SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
2. Install drive axles --> «40 - FRONT SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
3. Fill with coolant.
4. Install torque support --> «Torque support (with torque support valve N382), assembly overview»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

1. Install dome brace --> «47 - BRAKES - HYDRAULIC COMPONENTS»(/audi/a8/d3-2005-2007/remont/anti-locktraction-control/#brake-system) .
2. Mount wiper arms and adjust --> «92 - WINDSHIELD WIPER AND WASHER SYSTEM»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment) .
3. Before first engine start, fill hydraulic oil into power steering system refill tank; power steering pump must not run dry.
4. Connect battery --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment) .

1. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Install front bumper --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Fill up power steering oil and bleed steering system --> «48 - STEERING»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
4. Adjust headlights --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment) .

1. Check engine oil level before starting engine --> «Oil level, checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-level-checking) .
2. Check engine oil level of automatic transmission.
3. Perform axle alignment --> «44 - WHEELS, TIRES AND WHEEL ALIGNMENT»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

1. Raise windows with electric window regulators up to stop.
2. Activate all power window switches "up" again for at least one second to activate automatic window raising/lowering.
3. Set clock.

Torque specifications

Note. Torque specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not. Do not use any degreased parts. Tolerance for torque specifications ± 15%.

Alignment sleeves (- A - and - B -).

Scheme 88

Special tools, testers and auxiliary items required

1. Engine support bridge 10 - 222 A
2. Shackle 10 - 222 A/12
3. Adapter 10-222 A/21

Removing

Note. Before raising the vehicle on a hoist (wheels off the ground), first activate the vehicle jack mode --> 43 - SELF LEVELING SUSPENSION .

1. Remove rubber seal for plenum chamber cover - 1 -.
2. Remove plenum chamber cover - 2 - and - 3 -.

1. Remove engine cover - 1 - upward.

1. Remove clips - 1 -.
2. Remove bolt - 2 - and remove cover.

Note. Note clips when installing - arrows -.

Scheme 89

1. Remove left cover by removing bolt - 1 - and removing expanding rivet - 2 -.

Note. Note clips when installing - arrows -.

Scheme 90

1. Remove cover bracket - 1 -.
2. Remove bracket for A/C line - 2 -.
3. Unclip bracket for A/C line - 3 -.

1. Remove bolts - 4 - on left and right.

Scheme 91

1. Secure engine support bridge 10 - 222 A with adapters 10 - 222 A/21 at suspension strut domes.
2. Install adapters 10 - 222 A/21 to dome brace - 3 - at left and right.

1. Support for left and right side of vehicle is marked.
2. The center support point is secured on front bolts for dome brace.
3. Knurled-head bolt - 1 - must be turned downward far enough so that supporting plate makes contact on suspension strut dome.

Scheme 92

1. Secure shackles 10 - 222 A/12 to right rear engine lifting eyelets.
2. Hook shackles 10 - 222 A/12 into spindles of engine support bridge 10 - 222 A.
3. Slightly pre-tension engine using engine support bridge spindles.

For vehicles with parking/auxiliary heater

1. Remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

All

1. Remove front noise insulation - 1 -.

Scheme 93

1. Remove bolts - 1 through 3 - on left and right.
2. Lower engine carrier.

Engine mount, right

Scheme 94

1. Disconnect electrical connector - 2 - on engine mount.
2. Remove cable clip - 1 - from engine support.
3. Remove engine mount - arrows -.
4. Disconnect engine mount from engine support.

Engine mount, left

Scheme 95

1. Disconnect electrical connector - 1 - on engine mount.
2. Unclip electrical wire - 2 -.
3. Remove engine mount - arrows -.
4. Disconnect engine mount from engine support.

Installing

Installation is in reverse order of removal, note the following

Note. All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.

Torque specifications

Scheme 96

1 - 40 Nm

2 - Washer

3 - 40 Nm

4 - Torque bracket

5 - Knurled nut

1. For height compensation

6 - 23 Nm

7 - Torque support valve N382

8 - Bracket for torque support valve N382

9 - 23 Nm

10 - Long member

Special tools, testers and auxiliary items required

1. Drill
2. Stepped quick-helix drill (dia. 24 mm)

Note. Before raising the vehicle on a hoist (wheels off the ground), first activate the vehicle jack mode --> 43 - SELF LEVELING SUSPENSION .

1. Turn ignition and remove ignition key.
2. Turn light switch to "0" position.

For vehicles with parking/auxiliary heater

1. Remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

All

1. Remove front noise insulation - 1 -.
2. Remove front part of wheel housing liner at left and right front --> «66 - EXTERIOR EQUIPMENT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Remove front bumper cover --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Remove clips - 1 -.
2. Remove bolt - 2 - and remove cover.

Note. Note clips when installing - arrows -.

1. Disconnect intake air duct - 1 - from secondary air injection pump.

Scheme 97

1. Disconnect electrical connector - arrow -.

1. Disconnect electrical connector - 1 - from mass air flow (MAF) sensor.
2. Disconnect mass air flow sensor from intake air duct - 2 -.
3. Remove air filter box - arrows -.
4. Remove right headlight --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment) .

Scheme 98

1. Depress locking mechanisms - arrows - and remove air guide at right front from lock carrier.

1. Remove bolts - arrows -.
2. Remove air guide at right rear from lock carrier.

Scheme 99

1. Mark holes according to dimensions - a - and - b - at lock carrier as shown.

1. Dimension - a - = 40 mm.
2. Dimension - b - = 55 mm

1. Make a bore dia. 24 mm.

Note. The bore must be pre-bored and then drilled to dia. 24 mm using stepped quick-helix drill.

1. Unclip cable - arrows -.

Scheme 100

1. Remove bolts - 1 - and - 2 - for torque support.
2. Loosen bolt - 3 - several turns.

1. Separate torque support - arrow - from torque support valve N382.

Scheme 101

1. Remove bolts - 2 - and - 3 -.
2. Swivel torque support aside and disconnect electrical harness connector - 1 -.
3. Remove torque support valve N382.

Installation is in reverse order of removal, note the following

Note. All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine. Secure all hose connections using hose clamps appropriate for the model type .

1. Connect electrical harness connector - 1 - to torque support valve N382.
2. Insert torque support valve N382 and tighten bolts - 2 - and - 3 -.

Scheme 102

1. Turn adjustment ring - 1 - on torque support valve N382 clockwise until stop.

1. Tighten bolts - 1 - and - 3 - for torque support.

1. Turn adjustment ring - 1 - by hand counterclockwise until it makes contact at torque support valve N382.
2. Then, turn adjustment ring one rotation clockwise again.

1. Tighten bolt - arrow - on torque support valve N382.

1. Clip in cable - arrows -.
2. Install headlamps --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment) .
3. Install front bumper cover --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a8/d3-2005-2007/remont/procedures/#maintenance-procedures) .

Tightening torques --> Torque support (with torque support valve N382), assembly overview

Lock carrier, pulling toward front

Special tools, testers and auxiliary items required

Scheme 103

1. Support tool 3369

Note. Before raising the vehicle on a hoist (wheels off the ground), first activate the vehicle jack mode --> 43 - SELF LEVELING SUSPENSION .

Work procedure

For vehicles with auxiliary heater

1. Remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

All

1. Remove front noise insulation - 1 -.
2. Remove front bumper --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 104

1. Remove bolt - arrow - on left and right.

Scheme 105

1. Remove bolts - 2 - on left and right.

Scheme 106

1. Install M8x90 bolt - 1 - , e.g. from support tool 3369 on left and right.

Scheme 107

1. Remove bolts - arrows - and pull lock carrier toward front.

Installing

Installation is in reverse order of removal, note the following

Note. All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.

1. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Install front bumper --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Adjust headlights --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment) .

Ribbed belt drive, assembly overview

Note. Before removing toothed belt, mark the running direction with chalk or felt tip marker. A reversed turning direction can cause damage to the belt under operating conditions. When installing the ribbed belt, make sure it is seated correctly on the pulleys

Scheme 108

1 - Ribbed belt

1. Removing and installing --> «Ribbed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__ribbed-belt-removing-and-installing)

2 - 22 Nm

3 - 45 Nm

4 - Generator

1. Removing and installing --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment)

5 - 43 Nm

6 - Cover

1. For idler pulley

7 - 45 Nm

8 - Upper idler pulley

1. For ribbed belt

9 - Tensioning device for ribbed belt

1. To release tension on ribbed belt, swing using box wrench --> «Ribbed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__ribbed-belt-removing-and-installing)

10 - 22 Nm

11 - Vibration damper

1. With belt pulley for ribbed belt
2. Removing and installing --> «Vibration damper, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__vibration-damper-removing-and-installing)

12 - Lower idler pulley

1. For ribbed belt

13 - Pulley

1. For power steering pump
2. Removing and installing --> «Removing and installing belt pulley for power steering pump»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

14 - Shim

1. Different thicknesses
2. After replacing power steering vane pump, A/C compressor or bracket for vane pump and A/C compressor, determine thickness --> check alignment of ribbed belt --> «Ribbed belt alignment, checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__ribbed-belt-alignment-checking)

15 - Power steering pump

1. For power steering
2. Removing and installing --> «48 - STEERING»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering)

16 - 22 Nm

17 - 40 Nm

18 - Bracket

1. For A/C compressor and vane pump

19 - Alignment bushing

1. 2 pieces
2. Ensure they are seated correctly in bracket

20 - 22 Nm

21 - Air conditioner compressor

22 - 22 Nm

23 - Alignment bushing

1. 2 pieces
2. Check for proper seating

24 - 22 Nm

25 - 23 Nm

26 - Cover

1. For idler pulley

Scheme 109

1. Lock carrier pulled toward front --> «Lock carrier, pulling toward front»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__lock-carrier-pulling-toward-front) .
2. Ribbed belt removed --> «Ribbed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__ribbed-belt-removing-and-installing) .

1. For removing and installing bolts - arrows - , use Spanner Wrench 3212 to counter hold.

1. Installed location: Writing "front" indicates direction of travel
2. Check alignment of ribbed belt --> «Ribbed belt alignment, checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__ribbed-belt-alignment-checking)

Ribbed belt, removing and installing

Special tools, testers and auxiliary items required

1. Locking Pin T10060 A

Removing

Note. Before raising the vehicle on a hoist (wheels off the ground), first activate the vehicle jack mode --> 43 - SELF LEVELING SUSPENSION .

For vehicles with parking/auxiliary heater

1. Remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

All

1. Loosen mounting parts - 1 - and remove noise insulation.

Note. Before removing toothed belt, mark the running direction with chalk or felt tip marker. A reversed turning direction can cause damage to the belt under operating conditions. Note previously marked direction of belt rotation and be sure that it is seated correctly on pulley.

1. To loosen ribbed belt, turn tensioner clockwise in direction of - arrow - using 19 mm box wrench until two holes are aligned; counter hold in position using drift T10060.
2. Remove ribbed belt.

Installing

Installation is in reverse order of removal, note the following

Note. Check alignment of ribbed belt after replacing the following components --> Ribbed belt alignment, checking : Power steering pump Air conditioner compressor Bracket for power steering pump and A/C compressor

Scheme 110

1. Place ribbed belt over belt pulley in specified sequence.

1. Upper idler pulley
2. Crankshaft
3. Lower idler pulley
4. Power steering pump
5. Air conditioner compressor
6. Tensioning device for ribbed belt
7. Generator

1. Move ribbed belt tensioner in direction of - arrow -.
2. Remove mandrel T10060.
3. Ensure ribbed belt is seated and routed correctly.
4. Start engine and check belt running.

Ribbed belt alignment, checking

Check alignment of ribbed belt after replacing the following components

1. Power steering pump
2. Air conditioner compressor
3. Bracket for power steering pump and A/C compressor

Note. To prevent damage to the ribbed belt, check alignment of ribbed belt between A/C compressor and power steering vane pump.

Special tools, testers and auxiliary items required

Scheme 111

1. Alignment gauge 3201

Scheme 112

1. Spanner Wrench 3212

Test sequence

1. Lock carrier pulled toward front --> «Lock carrier, pulling toward front»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__lock-carrier-pulling-toward-front) .
2. Ribbed belt removed --> «Ribbed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__ribbed-belt-removing-and-installing) .

Scheme 113

1. Place alignment gauge 3201 on ribbed belt pulley of A/C compressor.

1. Ribbed belt pulley of vane pump and ribbed belt pulley of A/C compressor must align.

If ribbed belt pulleys do not align

1. Remove bolts - arrows - of ribbed belt pulley for vane pump.

Note. For removing and installing bolts use spanner wrench 3212 to counter hold. Installed location: Writing "front" on ribbed belt pulley indicates direction of travel.

