4.2L V8 4V Engine Mechanical, Engine Code(s): Bvj: Overview Audi A8 D3 facelift 2

Scheme 14

1. Engine number ("engine code" and "serial number") is located at front on cylinder block at top - arrow -.
2. The engine code is also located on vehicle data plate.

Note. The engine number is only visible if the front engine cover is removed.

Piston and connecting rod, assembly overview

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

Scheme 15

1 - Bolt

1. Replace
2. Lubricate threads and contact surface
3. 60 Nm plus an additional 90° ( 1 / 4 turn).
4. Tighten to 60 Nm to measure radial play, do not turn further

2 - Connecting rod bearing cap

1. Mark for re-installation
2. Mark affiliation to cylinder with paint --> «Mark connecting rod»(ref-289203-S38018198252009012200000)
3. Installation position of connecting rod pairs --> «Connecting rod, installed location»(ref-289203-S28788076932009012200000)

3 - Bearing shells

1. Check that retaining tabs are secured
2. Mark used bearing shells for reinstallation but not on running surface
3. Radial clearance, measuring --> «Radial clearance of connecting rod, measuring»(ref-289203-S23512145182008062700000)
4. Over-sized bearings are available for reworked crankshaft connecting rod journals

4 - Connecting rod

1. Only replace as set
2. Mark affiliation to cylinder with paint --> «Mark connecting rod»(ref-289203-S38018198252009012200000)
3. Installation position of connecting rod pairs --> «Connecting rod, installed location»(ref-289203-S28788076932009012200000)
4. Axial play for each new connecting rod pair: 0.20 to 0.27 mm

1. Axial play wear limit: 0.30 mm
2. Radial clearance, measuring --> «Radial clearance of connecting rod, measuring»(ref-289203-S23512145182008062700000)

5 - Piston pin

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

6 - Circlip

7 - Piston

1. Installation position of pistons --> «Piston installation position»(ref-289203-S18630446312009012200000)
2. Piston and cylinder dimensions --> «Piston and cylinder dimensions»(ref-289203-S14533348732008062700000)
3. Checking --> «Checking piston»(ref-289203-S03301075942009012200000)
4. Install with piston ring compressor

1. Measuring cylinder bore --> «Measuring cylinder bore»(ref-289203-S06094922662009012200000)

8 - Piston rings

1. Offset gaps by 120°
2. Use piston ring pliers for removal and installation
3. "TOP" marking or inscribed side must point to piston head
4. Gap, measuring --> «Piston ring end gap, measuring»(ref-289203-S14468613122009012200000)

1. Measuring side clearance --> «Measuring piston ring side clearance»(ref-289203-S05851601462009012200000)

Scheme 16

1. Slide piston ring down from above at a right angle to cylinder wall until it is approx. 15 mm from bottom edge of cylinder.
2. When sliding in, use a piston without piston rings.

Scheme 17

1. Clean ring groove of piston before checking.

Scheme 18

1. Measure approx. 15 mm from lower edge, at a 90° angle to piston pin axis using an external micrometer 75 to 100 mm.

1. Maximum deviation from nominal dimension: 0.03 mm.

Nominal dimension --> Piston and cylinder dimensions .

Scheme 19

1. Using an internal dial gauge 50 to 100 mm, measure at 3 points in diagonal sequence horizontally - A - and vertically - B -.

1. Maximum deviation from nominal dimension: 0.08 mm.

Nominal dimension --> Piston and cylinder dimensions .

Scheme 20

1. Mark allocation to cylinder with pen on piston crown for reinstallation.

Note. Do not use a center punch or scribe, since the piston head coating will be damaged.

Installed location

1. Arrows on piston heads point to belt pulley side.
2. Large valve recesses - 1 - point toward center of engine.

Scheme 21

Note. Only replace connecting rod as a set.

1. Mark connecting rod and connecting rod bearing cap to each other and to cylinder - arrow - with pen for reinstallation.

Scheme 22

1. Molded tabs - arrows - at the beveled surfaces of the connecting rod pairs 1 and 2, 3 and 4, 5 and 6 as well as 7 and 8 must point toward each other.

Scheme 23

1. Oil spray jet
2. Bolts - 9 Nm. Insert with locking compound

Note. Do not bend piston spray nozzles. Bend piston spray nozzles must be replaced.

Cylinder head, assembly overview

Note. Cylinder head for cylinder bank 2 (left) is shown in illustration.

Scheme 24

1 - Cylinder head gasket

1. Replacing --> «Cylinder head, removing and installing»(ref-289203-S20311116122008062700000) .
2. Installed location: Part Number, points to cylinder head
3. After replacing, change engine oil and coolant

2 - Cylinder head

1. Removing and installing --> «Cylinder head, removing and installing»(ref-289203-S20311116122008062700000)
2. Check for distortion --> «Checking cylinder head for distortion»(ref-289203-S36241368822009012200000)
3. Reworking dimension
4. After replacing, change engine oil and coolant

3 - Cylinder head cover gasket

1. Replace if damaged or leaking

4 - Cylinder head cover

1. Removing and installing: Left --> «Left cylinder head cover, removing and installing»(ref-289203-S30024037292008062700000) , right --> «Right cylinder head cover, removing and installing»(ref-289203-S09330649892008062700000)