Scheme 114

1. Adjust distance between ribbed belt pulley of vane pump to ribbed belt pulley of A/C compressor using spacer discs of 0.5, 1.0 and 1.5 mm, part number .
2. Check alignment of ribbed belt pulleys using alignment gauge 3201. Readjust if necessary.

Note. Secure all hose connections using hose clamps appropriate for the model type .

Torque specifications

Vibration damper, removing and installing

Removing

1. Lock carrier pulled toward front --> «Lock carrier, pulling toward front»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__lock-carrier-pulling-toward-front) .
2. Ribbed belt removed --> «Ribbed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__ribbed-belt-removing-and-installing) .

Scheme 115

1. Remove vibration damper of crankshaft after removing 8 attachment bolts - 1 -.

Installing

Installation is in reverse order of removal, note the following

Scheme 116

1. When installing, make sure that notch - arrow - in vibration damper aligns with locating lug on toothed belt gear.

Torque specifications

Scheme 117

1 - Plugs

2 - 43 Nm

3 - Bracket

1. For Torque Support Valve N382

4 - Toothed belt guard, right

5 - Toothed belt guard, center

6 - Toothed belt guard, left

7 - Sleeve

8 - 10 Nm

Toothed belt drive, assembly overview

Note. Before removing the ribbed belt, mark the running direction with chalk or felt tip marker. A reversed turning direction can cause damage to the belt under operating conditions.

Scheme 118

1 - 10 Nm

2 - Mounting pin

3 - 20 Nm plus an additional 90° ( 1 / 4 turn)

1. Replace

4 - Washer

1. For tensioning roller

5 - 40 Nm

6 - Tensioning roller

7 - Tensioning lever

8 - 22 Nm

9 - 55 Nm

1. Replace
2. Grease thread and head seating surface

10 - Securing plate

1. Replace
2. Side with writing "rear hinten" points toward rear

11 - Right camshaft gear

1. When removing and installing, remove toothed belt --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
2. Pull off using puller T40001 and claws T40001/2

12 - 10 Nm

1. Insert with locking fluid
2. Locking fluid

13 - Right rear toothed belt guard

14 - Idler roller

15 - Pin bolt, 9 Nm

16 - 14 Nm

1. Bolt class 10.9

17 - Coolant pump

1. Removing and installing --> «Coolant pump, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

18 - Gasket

1. Replace

19 - Left rear toothed belt guard

20 - 10 Nm

1. Insert with locking fluid
2. Locking fluid

21 - 10 Nm

22 - Left camshaft gear

1. When removing and installing, remove toothed belt --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
2. Pull off using puller T40001 and claws T40001/2

23 - Securing plate

1. Replace
2. Side with writing "rear hinten" points toward rear

24 - 55 Nm

1. Replace
2. Grease thread and head seating surface

25 - Toothed belt

1. Before removing, mark direction of rotation using chalk or felt-tip marker
2. Check for wear
3. Removing --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
4. Installing (adjusting valve timing) --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

26 - Eccentric roller

27 - 45 Nm

28 - Crankshaft toothed belt sprocket

1. There must be no oil on contact surface between toothed belt sprocket and crankshaft
2. Only possible to install in one position

29 - 200 Nm plus an additional 1 / 2 turn (180°)

1. Replace
2. Do not oil lubricate additionally
3. Use crankshaft holder 3242 for loosening and tightening
4. Install crankshaft holder 3242 --> (Scheme 126)

30 - Washer

1. For tension lever

31 - Tensioning element

Scheme 119

Special tools, testers and auxiliary items required

1. Tightener pulley wrench T40009
2. Crankshaft Holder 3242
3. Torque wrench V.A.G 1783
4. Ratchet 1/4" VAS 6234

1. Puller T40001 with claws T40001/2
2. Camshaft locator T40005

Scheme 120

1. Securing pin T40011

1. Spanner Wrench 3212

Toothed belt, removing

Note. Before raising the vehicle on a hoist (wheels off the ground), first activate the vehicle jack mode --> 43 - SELF LEVELING SUSPENSION .

1. Remove front bumper --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove lock carrier --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Remove ribbed belt --> «Ribbed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__ribbed-belt-removing-and-installing)

1. Remove engine cover - 2 - upward.
2. Remove upper toothed belt guard at left and right.

1. Turn crankshaft at center bolt of toothed belt gear in direction of engine rotation to TDC Cyl. 5 5 marking.

Scheme 121

1. Notch - B - aligns with marking - A

Note. Turning over engine is performed at the center bolt of the crankshaft.

1. Check position of camshafts

Scheme 122

1. The large holes - arrows - on securing plates at camshaft gears must align on inside.

1. In case they do not align, turn one more rotation.

Scheme 123

1. Disconnect water pipe - arrow - from oil pan.

Scheme 124

1. Disconnect water pipe from engine block - arrow -.

Scheme 125

1. Remove locking bolt - arrow - of TDC marking at upper part of oil pan.

Note. In the crankshaft, a TDC bore is located exactly behind the locking bolt (can be felt by touch).

Scheme 126

1. Install crankshaft holder 3242 in hole for removed locking bolt.

1. Remove vibration damper of crankshaft after removing 8 attachment bolts - 1 -.
2. Remove center toothed belt cover.

Scheme 127

1. Separate torque support - arrow - from torque support valve N382.

Scheme 128

1. Remove bracket for torque support valve N382 - arrows -.

Scheme 129

1. Using an 8 mm hex socket wrench, turn toothed belt tensioner in direction of - arrow - until tensioning lever pushes tensioner together far enough so that locking pin T40011 can be inserted into bores of pistons and housing.

Note. When inserting, bracket for torque support valve N382 remains installed. The locking pin can be guided through a hole in the bracket to be inserted into the holes in the tensioner. The toothed belt tensioner is oil-dampened. Compress it by slowly applying constant pressure. Mark direction of rotation of toothed belt. Reversed running direction can cause damage.

Scheme 130

1. Loosen bolt - arrow - of eccentric pulley.

Scheme 131

1. Install camshaft adjustment T40005 in locking plates of camshafts.
2. Loosen both camshaft gear bolts approx. 5 turns.

Note. The camshaft adjustment T40005 serves as a retainer.

1. Remove camshaft adjustment T40005.

Scheme 132

1. Remove left and right camshaft gears from cone using Puller T40001 with Claw T40001/2.
2. Remove toothed belt.

Installing (Adjusting valve timing)

Note. When turning camshaft, crankshaft must not be at TDC. Valves and/or pistons may be damaged.

Scheme 133

1. Replace bolts - 1 - for camshaft gears and securing plates - 2 -.
2. Grease threads and head seating surfaces of bolts for camshaft gears.
3. Install bolts far enough so that they can still just be turned and do not cant.
4. Observe proper seating of securing plates on camshafts.

Before installing toothed belt, make sure crankshaft and camshafts are set to TDC cylinder 5

1. The large holes - arrows - on securing plates at camshaft gears must align on inside.

1. Crankshaft holder 3242 must be installed.

Scheme 134

1. Route toothed belt in the following sequence: Toothed belt gear crankshaft - 5 - , eccentric pulley - 4 - , tensioner - 6 - , toothed belt gear left camshaft - 3 - , coolant pump - 2 -.
2. At last, place toothed belt on toothed belt gear of right camshaft - 1 -.

Scheme 135

1. Turn tensioning lever twice at 40 Nm in direction of - arrow - to pretension toothed belt.

Note. In the next two illustrations, depicted with torque support bracket removed, for the sake of illustration.

Scheme 136

1. Insert a 5 mm hex socket wrench flat between tensioning lever - 1 - and piston - 2 - of tensioner.

Scheme 137

1. Tighten toothed belt by turning eccentric pulley using tightener pulley wrench T40009 and turn torque wrench V.A.G 1783 using ratchet VAS 6234 indirection of - arrow - and hold.

1. Protection torque 6 Nm

1. Tighten eccentric pulley.

Note. Make sure that position does not change while tightening.

1. Insert camshaft adjustment T40005 into securing plates of both camshafts.

1. Press in camshaft adjustment as far as possible.

1. Tighten camshaft gears.

Note. The camshaft adjustment T40005 serves as a retainer.

1. Remove camshaft adjustment T40005.
2. Remove 5 mm hex socket wrench.

Scheme 138

1. Turn tensioning lever using 8 mm hex socket wrench in direction of - arrow - until Locking Pin T40011 can be pulled out.
2. Remove crankshaft holder 3242.
3. Turn crankshaft two complete rotations in direction of engine rotation until crankshaft stands at TDC cyl. 5 again.

1. The large holes - arrows - on securing plates at camshaft gears must align on inside.

Scheme 139

1. Check dimension - a - between tensioning lever and tensioner housing.

1. Dimension - a - = 5.0 ± 1.0 mm

Note. If dimension - a - is not obtained, repeat adjustment.

1. To check timing, bolt crankshaft holder 3242 in bore at upper part of oil pan again.

1. Check camshaft positions using camshaft adjustment T40005.

Note. If camshaft locator cannot be inserted, repeat adjustment.

1. Remove camshaft adjustment T40005 from both cylinder heads.
2. Remove crankshaft holder 3242.
3. Bolt locking bolt of TDC marking into upper part of oil pan using new sealing ring.

Further installation is in reverse order of removal, note the following

Note. Replace gaskets, seals and O-rings. Secure all hose connections using hose clamps appropriate for the model type .

1. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__ribbed-belt-removing-and-installing) .
2. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Fill with coolant.
4. Install torque support --> «Torque support (with torque support valve N382), assembly overview»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

Note. Only reuse drained coolant if cylinder head or engine block was not replaced. Dirty coolant must not be re-used.

Torque specifications

Scheme 140

1 - 10 Nm

2 - Oil baffle

3 - 14 Nm

4 - 14 Nm

1. Bolt class 10.9

5 - Seal

1. For crankshaft
2. Removing and installing --> «Seal for crankshaft (ribbed belt side), replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__seal-for-crankshaft-ribbed-belt-side)

6 - Spray nozzle valve, 35 Nm

7 - O-ring

1. Replace

8 - Sealing flange, front

1. Removing and installing --> «Front sealing flange, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__front-sealing-flange-removing-and-installing)

9 - Gasket

1. Replace

10 - Thrust collar

1. In case of signs of wear, pull off and turn, or replace --> «Seal for crankshaft (ribbed belt side), replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__seal-for-crankshaft-ribbed-belt-side)

11 - Gasket

1. Replace

12 - Rear sealing flange with sealing ring

1. Removing and installing --> «Rear sealing flange, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__rear-sealing-flange-removing-and-installing)

13 - Shim

1. 3.4 mm thick

14 - Drive plate

1. Removing and installing --> «Drive plate, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__drive-plate-removing-and-installing)

15 - Washer

1. 1.5 mm thick

16 - 30 Nm plus an additional 90° ( 1 / 4 turn)

17 - 10 Nm

18 - 14 Nm

19 - 10 Nm

1. Fasten diagonally in steps

20 - Oil pan (lower section)

1. Removing and installing --> «Lower part of oil pan, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__lower-part-of-oil-pan-removing)

Seal for crankshaft (ribbed belt side), replacing

Special tools, testers and auxiliary items required

Scheme 141

1. Thrust Piece T40007

Scheme 142

1. Seal remover T40019

Removing

1. Remove front bumper --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove lock carrier --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Toothed belt, removing --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

Scheme 143

1. Remove center bolt - 2 - for crankshaft toothed belt gear - 1 -.
2. Remove toothed belt gear.
3. Place inner part of oil seal extractor T40019 flush with outer part and secure using knurled-head screw.

Scheme 144

1. Lubricate threaded head of seal extractor, position and with forced pressure bolt into oil seal as far as possible.
2. Loosen knurled screw and turn inner portion against crankshaft until oil seal is pulled out.
3. Secure seal remover in a vise at the flat spots. Remove seal using pliers

Scheme 145

1. Mark front surface of thrust washer - arrow - using a waterproof felt pen.
2. Remove thrust washer from crankshaft.

Installing

1. Clean running and sealing surface.
2. Do not oil sealing lip and outer edge of seal before pressing in.

Scheme 146

1. Press in sealing ring using thrust piece T40007 and center bolt.

1. Rotate thrust washer and install on crankshaft.

Note. The thrust washer is rotated so that the new sealing ring runs on new sealing path. Marked front surface of thrust washer must now point toward engine.

1. Install toothed belt gear of crankshaft - 1 - with new center bolt - 2 -.

Note. There must be no oil on the contact surface between the toothed belt sprocket and crankshaft. Do not oil the bolt for crankshaft toothed belt sprocket.

Further installation is in reverse order of removal, note the following

1. Install toothed belt (adjust timing) --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
2. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Install torque support --> «Torque support (with torque support valve N382), assembly overview»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

Torque specifications

1. 1) Replace bolt
2. 2) 180° Corresponds to one half rotation.

Front sealing flange, removing and installing

Special tools, testers and auxiliary items required

Scheme 147

1. Crankshaft Holder 3242

1. Thrust Piece T40007
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Silicone sealant

Removing

1. Remove front bumper --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove lock carrier --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Remove ribbed belt --> «Ribbed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__ribbed-belt-removing-and-installing)

Scheme 148

1. Remove tension roller for ribbed belt - arrow -.
2. Remove cover for lower idler pulley.

Scheme 149

1. Remove lower idler pulley for ribbed belt - arrow -.
2. Remove upper toothed belt guard at left and right.

1. Turn crankshaft at center bolt of toothed belt gear in direction of engine rotation to TDC Cyl. 5 5 marking.

1. Notch - B - aligns with marking - A -.

Note. Turning over the engine is performed at the center bolt of the crankshaft.

1. Check position of camshafts

1. The large holes - arrows - on securing plates at camshaft gears must align on inside.

1. In case they do not align, turn one more rotation.

1. Disconnect water pipe - arrow - from oil pan.

1. Disconnect water pipe from engine block - arrow -.

1. Remove locking bolt - arrow - of TDC marking at upper part of oil pan.

Note. In the crankshaft, a TDC bore is located exactly behind locking bolt (can be felt by touch).

1. Install crankshaft holder 3242 in hole for removed locking bolt.

1. Remove vibration damper of crankshaft after removing 8 attachment bolts - 1 -.
2. Remove center toothed belt cover.

Scheme 150

1. Remove mounting bolts - arrows - and remove torque support.

1. Remove bracket for torque support valve N382 - arrows -.
2. Toothed belt, removing --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

1. Remove center bolt - 2 - for crankshaft toothed belt gear - 1 -.
2. Remove toothed belt gear.

Scheme 151

1. Remove eccentric roller - 3 - , tensioning lever with tensioning roller - 2 - and tensioner - 1 -.

Scheme 152

1. Remove spray jet valve - 2 -.
2. Remove bolts - 1 -.
3. Remove lower section of oil pan --> «Oil Level Thermal Sensor G266 , removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-level-thermal-sensor-g266) .

Scheme 153

1. Remove bolts - 1 - and - 2 -.
2. Remove front sealing flange.
3. Drive out seal from removed flange.

1. Mark front surface of thrust washer - arrow - using a waterproof felt pen.
2. Remove thrust washer from crankshaft.

Note. Illustration is shown with sealing flange installed.

Installing

Note. Replace gaskets, seals and O-rings.

1. Place a rag over open part of oil pan.
2. Carefully remove remaining sealant at upper part of oil pan.

Scheme 154

1. Remove remaining sealant on sealing flange using e.g. a rotating plastic brush.

1. Clean sealing surfaces, must be free of oil and grease.

Scheme 155

1. Cut tube nozzle at front marking (jet dia. approx. 1 mm).

Scheme 156

1. Place new sealing ring - 1 - onto cylinder block.
2. Apply thin silicone sealing bead - arrows - each between cylinder block and upper part of oil pan.

Scheme 157

1. Thinly coat lower sealing surface at sealing flange with silicone sealant (hatched area).

Note. The sealing flange must be installed within 5 minutes after application of silicon sealant.

1. Carefully slide sealing flange onto reamed bolt at cylinder block.

1. Tighten bolts - 1 - and spray jet valve - 2 -.

1. Tighten bolts - 1 - and - 2 -.
2. Install oil pan (lower part) --> «Oil Level Thermal Sensor G266 , removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-level-thermal-sensor-g266) .
3. Do not oil sealing lip and outer edge of seal before pressing in.

1. Press in sealing ring using thrust piece T40007 and center bolt. Rotate thrust washer and install on crankshaft.

Note. The thrust washer is rotated so that the new sealing ring runs on new sealing path. Marked front surface of thrust washer must now point toward engine.

1. Install toothed belt gear of crankshaft - 1 - with new center bolt - 2 -.

Note. There must be no oil on the contact surface between the toothed belt sprocket and crankshaft. Do not oil the bolt for crankshaft toothed belt sprocket. Note washer below tensioning lever.

Further installation is in reverse order of removal, note the following

Note. Secure all hose connections using hose clamps appropriate for the model type .

1. Install toothed belt (adjust timing) --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
2. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Install torque support --> «Torque support (with torque support valve N382), assembly overview»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

Torque specifications

1. 1) Replace bolt
2. 2) 90° Corresponds to a quarter turn.
3. 3) 180° Corresponds to one half rotation.

Rear sealing flange, removing and installing

Special tools, testers and auxiliary items required

1. Hand drill with plastic brush attachment
2. Protective glasses
3. Silicone sealant

Removing

1. Remove engine --> «Engine, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
2. Disconnect engine and transmission --> «Engine and transmission, separating»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__engine-and-transmission-separating) .
3. Remove drive plate --> «Drive plate, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__drive-plate-removing-and-installing) .

Scheme 158

1. Remove rear sealing flange - arrow -.

Installing

Note. Replace seals.

1. Place a rag over open part of oil pan.
2. Carefully remove remaining sealant at upper part of oil pan.

1. Remove remaining sealant on sealing flange using e.g. a rotating plastic brush.

1. Clean sealing surfaces, must be free of oil and grease.

1. Cut tube nozzle at front marking (jet dia. approx. 1 mm).

Scheme 159

1. Place new sealing ring - 1 - onto cylinder block.
2. Apply thin silicone sealing bead - arrows - each between cylinder block and upper part of oil pan.

Scheme 160

1. Thinly coat lower sealing surface at sealing flange with silicone sealant (hatched area).

Note. The sealing flange must be installed within 5 minutes after application of silicon sealant.

1. To install, slide guide sleeve from replacement kit onto crankshaft.
2. Carefully slide sealing flange onto reamed bolt at cylinder block.
3. Tighten rear sealing flange.
4. Install drive plate --> «Drive plate, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__drive-plate-removing-and-installing) .

1. Install engine --> «Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__installing) .

Torque specifications

Drive plate, removing and installing

Special tools, testers and auxiliary items required

1. Crankshaft Holder 3242

Removing

1. Engine removed --> «Engine, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
2. Engine separated from transmission --> «Engine and transmission, separating»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__engine-and-transmission-separating) .

1. Turn crankshaft at center bolt of toothed belt gear in direction of engine rotation to TDC Cyl. 5 marking.

1. Notch - B - aligns with marking - A -.

Note. Turning over the engine is performed at the center bolt of the crankshaft.

1. Disconnect water pipe - arrow - from oil pan.

1. Disconnect water pipe from engine block - arrow -.

1. Remove locking bolt - arrow - of TDC marking at upper part of oil pan.

Note. In the crankshaft, a TDC bore is located exactly behind the locking bolt (can be felt by touch).

1. Install crankshaft holder 3242 in hole for removed locking bolt.

Scheme 161

1. Mark drive plate, shim - 1 - and washer - 2 - to engine.
2. Remove drive plate.

Installing

Installation is in reverse order of removal, note the following

Note. Replace seals.

1. Install drive plate with the following shims

1 - Shim: Thickness 3.4 mm

2 - Washer: Thickness 1.50 mm

1. Replace bolts and tighten.

Torque specifications

1. 1) Replace bolt
2. 2) 90° Corresponds to a quarter turn.

Crankshaft, assembly overview

Note. Secure engine to assembly stand using engine and transmission holder VAS 6095 when performing repair work --> Engine, attaching to engine stand .

Scheme 162

1 - Bolt, 22 Nm

1. For bearing cap
2. Replace
3. Tightening order --> «Crankshaft bearing cap, installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

2 - Alignment bushing

1. Insert in cylinder block

3 - Drive sprocket for oil pump

1. Removing and installing --> «Oil pump drive sprocket, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-pump-drive-sprocket-removing-and)

4 - Bearing cap

1. Observe identification --> «Crankshaft bearing cap identification»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
2. Removing --> «Crankshaft bearing cap, removing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
3. Installing --> «Crankshaft bearing cap, installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

5 - Nut, 35 Nm plus an additional 90°

1. For bearing cap
2. Replace
3. Tightening order --> «Crankshaft bearing cap, installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

6 - Thrust washer

1. Only on 3rd crankshaft bearing
2. Lubricating grooves face outward
3. Observe locating point
4. Measuring crankshaft axial clearance --> «Axial clearance, measuring»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__axial-clearance-measuring)

7 - Bearing shell

1. For bearing cap without oil groove
2. Do not interchange used bearing shells (mark)
3. Insert new bearing shells for cylinder block with proper color marking --> «Allocation of crankshaft bearing shells for bearing cap»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

8 - Crankshaft

1. Measuring axial play --> «Axial clearance, measuring»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__axial-clearance-measuring)
2. Radial clearance, measuring --> «Radial clearance, measuring»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__radial-clearance-measuring)
3. Do not turn crankshaft when measuring radial play
4. Crankshaft dimensions --> «Crankshaft dimensions»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__crankshaft-dimensions)

9 - Thrust washer

1. Only on 3rd crankshaft bearing
2. Lubricating grooves face outward
3. Measuring crankshaft axial clearance --> «Axial clearance, measuring»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__axial-clearance-measuring)

10 - Bearing shell

1. For cylinder block with oil groove
2. Do not interchange used bearing shells (mark)
3. Insert new bearing shells for cylinder block with proper color marking --> «Allocation of crankshaft bearing shells for cylinder block»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

11 - Studs

12 - Cylinder block

13 - Bolt, 22 Nm

1. For bearing cap
2. Replace
3. Tightening order --> «Crankshaft bearing cap, installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

Scheme 163

1. Bearing 1 is located on belt pulley side.

Scheme 164

1. Remove crankshaft bearing cap bolts or nuts.
2. Remove crankshaft bearing caps from cylinder block using puller T10055.

Scheme 165

Bearing shells with correct thickness are allocated to cylinder block in the factory. Colored dots on bearing shells serve for identifying bearing shell thickness.

Note. Arrow - points to belt pulley side.

Allocation of bearing shells to cylinder block is identified with a letter by each bearing.

Scheme 166

Bearing shells with correct thickness are allocated to bearing cap at factory. Colored dots on the bearing shells serve for identifying bearing shell thickness - arrows -.

Allocation of bearing shells to crankshaft is marked at crankshaft counterweight by colored dots.

Scheme 167

1. Replace bolts - A - and nuts - 1 through 10 -.
2. Inserting alignment bushings into cylinder block.
3. Tighten bearing cap nuts or bolts in the following sequence

1. Hand-tighten bolts A.
2. Tighten nuts 1 through 10 to 35 Nm.
3. Tighten nuts 1 through 10 90° (1/4 additional turn) using a rigid wrench.
4. Tighten bolts A to 22 Nm.
5. Tighten bolts A 90 (1/4 turn) further using rigid wrench.

Crankshaft dimensions

(Dimensions in mm)

Axial clearance, measuring

Special tools, testers and auxiliary items required

Scheme 168

1. Dial gauge holder VW 387
2. Dial gauge

Scheme 169

1. Attach dial gauge with dial gauge holder VW 387 to cylinder block and set against crankshaft counterweight.
2. Press crankshaft against dial indicator by hand, set indicator to - 0 -.
3. Press crankshaft away from dial gauge.
4. Read value

Radial clearance, measuring

Special tools, testers and auxiliary items required

1. Plastigage

Note. Do not interchange used bearings Bearing shells that are worn down to the nickel layer must be replaced.

1. Remove main bearing cap. Clean bearing cap and journal.
2. Place Plastigage over entire width of bearing journal or into bearing shells.

1. Plastigage must rest in center of bearing shell.

1. Install main bearing cap and tighten to 30 Nm. Do not turn crankshaft.
2. Remove main bearing cap again.
3. Compare width of Plastigage with calibrated scale.
4. Read value

Oil pump drive sprocket, removing and installing

Special tools, testers and auxiliary items required

Scheme 170

1. Press tube 30 - 100

Scheme 171

1. 1 two-arm puller Kukko 20/10

Removing

1. Remove front sealing flange --> «Front sealing flange, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__front-sealing-flange-removing-and-installing) .

Scheme 172

1. Using standard claw remover - 2 - , remove crankshaft chain sprocket while protecting crankshaft end with appropriate washer - 1 -.