5 - Gasket

1. For cap
2. Replace if damaged or leaking

6 - Cap

7 - Ignition coil

1. Remove with Puller T40039

8 - Bolt

1. Replace if seal is damaged
2. Left cylinder head cover tightening sequence --> «Left cylinder head cover tightening sequence»(ref-289203-S16427006052009012200000)
3. Right cylinder head cover tightening sequence --> «Right cylinder head cover tightening sequence»(ref-289203-S32637605842009012200000)

9 - Camshaft Adjustment Valve 2 N208

10 - Bolt

1. 2.4 Nm

11 - O-ring

1. Replace

12 - Seal

1. Replace

13 - Locking bolt

1. 35 Nm

14 - Bolt

1. 2.4 Nm

15 - Camshaft Adjustment Valve 2 (exhaust) N319

16 - O-ring

1. Replace

17 - Bolt

1. Replace
2. Observe sequence for loosening --> see scheme 224
3. Tightening order --> «Cylinder head tightening sequence»(ref-289203-S35734874702009012200000)

Scheme 25

1. Tighten bolts - 1 to 15 - in sequence.

1. 9 Nm

Scheme 26

1. Tighten bolts - 1 to 16 - in sequence.

1. 9 Nm

Scheme 27

1. Tighten bolts in 5 stages - 1 to 5 - in sequence as follows
2. Insert bolts by hand as far as stop.
3. Tighten bolts to 30 Nm.
4. Tighten bolts to 60 Nm.

1. Tighten an additional 90° ( 1 / 4 turn).
2. Tighten an additional 90° ( 1 / 4 turn).
3. Insert bolts - arrows - with locking compound and tighten to 8 Nm; Locking compound .
4. Tighten bolts - arrows - an additional 90° ( 1 / 4 turn).

Scheme 28

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

1. Maximum permissible warpage: 0.1 mm.

Scheme 29

Resurfacing cylinder head (face grinding) is only permissible to minimum dimension - a -.

1. Minimum dimension: - a - = 139.5 mm.

Valvetrain, assembly overview

Note. Cylinder head for cylinder bank 2 (left) is shown in illustration.

Scheme 30

1 - Sealing plug

2 - Valve stem seal

1. Replacing --> «Valve stem seals, replacing»(ref-289203-S18354308942008062700000) .

3 - Valve spring

1. Installed location --> «Installed position of valve spring»(ref-289203-S41343865832009012200000)

4 - Support element

1. With hydraulic valve clearance compensation
2. Clipped into roller rocker lever - 8
3. Checking --> «Support elements with hydraulic adjustment, checking»(ref-289203-S27572867642008062700000)
4. Mark for re-installation

1. Lubricate contact surface

5 - Valve spring plate

6 - Valve keys

7 - Securing clip

1. Check for secure seat

8 - Roller rocker lever

1. Mark for re-installation
2. Check roller for easy movement
3. Lubricate contact surface
4. To assemble, clip onto support element - 4 - with securing clip - 7

9 - Intake camshaft

1. Removing and installing --> «Camshafts, removing and installing»(ref-289203-S17414273002008062700000)
2. Measuring axial play --> «Camshaft axial play, measuring»(ref-289203-S36153131892008062700000)
3. Measure radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance at bearing-dia. 24 mm: 0.024 to 0.066 mm

1. Radial clearance at bearing-dia. 36 mm: 0.032 to 0.078 mm
2. Run-out: maximum 0.04 mm

10 - Gasket

1. Replace

11 - Bearing bracket

1. With integrated camshaft bearings
2. Removing and installing --> «Camshafts, removing and installing»(ref-289203-S17414273002008062700000)

12 - Bolt

1. Tightening order --> «Bearing frame tightening sequence»(ref-289203-S11674724522009012200000)

13 - Camshaft position (CMP) sensor 2 G163

14 - Bolt

1. 9 Nm

15 - O-ring

1. Replace

16 - Bolt

1. 9 Nm

17 - Camshaft position (CMP) sensor 4 G301

18 - O-ring

1. Replace

19 - Compression ring

1. For camshaft adjuster

20 - Exhaust camshaft

1. Removing and installing --> «Camshafts, removing and installing»(ref-289203-S17414273002008062700000)
2. Measuring axial play --> «Camshaft axial play, measuring»(ref-289203-S36153131892008062700000)
3. Measure radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance at bearing-dia. 24 mm: 0.024 to 0.066 mm

1. Radial clearance at bearing-dia. 36 mm: 0.032 to 0.078 mm
2. Run-out: maximum 0.04 mm

21 - Cylinder head

1. Check valve guides --> «Valve guides, checking»(ref-289203-S09160226532008062700000)

22 - Intake valve

1. Do not rework, only lapping is permitted
2. Mark installed position for re-installation
3. Valve dimensions --> «Valve dimensions»(ref-289203-S35221073372008062700000)
4. Check valve guides --> «Valve guides, checking»(ref-289203-S09160226532008062700000)

23 - Exhaust valve

1. Do not rework, only lapping is permitted
2. Mark installed position for re-installation
3. Valve dimensions --> «Valve dimensions»(ref-289203-S35221073372008062700000)
4. Check valve guides --> «Valve guides, checking»(ref-289203-S09160226532008062700000)

Scheme 31

1. Tighten bolts in 2 stages in - 1 to 24 - sequence as follows.
2. Install bolts by hand as far as stop.
3. Tighten bolts to 8 Nm.

Scheme 32

1. The tight spring coils - arrow - face toward cylinder head.