Installing

Installation is in reverse order of removal, note the following

1. Heat up chain sprocket in an oven for approx. 15 minutes at 220°C.

Scheme 173

1. Using pliers, install chain sprocket on crankshaft end and slide onto crankshaft to stop using press tube 30 - 100.

Pistons and connecting rods, assembly overview

Note. Oil injector jet for piston cooling --> Oil spray jet for piston cooling

Scheme 174

1 - Connecting rod bolt - 30 Nm plus an additional 90° ( 1 / 4 turn)

1. Replace
2. Lubricate threads and contact surface
3. Tighten to 30 Nm to measure radial play, do not turn further

2 - Connecting rod bearing cap

1. Do not interchange
2. Mark allocation to cylinder using a color marker - B - --> «Mark connecting rod»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
3. When installing bearing cap, observe: Tabs on contact surfaces on front side of connecting rod must align - A
4. Installation position of connecting rod pairs --> «Connecting rod, installed location»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

3 - Bearing shell

1. Note installation position
2. Do not interchange used bearing shells (mark)
3. Radial clearance, measuring --> «Radial clearance of connecting rod, checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__radial-clearance-of-connecting-rod-checking)

4 - Connecting rod

1. Only replace as set
2. Mark allocation to cylinder using a color marker - B - --> «Mark connecting rod»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
3. When installing bearing cap, observe: Tabs on contact surfaces on front side of connecting rod must align - A
4. Installation position of connecting rod pairs --> «Connecting rod, installed location»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

5 - Circlip

6 - Piston pin

1. If tight, heat piston to 60°C
2. Removing and installing using a drift VW 222 A

7 - Piston

1. Installed position and allocation, piston/cylinder --> «Installed position of piston and piston/cylinder allocation»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
2. Arrow on piston face points toward belt pulley side
3. Checking --> «Checking piston»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__checking-piston)
4. Install with piston ring compressor

1. Piston and cylinder dimensions --> «Piston and cylinder dimensions»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__piston-and-cylinder-dimensions)
2. Cylinder bore, checking --> «Checking cylinder bores»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__checking-cylinder-bores)

8 - Piston rings

1. Offset gaps by 120°
2. Use piston ring pliers for removal and installation
3. Marking or identification "TOP" i.e. marked side must face toward piston head
4. Checking ring gap --> «Checking piston ring gap»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

1. Check piston ring groove clearance --> «Checking ring to groove clearance»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

Scheme 175

1. Push ring squarely from above down to approx. 15 mm from bottom end of cylinder. To do this use a piston without rings.

Scheme 176

1. Clean ring groove of piston before checking.

Checking piston

Special tools, testers and auxiliary items required

Scheme 177

1. External micrometer 75 to 100 mm

1. Measure pistons approx. 10 mm from bottom edge and at points offset by 90° to piston pin axis.

1. Deviation from nominal size maximum 0.04 mm

Nominal size --> Piston and cylinder dimensions .

Checking cylinder bores

Special tools, testers and auxiliary items required

Scheme 178

1. Inner bore gauge 50 to 100 mm

1. Measure diagonally at 3 positions transversely - A - and longitudinally - B -.

1. Deviation from nominal size maximum 0.08 mm

Nominal size --> Piston and cylinder dimensions .

Scheme 179

1. Mark installed position and allocation to cylinder on piston head using chalk or waterproof felt pen.

Note. Do not use a center punch or scribe, since the piston head coating will be damaged. Installed location: Arrow on piston face points toward belt pulley side

Scheme 180

Note. Only replace connecting rod as a set. Do not interchange connecting rod bearings.

1. Before removing, mark allocation of connecting rod and connecting rod bearing caps to each other and to cylinder - arrow - using a color marker.

Scheme 181

1. Molded tabs - arrows - at the beveled surfaces of connecting rod pairs 1 and 2, 3 and 4 as well as 5 and 6 must point toward each other

Scheme 182

1 - Bolt, 10 Nm

2 - Oil spray jet for piston cooling

Piston and cylinder dimensions

1. 1) Measurements without graphite coating (thickness = 0.02 mm). Graphite coating wears away

Radial clearance of connecting rod, checking

Special tools, testers and auxiliary items required

1. Plastigage

Test sequence

1. Remove connecting rod bearing cap. Clean the bearing cap and journal.
2. Place Plastigage over entire width of bearing journal or into bearing shells.
3. Install connecting rod bearing cap and tighten to 30 Nm. Do not turn crankshaft.
4. Reinstall connecting rod cover.

1. Compare width of Plastigage with calibrated scale.

1. Always replace connecting rod bolts.

Cylinder head, assembly overview

Note. Illustration depicts cylinder head of cylinder bank 2 (left).

Scheme 183

1 - Cylinder head

1. Remove left cylinder head --> «Left cylinder head, removing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__left-cylinder-head-removing)
2. Remove right cylinder head --> «Right cylinder head, removing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__right-cylinder-head-removing)
3. Check for distortion --> «Checking cylinder head for distortion»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
4. Resurfacing is not permissible

1. Installing --> «Cylinder head, installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__cylinder-head-installing)
2. Renew coolant after replacing

2 - Cylinder head bolt

1. Replace
2. Note loosening sequence
3. Left cylinder head --> (Scheme 194)
4. Right cylinder head --> see scheme 287

1. Observe sequence for tightening --> (Scheme 200)

3 - Cylinder head cover gaskets and ignition coils

1. Replace if damaged or leaking

4 - Cylinder head cover gasket

1. Replace if damaged or leaking
2. Seal contact surfaces with sealant before installing --> «Seal contact surfaces of bearing cap/cylinder head»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
3. Sealant

5 - Cylinder head cover

1. Removing and installing left cylinder head cover --> «Left cylinder head cover, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__left-cylinder-head-cover-removing-and)
2. Removing and installing right cylinder head cover --> «Right cylinder head cover, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__right-cylinder-head-cover-removing-and)

6 - Special bolt, 10 Nm

1. Replace if damaged or leaking

7 - Gasket

1. Replace if damaged or leaking

8 - Gasket

1. For cap
2. Replace if damaged or leaking

9 - Cap

10 - 10 Nm

11 - Ignition coil

1. Removing --> «01 - MAINTENANCE»(/audi/a8/d3-2005-2007/remont/procedures/#maintenance-procedures)

12 - Gasket

1. Replace if damaged

13 - Cylinder head cover gasket

1. Replace if damaged or leaking

14 - O-ring

1. Replace

15 - Rear coolant pipe

16 - 10 Nm

17 - Combination valve for Secondary Air Injection (AIR)

18 - 10 Nm

19 - Gasket

1. Replace

20 - Cylinder head gasket

1. Replacing --> Cylinder head, removing --> «Left cylinder head, removing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__left-cylinder-head-removing)
2. Installed location: Part number facing cylinder head
3. Replace coolant after replacing

Scheme 184

1. Check cylinder head at multiple points for distortion, using straight edge and feeler gauges.

1. Maximum permissible warpage: 0.1 mm

Scheme 185

1. Apply thin layer of sealant (dia. approx. 5 mm) - arrows - to edges of sealing surfaces between bearing cap and cylinder head.

1. Sealant

Left cylinder head cover, removing and installing

Removing

1. Remove engine cover - 1 - and - 2 - upward.
2. Remove ignition coils --> «28 IGNITION/GLOW PLUG SYSTEM»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm) .
3. Disconnect crankcase ventilation hose from cylinder head cover.
4. Remove toothed belt guard.

Scheme 186

1. Remove left cylinder head cover bolts in sequence - 12 to 1 -.
2. Remove cylinder head cover.

Installing

Installation is in reverse order of removal, note the following

Note. Replace cylinder head cover gaskets and ignition coils if damaged. Replace bolts for cylinder head cover if gasket is damaged.

1. Clean sealing surfaces, must be free of oil and grease.

1. Apply thin layer of sealant (dia. approx. 5 mm) - arrows - to edges of sealing surfaces between bearing cap and cylinder head.

1. Sealant

1. Tighten cylinder head cover in sequence - 1 to 12 -.

Torque specifications

Right cylinder head cover, removing and installing

Removing

1. Remove engine cover -1 and 2- upward.

1. Remove hose - 1 -.

1. Disconnect hose - 1 -.
2. Unclip hose - 2 -.
3. Remove air intake tube - arrows -.

Scheme 187

1. Disconnect hose - 1 -.
2. Disconnect connectors of fuel injectors - 2 -.
3. Remove fuel distributor - 3 - and lay aside.

Note. Do not open fuel supply and return line.

1. Remove ignition coils --> «28 IGNITION/GLOW PLUG SYSTEM»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm) .
2. Disconnect crankcase ventilation hose from cylinder head cover.
3. Remove toothed belt cover.

1. Remove left cylinder head cover bolts in sequence - 12 to 1 -.
2. Remove cylinder head cover.

Installing

Installation is in reverse order of removal, note the following

Note. Replace cylinder head cover gaskets and ignition coils if damaged. Replace bolts for cylinder head cover if gasket is damaged.

1. Clean sealing surfaces, must be free of oil and grease.

1. Apply thin layer of sealant (dia. approx. 5 mm) - arrows - to edges of sealing surfaces between bearing cap and cylinder head.

1. Sealant

1. Tighten cylinder head cover in sequence - 12 to 1 -.

Torque specifications

Left cylinder head, removing

Special tools, testers and auxiliary items required

Scheme 188

1. Polydrive Bit and Drive Socket T10070

1. Crankshaft Holder 3242

Removing

Note. Before raising the vehicle on a hoist (wheels off the ground), first activate the vehicle jack mode --> 43 - SELF LEVELING SUSPENSION .

Note. Secure all hose connections using hose clamps appropriate for the model type . All cable ties which are opened or cut open when removing, must be replaced in the same position when installing. Replace cylinder head bolts. Always replace self-locking nuts, bolts which have been tightened to tightening torque as well as gaskets and O-rings. When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced.

1. Remove engine --> «Engine, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

Scheme 189

1. Remove guide pipe for oil dipstick from cylinder head.
2. Toothed belt, removing --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
3. Remove camshaft gear from cylinder bank 5 to 8.

Scheme 190

1. Remove bolts - 2 - and remove toothed belt guard at rear.
2. Loosen nuts - 1 -.

Scheme 191

1. Disconnect hose - 1 -.
2. Remove bolts - 2 -.
3. Disconnect connector - 3 -.
4. Remove bolt - 4 - and pull out oil line.

1. Remove bolts - 5 - and remove combination valve.

Scheme 192

1. Remove water pipe - arrows - at left and right.
2. Remove intake manifold --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm) .

Scheme 193

1. Remove pipe of crankshaft housing ventilation - arrows -.
2. Remove left front exhaust pipe with catalytic converter.
3. Remove ignition coils --> «28 IGNITION/GLOW PLUG SYSTEM»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm) .

1. Remove left cylinder head cover bolts in sequence - 12 to 1 -.
2. Remove cylinder head cover.

Scheme 194

1. Follow sequence - 1 to 10 - when loosening cylinder head bolts.
2. Remove cylinder head and place it on a soft surface (foam).

Right cylinder head, removing

Special tools, testers and auxiliary items required

1. Polydrive Bit and Drive Socket T10070

1. Crankshaft Holder 3242

Removing

Note. Before raising the vehicle on a hoist (wheels off the ground), first activate the vehicle jack mode --> 43 - SELF LEVELING SUSPENSION .

Note. Secure all hose connections using hose clamps appropriate for the model type . All cable ties which are opened or cut open when removing, must be replaced in the same position when installing. Replace cylinder head bolts. Always replace self-locking nuts, bolts which have been tightened to tightening torque as well as gaskets and O-rings. When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced.

1. Remove engine --> «Engine, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
2. Remove toothed belt cover.

Scheme 195

1. Disconnect connector - 1 - from Camshaft Position (CMP) sensor.
2. Toothed belt, removing --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
3. Remove camshaft gear.

Scheme 196

1. Remove idler pulley - arrow -.
2. Remove bolts - 1 - and - 2 - and remove bolts .
3. Remove intake manifold --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm) .

Scheme 197

1. Remove crankshaft housing ventilation pipe, remove bolt - 2 - and loosen hose clamp - 4 - to do so.
2. Remove coolant pipe from cylinder head (bolts - 1 - and - 3 -).
3. Remove ignition coils --> «28 IGNITION/GLOW PLUG SYSTEM»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm) .

1. Remove left cylinder head cover bolts in sequence - 12 to 1 -.
2. Remove cylinder head cover.

1. Remove water pipe - arrows -.

Scheme 198

1. Disconnect connector - 1 -.
2. Disconnect hose - 2 -.
3. Remove bracket - 3 -.
4. Disconnect connector - 4 -.

1. Remove Ground (GND) cable - 5 - from cylinder head.
2. Remove bolts - 6 -.
3. Disconnect hose - 7 - from combination valve.
4. Remove bolts - 8 -.

1. Disconnect connector - 9 -.
2. Remove water pipe.
3. Remove right front exhaust pipe with catalytic converter.

1. Follow sequence - 1 to 10 - when loosening cylinder head bolts.
2. Remove cylinder head and place it on a soft surface (foam).

Cylinder head, installing

Special tools, testers and auxiliary items required

1. Polydrive Bit and Drive Socket T10070

1. Crankshaft Holder 3242

Installing

Note. Replace cylinder head bolts. During assembly, replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as O-rings and gaskets. Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. Carefully remove all grinding and sanding residue. There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block. After installing a replacement cylinder head with camshafts installed, oil contact surfaces between valve lifters, cam followers and cam lubricating surfaces after installing cylinder head. Do not remove plastic bases protecting exposed valves until immediately before installing cylinder head. When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced. Reworking the cylinder heads is not permissible. Cylinder heads with cracks between valve seats or between valve seat and spark plug thread can still be used without loss of service life if the cracks are minute (max. 0.3 mm width) or only the first four threads of a spark plug thread are cracked. Only unpack new cylinder head gasket immediately prior to installation. Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks. Install cylinder head gasket onto guide sleeves. Marking "oben" (top) or part number must face toward cylinder head. Secure all hose connections using hose clamps appropriate for the model type . After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons. All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

1. Before positioning cylinder head, set crankshaft and camshafts on DTC cylinder 5

1. The large holes - arrows - on securing plates at camshaft gears must align on inside.

1. Crankshaft holder 3242 must be installed.

Scheme 199

1. Set cylinder head gasket in place.

1. Pay close attention to alignment bushings in cylinder block - arrows -.
2. Pay attention to installation position of cylinder head gasket, marking "oben" (top) or part number must face toward cylinder head.

1. Set cylinder head in place.
2. Insert new cylinder head bolts and tighten by hand.

Scheme 200

1. Tighten cylinder head in sequence indicated, in four stages as follows
2. Tighten with torque wrench

1. 1. Step: 30 Nm
2. 2. Step: 60 Nm

1. Tighten using a solid wrench

1. 3. Step: 90° ( 1 / 4 turn) further
2. 4. Step: 90° ( 1 / 4 turn) further

Note. There is no requirement to retighten the cylinder head bolts after repairs.

Further installation is in reverse order of removal, note the following

1. Install cylinder head cover on left --> «Left cylinder head cover, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__left-cylinder-head-cover-removing-and) or right --> «Right cylinder head cover, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__right-cylinder-head-cover-removing-and) .
2. Install right combination valve for secondary air injection system --> «Secondary Air Injection (AIR) (right combination valve), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__secondary-air-injection-air-right-combination) .
3. Install front exhaust pipe.
4. Install intake manifold --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm) .

1. Install toothed belt (adjust timing) --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

Note. After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

1. Install engine --> «Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__installing) .
2. Replace coolant.
3. Install torque support --> «Torque support (with torque support valve N382), assembly overview»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

Torque specifications

1. Insert 1) bolts using locking compound; locking compound

Compression pressures, checking

Special tools, testers and auxiliary items required

Scheme 201

1. Spark plug removal tool 3122 B

Scheme 202

1. Compression tester V.A.G 1763

Test conditions

1. Engine oil temperature at least 30°C
2. Battery voltage at least 12.7 V

Test sequence

1. Remove engine cover - 1 - and - 2 - upward.

1. Remove hose - 1 -.

1. Disconnect hose - 1 -.
2. Unclip hose - 2 -.
3. Remove air intake tube - arrows -.

1. Disconnect connectors of fuel injectors - 2 -.
2. Remove ignition coils --> «28 IGNITION/GLOW PLUG SYSTEM»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm) .
3. Using spark plug removal tool 3122 B , remove spark plugs.
4. Open throttle valve completely.

1. Check compression pressure using the compression tester V.A.G 1763.

Note. Using tester operating instructions.

1. Operate starter until tester shows no further pressure increase.

Compression pressure

Assembly is in reverse order of removal, note the following

The following work step must be performed after engine compression test.

1. Query fault memory and erase, if necessary.

Use Vehicle Diagnosis, Testing and Information System VAS 5051 to do so.

Torque specifications

Valvetrain, assembly overview

Note. Cylinder heads with cracks between valve seats or between valve seat and spark plug thread can still be used without loss of service life if the cracks are minute (max. 0.3 mm width) or only the first four threads of a spark plug thread are cracked. After installing the camshafts, the engine may not be started for approx. 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons). After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting. Always replace seals, sealing rings and O-rings.

Scheme 203

1 - Double bearing cap

1. Before installing, coat contact surfaces of front and rear bearing caps lightly with sealant --> «Coat bearing cap with sealant»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
2. Sealant

2 - 5 Nm plus an additional 90° ( 1 / 4 turn)

1. Replace

3 - Hydraulic plunger

1. Pressed into roller rocker lever

4 - Exhaust camshaft

1. Checking axial play --> «Camshafts, checking axial clearance»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-checking-axial-clearance)
2. Removing and installing --> «Camshafts and camshaft adjusters (right cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-right-cylinder)
3. Check radial play using Plastigage (cam follower removed), wear limit 0.1 mm, run-out max. 0.01 mm

5 - Bearing cap for intake camshaft

1. Note installation position and allocation --> see scheme 330
2. Observe alignment bushings if present

6 - Bearing cap for exhaust camshaft

1. Note installation position and allocation --> see scheme 330
2. Observe alignment bushings if present

7 - 5 Nm plus an additional 90° ( 1 / 4 turn)

1. Replace

8 - Double bearing cap

9 - Cap

1. Replace
2. To remove, push through using screwdriver and pry out
3. To install, drive in using retractors 3202 or suitable lever

10 - Bearing cap

1. Before installing, coat contact surfaces of front and rear bearing caps lightly with sealant --> «Coat bearing cap with sealant»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
2. Sealant

11 - Roller rocker lever

1. For exhaust camshaft
2. Removing and installing --> «Roller rocker lever, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__roller-rocker-lever-removing-and-installing)

12 - Drive chain

1. Installing
2. Left cylinder head --> «Camshafts and camshaft adjusters (left cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-left-cylinder)
3. Right cylinder head --> «Camshafts and camshaft adjusters (right cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-right-cylinder)

13 - Roller rocker lever

1. For intake camshaft
2. Removing and installing --> «Roller rocker lever, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__roller-rocker-lever-removing-and-installing)

14 - Intake camshaft

1. Checking axial play --> «Camshafts, checking axial clearance»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-checking-axial-clearance)
2. Removing and installing --> «Camshafts and camshaft adjusters (right cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-right-cylinder)
3. Check radial play using Plastigage (cam follower removed) wear limit 0.1 mm, run-out max. 0.01 mm

15 - 5 Nm plus an additional 90° ( 1 / 4 turn)

1. Replace

16 - Mechanical camshaft adjuster

1. With Camshaft Adjustment Valve 1 N205
2. Before removing, secure using Bracket For Chain Adjustment 3366 --> «Camshafts and camshaft adjusters (right cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-right-cylinder)

17 - Rubber/metal seal

1. Replace

18 - Valve keepers

19 - Valve spring plate

20 - Valve spring

21 - Valve stem seal

1. Replacing --> «Valve stem seals, replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

22 - Gasket

1. Replace

23 - Cylinder head

1. See note --> «Valvetrain, assembly overview»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__valvetrain-assembly-overview)
2. Check valve guides, grind valve seats --> «Valve guides, checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__valve-guides-checking)
3. Rework valve seats --> «Valve seats, reworking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__valve-seats-reworking)

24 - Exhaust valve

1. Do not rework, only lapping is permitted
2. Valve dimensions --> «Valve dimensions»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
3. Check valve guides, grind valve seats --> «Valve guides, checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__valve-guides-checking)

25 - Intake valve

1. Do not rework, only lapping is permitted
2. Valve dimensions --> «Valve dimensions»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)
3. Check valve guides, grind valve seats --> «Valve guides, checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__valve-guides-checking)

26 - Seal

1. For Camshaft Position (CMP) Sensor
2. Replacing --> «Camshaft Position (CMP) Sensor seals, replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshaft-position-cmp-sensor-seals-replacing) .

27 - Cover for Camshaft Position (CMP) Sensor

1. Note installation location, notch in camshaft

28 - Washer

1. Conical

29 - 23 Nm

30 - Camshaft Position (CMP) sensor

31 - 10 Nm

32 - Shaft for roller rocker lever, intake side

1. Removing and installing --> «Roller rocker lever, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__roller-rocker-lever-removing-and-installing)

33 - 10 Nm

34 - 10 Nm

35 - Shaft for roller rocker lever, exhaust side

1. Removing and installing --> «Roller rocker lever, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__roller-rocker-lever-removing-and-installing)

36 - 55 Nm

37 - Camshaft sprocket

38 - Seal

1. For camshaft
2. Replacing --> «Camshaft seals, replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshaft-seals-replacing) .

39 - O-ring

1. For roller rocker lever shaft
2. Replace

Scheme 204

Note. Valves must not be reworked. Only lapping is permitted.

Scheme 205

1. Lightly coat hatched surface of double bearing cap as well as outer bearing cap next to camshaft adjuster with sealant and install bearing cap (observe alignment bushings).

1. Sealant

Camshafts, checking axial clearance

Special tools, testers and auxiliary items required

1. Dial gauge holder VW 387
2. Dial gauge

Test sequence

1. Camshafts, removing --> «Camshafts and camshaft adjusters (right cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-right-cylinder) .
2. Removing cam follower --> «Roller rocker lever, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__roller-rocker-lever-removing-and-installing) .

Scheme 206

1. Install camshafts without chain into cylinder head and tighten with bearing caps 3, 5 and 7.

Scheme 207

1. Secure dial gauge holder VW 387 to dial gauge on cylinder head

Intake camshaft

Exhaust camshaft

Scheme 208

Wear limit for intake and exhaust camshaft

1. Axial clearance: maximum 0.20 mm

Camshaft seals, replacing

Special tools, testers and auxiliary items required

Scheme 209

1. Seal remover 3240

Scheme 210

1. Seal installer 3241

Removing

1. Toothed belt, removing --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
2. Remove camshaft gears.

Note. If shaft seal leaks, replace seals on both cylinder heads.

1. Align inner part of seal extractor 3240 flush with outer part.

Left cylinder head

1. Remove inner part of seal extractor 2 rotations and lock using knurled-head screw.

Right cylinder head

1. Remove inner part of seal extractor 7 rotations and lock using knurled-head screw.

Continued for both sides

Scheme 211

1. Lubricate threaded head of seal extractor 3240 , position and forcefully screw into oil seal as far as possible.
2. Loosen knurled bolt and turn inner part against camshaft until seal is removed.
3. Secure seal remover in a vise at flat spots. Remove seal using pliers
4. Clean running and sealing surface.

Installing

1. Slide oil seal onto cone of camshaft.

Scheme 212

1. Press in seal until stop using thrust sleeve 3241/1 and bolt 3241/6.
2. Install toothed belt (adjust timing) --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

Camshaft Position (CMP) Sensor seals, replacing

Special tools, testers and auxiliary items required

Scheme 213

1. Seal remover 2085

1. Seal installer 3241

Work procedure

Left cylinder head

1. Remove engine cover - 1 - upward.
2. Remove left combination valve for secondary air injection system --> «Secondary Air Injection (AIR) (left combination valve), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__secondary-air-injection-air-left-combination) .

Scheme 214

1. Disconnect electrical harness connector - arrow - at Camshaft Position (CMP) Sensor 2 G163.
2. Remove housing for Hall sensor.
3. Remove washer and cover for Hall sensor.

Right cylinder head

1. Remove engine cover - 2 - upward.
2. Pull lock carrier toward front --> «Lock carrier, pulling toward front»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__lock-carrier-pulling-toward-front) .

Scheme 215

1. Disconnect electrical harness connector - arrow - at Camshaft Position (CMP) Sensor G40.
2. Remove right toothed belt cover.

Scheme 216

1. Remove bolts - arrows -.
2. Pull toothed belt guard slightly toward front and remove camshaft position sensor.
3. Remove washer and cover for Hall sensor.

Continued for both sides

Note. In the following illustrations, the right cylinder head is depicted.

Scheme 217

1. To guide seal puller, thread adapter 2085/1 in camshaft by hand until stop.
2. Remove inner portion of seal extractor 2085 two rotations from outer portion and secure with knurled-head bolt.

Scheme 218

1. Grease threaded head of seal puller 2085 , position and install oil seal as far as possible with forced pressure.
2. Loosen knurled bolt and turn inner part against camshaft until seal is removed.

Scheme 219

1. Place guide sleeve 3241/2 on camshaft pin.
2. Push seal over guide sleeve.

Scheme 220

1. Press in seal up to stop using Thrust Sleeve 3241/1. To do so, use bolt 3241/3.

Further installation is in reverse order of removal, note the following

Note. Replace O-ring. Secure all hose connections using hose clamps appropriate for the model type . Hose connections and charge air system hoses must be free of oil and grease before installing. Do not use lubricant under any circumstances.

Left cylinder head

1. Install left combination valve for secondary air injection system --> «Secondary Air Injection (AIR) (left combination valve), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__secondary-air-injection-air-left-combination) .

Right cylinder head

1. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .

Torque specifications

1. Insert 1) using locking compound; locking compound

Camshafts and camshaft adjusters (left cylinder head), removing and installing

Note. Installation of camshaft drive chain to left and right cylinder heads differ basically. Note different procedures!

Special tools, testers and auxiliary items required

Scheme 221

1. Bracket For Chain Adjustment 3366

Scheme 222

1. Seal installer 3202
2. Sealant

Removing

1. Engine installed.

1. Toothed belt, removing --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
2. Remove camshaft gear.

1. Loosen nuts - 1 -.
2. Remove bolts - 2 - and remove toothed belt guard at rear.

Scheme 223

1. Disconnect electrical harness connector - arrow - from Camshaft Adjustment Valve 2 N208.
2. Remove left cylinder head cover --> «Left cylinder head cover, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__left-cylinder-head-cover-removing-and) .

1. Disconnect electrical harness connector - arrow - at Camshaft Position (CMP) Sensor 2 G163.
2. Remove housing for Hall sensor.
3. Remove washer and cover for Hall sensor.
4. Rotate crankshaft at mounting bolt for toothed belt sprocket counterclockwise approx. 45° so that no pistons stand at TDC.

Scheme 224

1. Verify camshaft TDC position again

1. The two camshaft markings must align with both arrows on bearing caps.

When reusing the old drive chain

1. Clean drive chain and camshaft chain sprockets across from both arrows on bearing caps and mark installed position with a color marking.

Scheme 225

1. The distance between both arrows or colored markings consists of 15 rollers of the drive chain.

Note. Do not mark chain using a center punch or similar means!

Continued

Scheme 226

1. Secure camshaft adjuster using Bracket For Chain Adjustment 3366.

Note. If chain tensioner retainer is fastened too tightly, the camshaft adjuster can be damaged.

1. Independent of the existing markings on the bearing caps, mark sequence and installation position on all bearing caps, as shown in the illustration.
2. For marking, clean bearing cap and use waterproof felt pen.
3. Remove mounting bolts of camshaft adjuster - 10 -.
4. Remove bearing cap 1.

1. Remove bearing caps 2, 4, 6, 8 and 9 and lay on a clean surface in corresponding sequence.
2. Alternating in diagonal sequence, loosen bearing caps 3, 5 and 7 of intake and exhaust camshafts and remove.
3. Raise both camshafts with camshaft adjuster.

Installing

1. Replace bolts for camshaft bearing and camshaft adjuster.
2. Replace half-round sealing plugs.
3. Remove sealant residue from cylinder head and bearing caps.

Scheme 227

1. Replace rubber/metal camshaft adjuster gasket and spread thin layer of sealant on hatched surface.

1. Sealant

1. Place drive chain onto camshaft chain sprockets as follows

When using old drive chain

Scheme 228

1. Align color markings - arrows -.

When using a new drive chain

Scheme 229

1. Distance between notches - A - and - B - at camshafts must be distance of 15 rollers at drive chain. Illustration shows where first and fifteenth drive chain rollers must be installed on chain gears.

Continued

1. Slide camshaft adjuster between drive chain (2nd technician needed).
2. Install camshafts with drive chain and camshaft adjuster in cylinder head.
3. Oil running surfaces of both camshafts.

Note. Alignment bushings for bearing caps and camshaft adjuster must be installed in cylinder head.

1. Install bearing caps 3, 5, and 7 according to marking.
2. Tighten bearing caps 3, 5 and 7 of intake and exhaust camshafts in alternating diagonal sequence.
3. Tighten camshaft adjuster - 10 -.
4. Remove Bracket For Chain Adjustment 3366.

1. Check whether camshafts are correctly adjusted

1. The two camshaft markings must align with both arrows on bearing caps - arrows -.

Note. So that both markings line up, turn camshaft slightly back or forth if necessary.

1. Lightly coat hatched surface of double bearing cap as well as outer bearing cap next to camshaft adjuster with sealant and install bearing cap.

1. Sealant

1. Install remaining bearing caps.
2. Replacing and installing oil seals for intake and exhaust camshaft --> «Camshaft seals, replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshaft-seals-replacing) for camshafts or --> «Camshaft Position (CMP) Sensor seals, replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshaft-position-cmp-sensor-seals-replacing) for camshaft position sensor.
3. Carefully drive in cap using retractors 3202.
4. Rotate crankshaft at mounting bolt for toothed belt sprocket clockwise approx. 45° to TDC again and secure crankshaft using locking pin.

Further installation is in reverse order of removal, note the following

1. Install toothed belt (adjust timing) --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
2. Install cylinder head cover --> «Right cylinder head cover, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__right-cylinder-head-cover-removing-and) .
3. Install torque support --> «Torque support (with torque support valve N382), assembly overview»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

Note. After installing the camshafts, the engine may not be started for approx. 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons). After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

Torque specifications

1. 1) Replace bolt
2. 2) 90° Corresponds to a quarter turn.
3. Insert 3) using locking compound; locking compound

Camshafts and camshaft adjusters (right cylinder head), removing and installing

Note. Installation of camshaft drive chain to left and right cylinder heads differ basically. Note different procedures!

Special tools, testers and auxiliary items required

1. Bracket For Chain Adjustment 3366

1. Seal installer 3202

Sealant

Removing

1. Remove engine --> «Engine, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
2. Toothed belt, removing --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
3. Remove camshaft gear.

1. Remove idler pulley - arrow -.
2. Remove bolts - 1 - and - 2 - and remove toothed belt guard at rear.

1. Disconnect electrical harness connector - arrow - at Camshaft Position (CMP) Sensor G40.
2. Remove housing for Hall sensor.
3. Remove washer and cover for Hall sensor.
4. Disconnect electrical harness connector at camshaft adjustment solenoid valve.

1. Remove right cylinder head cover --> «Right cylinder head cover, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__right-cylinder-head-cover-removing-and) .
2. Rotate crankshaft at mounting bolt for toothed belt sprocket counterclockwise approx. 45° so that no pistons stand at TDC.

1. Verify camshaft TDC position again

1. The two camshaft markings must align with both arrows on bearing caps.

When reusing old drive chain

1. Clean drive chain and camshaft chain sprockets across from both arrows on bearing caps and mark installed position with a color marking.

Scheme 230

1. The distance between both arrows or colored markings consists of 16 rollers of drive chain.
2. The notch on intake camshaft is slightly offset inward toward drive chain roller - 16 -.

Note. Do not mark chain using a center punch or similar means!

Continued

1. Secure camshaft adjuster using Bracket For Chain Adjustment 3366.

Note. If the chain tensioner retainer is fastened too tightly, the camshaft adjuster can be damaged.

1. Independent of existing markings on bearing caps, mark sequence and installation position on all bearing caps, as shown in the illustration.
2. For marking, clean bearing cap and use waterproof felt pen.
3. Remove mounting bolts of camshaft adjuster - 10 -.
4. Remove bearing cap 1.

1. Remove bearing caps 2, 4, 6, 8 and 9 and lay on a clean surface in the corresponding sequence.
2. Alternating in diagonal sequence, loosen bearing caps 3, 5 and 7 of intake and exhaust camshafts and remove.
3. Raise both camshafts with camshaft adjuster.

Installing

1. Replace bolts for camshaft bearing and camshaft adjuster.
2. Replace half-round sealing plugs.
3. Remove sealant residue from cylinder head and bearing caps.

1. Replace rubber/metal camshaft adjuster gasket and spread thin layer of sealant on hatched surface.

1. Sealant

1. Place drive chain onto camshaft chain sprockets as follows

When using old drive chain

1. Align color markings - arrows -.

When using a new drive chain

Scheme 231

1. Distance between notches - A - and - B - at camshafts must be distance of 16 rollers at drive chain. Illustration shows where first and sixteenth drive chain rollers must be installed on chain gears.
2. Notch - B - is slightly offset inward toward chain roller - 16

Continued

1. Slide camshaft adjuster between drive chain (2nd technician needed).
2. Install camshafts with drive chain and camshaft adjuster in cylinder head.
3. Oil running surfaces of both camshafts.

Note. Alignment bushings for bearing caps and camshaft adjuster must be installed in cylinder head.

1. Install bearing caps 3, 5, and 7 according to marking.
2. Tighten bearing caps 3, 5 and 7 of intake and exhaust camshafts in alternating diagonal sequence.
3. Tighten camshaft adjuster - 10 -.
4. Remove Bracket For Chain Adjustment 3366.

1. Check whether camshafts are correctly adjusted

1. The two camshaft markings must align with both arrows on bearing caps - arrows -.

Note. So that both markings line up, turn camshaft slightly back or forth if necessary.

1. Lightly coat hatched surface of double bearing cap as well as outer bearing cap next to camshaft adjuster with sealant and install bearing cap.

1. Sealant

1. Install remaining bearing caps.
2. Replacing and installing oil seals for intake and exhaust camshaft --> «Camshaft seals, replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshaft-seals-replacing) for camshaft or --> «Camshaft Position (CMP) Sensor seals, replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshaft-position-cmp-sensor-seals-replacing) for camshaft position sensor.
3. Carefully drive in cap using retractors 3202.
4. Rotate crankshaft at mounting bolt for toothed belt sprocket clockwise approx. 45° to TDC again and secure crankshaft using locking pin.

Further installation is in reverse order of removal, note the following

1. Install toothed belt (adjust timing) --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
2. Install cylinder head cover --> «Right cylinder head cover, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__right-cylinder-head-cover-removing-and) .
3. Install engine --> «Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__installing) .
4. Install torque support --> «Torque support (with torque support valve N382), assembly overview»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

Note. After installing the camshafts, the engine may not be started for approx. 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons). After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

Torque specifications

1. 1) Replace bolt
2. 2) 90° Corresponds to a quarter turn.
3. Insert 3) using locking compound; locking compound

Roller rocker lever, removing and installing

Removing

1. Engine removed --> «Engine, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

1. Remove camshafts and camshaft adjusters for right cylinder head --> «Camshafts and camshaft adjusters (left cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-left-cylinder) and left cylinder head --> «Camshafts and camshaft adjusters (right cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-right-cylinder) .
2. Mark allocation of roller rocker lever and shafts for roller cam follower for re-installation.

Scheme 232

1. Remove bolts - arrows -.
2. Thread a M6-bolt into hole in shaft for roller rocker lever.
3. Remove shaft from cylinder head and remove roller rocker lever.

Installing

Installation is in reverse order of removal, note the following

Note. Replace O-rings.

1. Before installing, oil bearing areas for roller rocker lever.
2. Install camshafts and camshaft adjusters --> «Camshafts and camshaft adjusters (right cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-right-cylinder) for left cylinder head and --> «Camshafts and camshaft adjusters (left cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-left-cylinder) for right cylinder head.

Torque specifications

Scheme 233

Special tools, testers and auxiliary items required

1. Spark plug removal tool 3122 B
2. Valve seal removal tool 3364
3. Valve stem seal driver 3365
4. Valve cotter disassembly and assembly device VAS 5161

1. Adapter T40012

Removing

1. Engine removed --> «Engine, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

1. Remove camshafts and camshaft adjusters for right cylinder head --> «Camshafts and camshaft adjusters (left cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-left-cylinder) and left cylinder head --> «Camshafts and camshaft adjusters (right cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-right-cylinder) .
2. Using spark plug removal tool 3122 B , remove spark plugs.

Scheme 234

1. Turn roller rocker lever upward and secure it with a rubber band.

Scheme 235

1. Place Guide Plate VAS 5161/7 from Valve Cotter Disassembly and Assembly Device VAS 5161 on cylinder head.
2. Secure guide plate VAS 5161/7 with knurled screws VAS 5161/12.
3. Insert drift VAS 5161/3 into guide plate and loosen stuck valve keepers using a plastic hammer.

Scheme 236

1. Install engaging device VAS 5161/6 with VAS 5161/5 into guide plate VAS 5161/7.
2. Guide installation cartridge VAS 5161/8 into guide plate VAS 5161/7.
3. Install adapter T40012 with gasket by hand into respective spark plug thread and apply constant pressure.

1. Minimum pressure: 6 bar pressure

1. Engage pressure fork VAS 5161/2 at engaging device VAS 5161/6 and press down installation cartridge.
2. At the same time, turn knurled bolt of installation cartridge to right, until points engage in valve keepers.
3. Lightly move knurled bolt back and forth, causing valve keepers to be pressed apart and be captured in installation cartridge.
4. Release pressure fork.

1. Remove installation cartridge.
2. Remove guide plate.

1. Pressurized air hose remains connected.

Scheme 237

1. Remove valve stem seals using Valve Seal Removal Tool 3364.

Installing

Note. For pressing on valve stem seals from delivery program, the Valve Stem Seal Driver 3365 must be drilled to 6.5 mm dia. A plastic sleeve - A - is supplied with the new valve shaft seals.

1. Place plastic sleeve - A - on valve stem to prevent damage to new valve stem oil seals - B -.
2. Lightly oil valve stem seal.
3. Push valve stem seal onto plastic sleeve.
4. Carefully press valve stem oil seal onto valve guide using valve stem seal driver 3365.

1. Remove plastic sleeve again.

Scheme 238

1. If valve keys were removed from the installation cartridge, they must be inserted into insertion device VAS 5161/18 next.

Note. The large diameter of the valve keepers point upward.

1. Insert valve spring and valve spring plate.
2. Install Guide Plate VAS 5161/7 onto cylinder head again.

1. Insert installation cartridge VAS 5161/8 into guide plate.
2. Press down pressure fork and pull knurled-head bolt upward - thereby valve keepers are inserted.
3. Release pressure fork with knurled bolt still pulled.
4. Install camshafts and camshaft adjusters --> «Camshafts and camshaft adjusters (right cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-right-cylinder) for left cylinder head and --> «Camshafts and camshaft adjusters (left cylinder head), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__camshafts-and-camshaft-adjusters-left-cylinder) for right cylinder head.

Note. After installing the camshaft, the engine may not be started for approx. 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons). After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.

Valve guides, checking

Special tools, testers and auxiliary items required

1. Dial gauge holder VW 387
2. Dial gauge

Test sequence

Scheme 239

1. Insert valve into guide. The end of the valve stem must be flush with the guide. Due to the slight difference in stem dimensions, ensure that only an intake valve is used in the intake guide and an exhaust valve in exhaust guide.
2. Determine tip clearance.

Wear limit

Note. If wear limit is exceeded, re-measure using new valves. If wear limit is still exceeded, replace cylinder head. The valve guides cannot be replaced. If the valve is to be replaced as part of a repair, use a new valve for the calculation.

Valves, checking

1. Visually check for signs of wear on stem and on seating surface. Replace valve if it shows significant signs of wear.

Valve seats, reworking

Note. If a perfect contact pattern is not achieved by grinding the valve seats, rework the valve seats.

Special tools, testers and auxiliary items required

1. Depth gauge
2. Valve seat refacing tool

Note. When repairing engines with leaking valves, it is not sufficient to rework or replace valve seats and valves. It is particularly important to check valve guides for wear on engines with higher mileage performance --> Valve guides, checking . Only reface valve seats enough until a perfect contact pattern is obtained. Before refacing, determine maximum refacing dimension. If the reworking dimension is exceeded, the function of the hydraulic lifters can no longer be guaranteed and therefore the cylinder head should be replaced.

Determining maximum allowable refacing dimension

1. Insert valve and press it firmly against the valve seat.

Note. If the valve is to be replaced as part of a repair, use a new valve for the calculation.

Scheme 240

1. Measure distance - a - between end of valve stem and camshaft center axle (camshaft center axle is located at the level of cylinder head upper edge).
2. Determine maximum allowable refacing dimension using distance measured and minimum dimension.

Measured distance minus minimum dimension = maximum permissible refaced dimension.

Note. If the maximum permissible refacing dimension is 0 mm or less, repeat measurement using new valve. If measurement result is still 0 mm or less than 0 mm, replace cylinder head.

Scheme 241

Valve seats, reworking

Camshaft adjustment, checking

The adjustment of intake camshaft is load and RPM dependent. Oil pressure is switched to respective camshaft adjuster (mechanical adjustment devices) via solenoid valve for camshaft adjustment.

Note. Camshaft adjustment is active only 25 seconds after engine start.

Scheme 242

1. Vehicle Diagnosis, Testing and Information System VAS 5051 with VAS 5051/1 (VAS 5051 B version shown as example only)

Test conditions

1. Coolant temperature at least 80°C.
2. Vehicles with automatic transmission: Selector lever in position P or N.

Test sequence

1. Connect Vehicle Diagnostic, Testing and Information System VAS 5051 and select vehicle system "01 - engine electronics". Engine must run at idle for this.

Display on VAS 5051

Scheme 243

1. In selection - 1 - , press diagnostic function "04- Basic Setting".

Display on VAS 5051

1 - Enter display group

Scheme 244

1. Select function "094" in button field - 2 - for "display group number 094" and press Q to confirm input.

Display on VAS 5051

Scheme 245

1. Activate basic setting by pressing button A.
2. Increase engine speed to approx. 2000 RPM for about 10 seconds.
3. Check specified values in display fields - 3 - and - 4 -.

If specified value "Syst. OK" is not obtained

1. Click on button twice.

Display on VAS 5051

1. In selection - 1 - , click on diagnostic function "08 - Read measuring value block".

Display on VAS 5051

1 - Enter display group

1. Select function "090" in button field - 2 - for "display group number 090" and press Q to confirm input.

Scheme 246

Display on VAS 5051

Test conditions

1. Engine running at idle.

1. Check specified values in display fields - 3 - and - 4 -.

1. Perform test drive.
2. Check specified values in display fields - 3 - and - 4 -.

1. Press button to end function "08 - Read measuring value block".

If specifications are not obtained

1. Check solenoid valves for camshaft adjustment Guided Fault Finding.

Note. If display field indicates a value between 6.0° Crankshaft and 16.0° Crankshaft during a road test, the electrical valve for camshaft adjustment is correctly switching the oil pressure to mechanical camshaft adjuster but the mechanical camshaft adjuster cannot reach its end position (e.g. due to difficulty of movement).

Lubrication system components, removing and installing

Note. If large quantities of metal shavings or abraded material are found in the engine oil while servicing the engine, the oil passages must be carefully cleaned to prevent resulting damage and the oil cooler must be replaced. The oil level must not be above the max. mark - danger of damage to catalytic converter!

Viscosity classes and oil specifications --> 01 - MAINTENANCE

Oil system capacity: Fluid Capacity Chart

Scheme 247

1 - Oil pan (lower section)

1. Removing and installing --> «Lower part of oil pan, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__lower-part-of-oil-pan-removing)
2. With Oil Level Thermal Sensor G266

2 - 10 Nm

3 - Chain sprocket

1. For oil pump
2. Installed location: Side with writing points toward front
3. Removing and installing --> Chain drive for oil pump, removing and installing --> «Oil pump drive sprocket, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-pump-drive-sprocket-removing-and)

4 - 34 Nm

5 - Chain sprocket

1. For crankshaft
2. Removing and installing --> Chain drive for oil pump, removing and installing --> «Oil pump drive sprocket, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-pump-drive-sprocket-removing-and)

6 - Drive chain for oil pump

1. Removing and installing --> Chain drive for oil pump, removing and installing --> «Oil pump drive sprocket, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-pump-drive-sprocket-removing-and)

7 - Chain tensioner

1. Before removing, secure using piece of wire
2. Do not disassemble
3. Removing and installing --> Chain drive for oil pump, removing and installing --> «Oil pump drive sprocket, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-pump-drive-sprocket-removing-and)

8 - Oil pump

1. Do not disassemble
2. With relief valve approx. 7 bar
3. Removing and installing --> «Oil pump, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-pump-removing-and-installing)

9 - 30 Nm

10 - Oil strainer

1. Clean if soiled

11 - Intake tube

12 - Circlip

13 - Oil baffle

14 - 10 Nm

1. Different lengths

15 - 10 Nm

1. Fasten diagonally in steps

16 - Seal

1. Replace

17 - Oil drain plug, 50 Nm

18 - 10 Nm

19 - Oil Level Thermal Sensor G266

1. Removing and installing --> «Oil Level Thermal Sensor G266 , removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-level-thermal-sensor-g266)

20 - Seal

1. Replace

Oil Level Thermal Sensor G266 , removing and installing

Removing

Note. Before raising the vehicle on a hoist (wheels off the ground), first activate the vehicle jack mode --> 43 - SELF LEVELING SUSPENSION .

For vehicles with parking/auxiliary heater

1. Remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

All

1. Loosen mounting parts - 1 - and remove noise insulation.
2. Place oil receptacle beneath.
3. Drain engine oil.

Scheme 248

1. Disconnect electrical harness connector at Oil Level Thermal Sensor G266 - 1 -.
2. Remove Oil Level Thermal Sensor G266.

Installing

Note. Replace seals.

1. Clean sealing surfaces, must be free of oil and grease.

Scheme 249

1. Apply sealant to studs of oil pan - arrows -.

Sealant

1. Install Oil Level Thermal Sensor G266 - 4 -.
2. Connect electrical wire - 3 -.
3. Add engine oil and check oil level.
4. Install sound insulation.

Torque specifications

Lower part of oil pan, removing and installing

Special tools, testers and auxiliary items required

1. Oil receptacle
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Silicone sealant

Removing

Note. Before raising the vehicle on a hoist (wheels off the ground), first activate vehicle jack mode --> 43 - SELF LEVELING SUSPENSION .

For vehicles with parking/auxiliary heater

1. Remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

All

1. Loosen mounting parts - 1 - and remove noise insulation.
2. Place oil receptacle beneath.
3. Drain engine oil.

1. Disconnect electrical harness connector at Oil Level Thermal Sensor G266 - 1 -.
2. Remove lower section of oil pan - arrow -.

Installing

Note. Replace seals.

Scheme 250

1. Remove remaining sealant from lower and upper part of oil pan using e.g. rotating plastic brush.

1. Clean sealing surfaces, must be free of oil and grease.

1. Cut tube nozzle at front marking (jet dia. approx. 1 mm).

Scheme 251

1. Apply silicon sealant bead - arrow - to clean sealing surfaces of oil pan (lower section) as shown in illustration.

1. Thickness of sealant bead - arrow - : 1.5 mm

Note. The lower part of the oil pan must be installed within 5 minutes after application of silicone sealant. Sealant bead must not be thicker than specified, otherwise sealant could get into lower part of oil pan and clog oil pump strainer.

1. Set lower part of oil pan in place and fasten all bolts in diagonal sequence to 5 Nm.
2. Fasten bolts for lower part of oil pan in a diagonal sequence to 10 Nm.
3. Add engine oil and check oil level.

Torque specifications

Chain drive for oil pump, removing and installing

Removing

1. Toothed belt, removing --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
2. Remove front sealing flange --> «Front sealing flange, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__front-sealing-flange-removing-and-installing) .

Scheme 252

1. Remove baffle plate - arrows -.

Scheme 253

1. Secure chain tensioner for oil pump using an angled piece of wire - 2 -.
2. Remove bolt - 1 - and pull off chain sprocket from oil pump.
3. Pull off chain sprocket with chain from crankshaft.
4. If necessary, remove chain tensioner from oil pump.

Installing

Installation is in reverse order of removal, note the following

Note. Note installation position of chain sprockets. Sides with marking point toward front.

1. Note installation position of chain sprockets.

1. Installed location: Marking points toward front.

1. Install front sealing flange --> «Front sealing flange, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__front-sealing-flange-removing-and-installing) .
2. Install toothed belt (adjust timing) --> «Toothed belt, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
3. Install torque support --> «Torque support (with torque support valve N382), assembly overview»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

Torque specifications

Oil pump, removing and installing

Removing

1. Remove lower section of oil pan --> «Lower part of oil pan, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__lower-part-of-oil-pan-removing) .

1. Remove baffle plate - arrows -.

1. Secure chain tensioner for oil pump using an angled piece of wire - 2 -.
2. Remove bolt - 1 - and pull off chain sprocket from oil pump.

Scheme 254

1. Remove oil pump - arrows -.

Installing

Installation is in reverse order of removal, note the following

1. Note installation position of chain sprocket for oil pump.

1. Installed location: Marking points toward front.

1. Install oil pan (lower part) --> «Lower part of oil pan, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__lower-part-of-oil-pan-removing) .

Torque specifications

Scheme 255

1 - Oil pan (lower section)

1. Removing and installing --> «Lower part of oil pan, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__lower-part-of-oil-pan-removing)
2. With Oil Level Thermal Sensor G266
3. Oil Level Thermal Sensor G266 , removing and installing --> «Oil Level Thermal Sensor G266 , removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-level-thermal-sensor-g266)

2 - Oil baffle

3 - 14 Nm

1. Observe sequence for tightening --> «Oil pan (upper part), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

4 - Oil pan (upper section)

1. Removing and installing --> «Oil pan (upper part), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

5 - 22 Nm

6 - Baffle plate

7 - 22 Nm

8 - Guide tube for oil dipstick

9 - Seals

1. Replace

10 - 32.5 Nm

11 - Coolant drain tube

12 - 10 Nm

13 - O-ring

1. Replace

14 - 22 Nm

1. Observe sequence for tightening --> «Oil pan (upper part), removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

15 - 65 Nm

16 - Intake tube

17 - Circlip

18 - 10 Nm

19 - 10 Nm

1. Fasten diagonally in steps

20 - Oil drain plug, 50 Nm

21 - Seal

1. Replace

Scheme 256

Special tools, testers and auxiliary items required

1. Engine support bridge 10 - 222 A
2. Shackle 10 - 222 A/12
3. Adapter 10-222 A/21
4. Pry Lever - Rmv Outside Mirror 80 - 200

1. Old oil collecting and extracting device V.A.G 1782
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Silicone sealant

1. Block of wood, 50 x 50 x 50 mm

Removing

Note. Before raising the vehicle on a hoist (wheels off the ground), first activate the vehicle jack mode --> 43 - SELF LEVELING SUSPENSION .

1. Remove rubber seal for plenum chamber cover - 1 -.
2. Remove plenum chamber cover - 2 - and - 3 -.

1. Remove engine cover - 1 - upward.

1. Remove clips - 1 - using Pry Lever - Rmv Outside Mirror 80 - 200.
2. Remove bolt - 2 - and remove cover.

Note. Note clips when installing - arrows -.

1. Remove left cover by removing bolt - 1 - and removing expanding rivet - 2 - using Pry Lever - Rmv Outside Mirror 80 - 200.

Note. Note clips when installing - arrows -.

1. Remove cover bracket - 1 -.
2. Remove bracket for A/C line - 2 -.
3. Unclip bracket for A/C line - 3 -.

1. Remove bolts - 4 - on left and right.

1. Secure engine support bridge 10 - 222 A with adapters 10 - 222 A/21 at suspension strut domes.
2. Install adapters 10 - 222 A/21 to dome brace - 3 - at left and right.

1. Support for left and right side of vehicle is marked.
2. The center support point is secured on front bolts for dome brace.
3. Knurled-head screw - 1 - must be turned downward far enough so that supporting plate makes contact on suspension strut dome.

1. Secure shackles 10 - 222 A/12 to right rear engine lifting eyelets.
2. Hook shackles 10 - 222 A/12 into spindles of engine support bridge 10 - 222 A.
3. Slightly pre-tension engine using engine support bridge spindles.

For vehicles with parking/auxiliary heater

1. Remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

All

1. Loosen mounting parts - 1 - and remove noise insulation.

1. Remove bolts - 1 through 3 - on left and right.
2. Lower engine carrier.

1. Disconnect water pipe - arrow - from oil pan.

1. Disconnect water pipe from engine block - arrow -.
2. Drain coolant --> «Cooling system, draining and filling»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

Scheme 257

1. Remove bolts - 1 - and - 2 - and remove coolant drain tube.

Scheme 258

1. Remove bolt - 1 - and loosen bolt - 2 - a few rotations.
2. Remove guide tube - 3 - with oil dipstick.

1. Remove coupling rod - 1 - at left and right control arms.
2. Pull subframe downward.

Scheme 259

1. Place block of wood (height - a - = 50 mm) between front subframe mount and body.

Note. To avoid measuring wheel alignment, the subframe must only be loosened and lowered at the front end.

1. Place oil receptacle beneath.
2. Drain engine oil.

1. Disconnect electrical harness connector at Oil Level Thermal Sensor G266 - 1 -.
2. Remove lower section of oil pan - arrow -.

1. Remove baffle plate - arrows -.
2. Remove tensioning ring.

Scheme 260

1. Disconnect intake connection - arrow - from oil pump.

Scheme 261

1. Remove engine/transmission connecting bolts - arrows - in area of oil pan (upper part).

Scheme 262

1. Remove bolts - 1 - and - 2 - from oil pan (upper part).
2. Press upper part of oil pan from alignment pins of cylinder block.

Installing

Scheme 263

1. Using e.g. rotating plastic brush, remove remaining sealant from upper part of oil pan and from cylinder block.

1. Clean sealing surfaces, must be free of oil and grease.

1. Cut tube nozzle at front marking (jet dia. approx. 1 mm).

Scheme 264

1. Apply silicon sealant bead to clean sealing surfaces of oil pan (upper section) as shown in illustration.

1. Thickness of sealant bead: approx. 1.5 mm

Note. The oil pan (upper part) must be installed within 5 minutes after application of silicone sealant. Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer. Apply sealant bead in area of cylinder block bore as well as rear sealing flange - arrows - extremely carefully.

1. Attach upper part of oil pan and pre-tighten all bolts - 1 - and - 2 - of oil pan (upper part) to cylinder block in diagonal sequence to 5 Nm.
2. Tighten bolts - 1 - and bolts - 2 - in diagonal sequence.

1. Install engine/transmission connecting bolts - arrows - in area of oil pan (upper part).
2. Tighten bolts for oil pan (upper part) to transmission.
3. Replace oil dipstick guide tube O-ring.

Further installation is in reverse order of removal, note the following

Note. Replace seals and O-rings. Secure all hose connections using hose clamps of series-production status Hose connections and charge air system hoses must be free of oil and grease before installing. Do not use lubricant under any circumstances.

1. Install oil pan (lower part) --> «Oil Level Thermal Sensor G266 , removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-level-thermal-sensor-g266) .
2. Install subframe --> «40 - FRONT SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
3. Add engine oil and check oil level.
4. Fill with coolant.

Torque specifications

Scheme 265

1 - O-ring

1. Replace

2 - Oil check valve, 20 Nm

1. For oil supply to left cylinder head

3 - Gasket

1. Replace

4 - Cover

1. With connection for crankshaft housing ventilation

5 - 10 Nm

6 - Connecting hose

7 - Crankcase ventilation pipe

1. Cylinder bank 1 (right)

8 - 10 Nm

9 - 10 Nm

10 - Crankcase ventilation pipe

1. Cylinder bank 2 (left)

11 - Connecting hose

12 - Oil check valve, 20 Nm

1. For oil supply to right cylinder head

13 - O-ring

1. Replace

Oil check valves, replacing

Note. If irregular valve noise occurs repeatedly during short journeys and disappears after extended driving, the oil check valves must be replaced.

Removing

1. Remove intake manifold --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm) .

Scheme 266

1. Remove crankcase ventilation pipes - 1 - and - 2 -.
2. Remove cover - 3 - below intake manifold.

Scheme 267

1. Remove oil check valves - 1 - and - 2 -.

Installing

Installation is in reverse order of removal, note the following

Note. Replace gaskets and O-rings. Secure all hose connections using hose clamps of series-production status

1. Install intake manifold --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm) .

Torque specifications

Scheme 268

Special tools, testers and auxiliary items required

1. Oil pressure gauge V.A.G 1342
2. Voltage tester V.A.G 1527 B
3. Connector test set V.A.G 1594 C
4. Vehicle diagnostic, testing, and information system VAS 5051

Test requirements

1. Oil level OK
2. Engine oil temperature approximately 80°C.

Checking oil pressure switch F1

Scheme 269

1. Disconnect electrical harness connector - arrow - from oil pressure switch F1.
2. Remove oil pressure switch F1.

Scheme 270

1. Connect oil pressure gauge V.A.G 1342 with adapter V.A.G 1342/14 to hole for oil pressure switch F1.
2. Install oil pressure switch F1 - 2 - into oil pressure gauge V.A.G 1342.
3. Connect brown wire - 1 - of tester to Ground (GND).
4. Connect voltage tester V.A.G 1527B using adapter cables from connector test kit V.A.G 1594A to oil pressure switch F1 and battery plus (+).

1. LED must not light up.

1. If LED is lit, replace oil pressure switch F1.
2. Start engine.

Note. While starting engine, watch Pressure Tester and LED as oil pressure switch may open during start.

Black oil pressure switch

1. At 1.2 to 1.6 bar pressure, LED must light up.

1. If LED is not lit, the oil pressure switch must be replaced.

Oil pressure, checking

1. Disconnect electrical harness connector from oil pressure switch - arrow -.
2. Remove oil pressure switch.

1. Connect oil pressure gauge V.A.G 1342 with adapter V.A.G 1342/14 to hole for oil pressure switch.
2. Install oil pressure switch - 2 - in oil pressure gauge V.A.G 1342.
3. Start engine (engine oil temperature approximately 80°C).

1. Oil pressure at idle: at least 1.0 bar
2. Oil pressure at 2000 RPM: at least 3.5 bar

Engine oil

Viscosity classes and oil specifications --> 01 - MAINTENANCE .

Oil level, checking

Test requirements

1. Engine oil temperature at least 60°C.
2. Vehicle in level position.
3. After stopping engine, wait a few minutes to allow oil to flow back into oil pan.

1. Pull out oil dipstick, wipe off with a clean cloth and re-insert dipstick again up to stop.
2. Withdraw dipstick again and read oil level.

Scheme 271

a - Oil must not be added.

b - Oil may be topped off. After topping off, oil may be in range - a -.

c - Oil must be added. After topping off, it is sufficient if oil level is somewhere in range - b - (shaded area).

Note. Oil level must not exceed mark - a - on oil dipstick.

Scheme 272

1 - Seal

1. Replace

2 - Bracket

3 - Bolt

1. 9 Nm

4 - Coolant line

5 - Seal

1. Replace

6 - Coolant line

7 - Seal

1. Replace

8 - Cap

1. 25 Nm

9 - Oil filter element

1. Observe change intervals --> «01 - MAINTENANCE»(/audi/a8/d3-2005-2007/remont/procedures/#maintenance-procedures)

10 - Bolt

1. 45 Nm

11 - Oil filter housing

1. With oil cooler
2. Removing and installing --> «Oil filter housing, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-filter-housing-removing-and-installing)

12 - Gasket

1. Replace

13 - Coolant drain plug

1. 10 Nm

14 - Oil Pressure Switch F1

1. 20 Nm
2. Checking --> «Oil pressure and oil pressure switch F1 , checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm)

15 - Oil drain plug

1. 10 Nm

16 - Seal

1. Replace

17 - Dowel sleeve

18 - Gasket

1. For oil channel
2. Replace

19 - Seal

1. Replace

20 - Coolant line

21 - Dowel sleeve

22 - Coolant line

23 - Bolt

1. 9 Nm

24 - Seal

1. Replace

Oil filter housing, removing and installing

1. Remove engine --> «Engine, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .
2. Remove generator --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment)

Scheme 273

1. Disconnect electrical connector - 1 - from oil pressure switch F1.
2. Disconnect electrical connector - 2 - from engine mount.
3. Disconnect electrical connector - 3 - from torque support valve N382.
4. Remove right exhaust manifold --> «Right exhaust manifold, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__right-exhaust-manifold-removing-and-installing) .

1. Remove coolant pipe to oil filter housing --> «Coolant pipe to oil filter housing, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__coolant-pipe-to-oil-filter-housing)

Scheme 274

1. Remove oil filter housing - arrows -.

Installing

Installation is in reverse order of removal, note the following

Note. Replace gaskets and O-rings.

1. Install generator --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment)
2. Install right exhaust manifold --> «Right exhaust manifold, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__right-exhaust-manifold-removing-and-installing)
3. Install coolant pipe to oil filter housing --> «Coolant pipe to oil filter housing, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__coolant-pipe-to-oil-filter-housing)
4. Install torque support --> «Torque support (with torque support valve N382), assembly overview»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm) .

Torque specifications

Tightening torques --> Oil filter housing, assembly overview Oil filter housing, assembly overview

Cooling system components, removing and installing

Note. When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work. Secure all hose connections using hose clamps appropriate for the model type . Hose clip pliers V.A.G 1921 are recommended for installing spring-type clamps. Always replace gaskets and seals. Arrows on coolant pipes and coolant hoses must line up across from each other.

Scheme 275

1 - Radiator

1. Replace coolant after replacing

2 - Oil filter housing

1. With oil cooler
2. Removing and installing --> «Oil filter housing, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bfm__oil-filter-housing-removing-and-installing)

3 - Generator

1. Liquid-cooled

4 - Bleeder screw

1. In hose to pump-valve unit

5 - Heater core in air conditioner, right

1. Removing and installing --> «87 - AIR CONDITIONING»(/audi/a8/d3-2005-2007/remont/ac-compressor/#heating-air-conditioning)
2. Renew coolant after replacing

6 - Pump valve unit