4.2l v8 5v Engine Mechanical, Engine Code(s): Bhf Audi S4 B8

Scheme 1

Note. A sticker - arrow - with "engine code" and "serial number" is affixed at right on intake manifold. The engine code is also located on the vehicle data plate. The engine number is only visible after a work step.

1. Bring lock carrier into service position --> «Lock carrier, moving into service position»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__lock-carrier-moving-into-service-position) .

Scheme 2

1. Remove front engine cover - arrows 1 and 2 -.

Scheme 3

Engine number ("engine code" and "serial number") is located at front on cylinder block at top - arrow -.

Engine data

*Super unleaded RON 95 is permissible, but with reduced power.

Safety precautions

Note the following when working on the fuel system

To prevent personal injury and damage to the injection and ignition system, observe the following

1. The ignition must be switched off before connecting or disconnecting injection and ignition system wiring or tester cables.
2. Only clean engine with ignition switched off.
3. If electrical connectors were disconnected, faults are saved in ECM

1. Connect Vehicle Diagnosis, Testing and Information System VAS 5051B.
2. Start "Guided Functions" operating mode.
3. Generate readiness code in ECM.

1. Disconnect battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/s4/b8-2008-2011/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Note the following when working on the cooling system

If it is necessary to use testing and measuring devices on road tests, observe the following

Rules for cleanliness

Even a little contamination can lead to faults. Therefore when working on the fuel supply and injection system, pay careful attention to the following rules of cleanliness

1. Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
2. Seal open lines and connections immediately using suitable protective caps.
3. Place parts that have been removed on a clean surface and cover them. Use lint-free cloths.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpackaged (e.g. in tool boxes etc.).

1. Carefully cover over opened components or seal, if repairs are not performed immediately.
2. When system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
3. Protect disconnected electrical connectors from dirt and moisture and only connect if dry.

Fuel supply system, checking for leaks

1. Let engine run a few minutes at average RPM.
2. Switch off ignition.
3. Check entire fuel supply system for leaks.
4. If there are leaks in spite of correct tightening torque, the corresponding component must be replaced.

Contact corrosion!

Contact corrosion can occur if appropriate connecting elements (bolts, nuts, washers, etc.) are not used.

For this reason, only install connecting elements that are treated with a special coating.

Also, rubber or plastic parts and adhesive consist of non-conductive materials.

If there are doubts about the suitability of parts, generally use new parts .

Note. Only original replacement parts are recommended, they are checked and compatible with aluminum. Audi accessories are recommended. Damage due to contact corrosion is not covered by warranty.

Engine (vehicles with manual transmission)

Note. With lock carrier removed, engine is removed downward with transmission and subframe.

Scheme 4

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782
2. Hose clamp pliers V.A.G 1921
3. Spark plug connector pliers V.A.G 1922
4. Step ladder VAS 5085

1. Scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10
2. Drip tray for workshop crane VAS 6208

Note. If engine and transmission are to be separated after removal, the Supplementary Set, Audi A8 > 2002 VAS 6131/11 will also be required.

Special tools, testers and auxiliary items required

Scheme 5

1. Lifting Eyebolt 3368

Scheme 6

1. Tension strap T10038

Work procedure

Note. Drained coolant must be stored in a clean container for disposal or reuse. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

1. Remove plenum chamber cover rubber seal.

Scheme 7

1. Remove plenum chamber cover - 1 - toward front - arrows -.

Scheme 8

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Discharge refrigerant circuit --> «87 - AIR CONDITIONING»(/audi/s4/b8-2008-2011/remont/automatic-hvac-system/#refrigerant-r134a-servicing) .
3. Extract hydraulic oil for power-steering from reservoir using old oil collecting and extracting device V.A.G 1782.

1. Open cap of coolant expansion tank.
2. Remove both front wheels.

Scheme 9

1. Remove quick-release fasteners - 1 - , remove screws - 2 - and remove noise insulation.

Scheme 10

1. Remove bracket for noise insulation - arrows -.
2. Remove left front and right front wheel housing liners --> «66 EXTERIOR EQUIPMENT»(ref-278920-S32431341132008020700000) «66 - EXTERIOR EQUIPMENT»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Remove front bumper cover --> «63 BUMPER»(ref-278920-S18413101412008020700000) «63 - BUMPERS»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

Scheme 11

1. Remove left air guide - arrow - in front of auxiliary cooler.

Scheme 12

1. Remove right air guide - arrow - in front of auxiliary cooler.
2. Place drip tray for workshop crane VAS 6208 under engine.

Scheme 13

1. Remove drain plug - arrow - on coolant thermostat housing and drain coolant from engine.

Scheme 14

1. Disconnect lower coolant hose from radiator - arrow - and drain residual coolant.

Scheme 15

1. Place old oil collecting and extracting device V.A.G 1782 under engine.
2. Disconnect hydraulic lines to cooling coil at left rear of bumper - arrows -.

Scheme 16

1. Remove cover - 1 - in engine compartment (left side).

Scheme 17

1. Remove cover - 1 - in engine compartment (right side).

Scheme 18

1. Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - from air guide.
2. Remove bolts - arrows -.
3. Remove air duct - 2 -.

Scheme 19

1. Disconnect top coolant hose - arrow - from radiator.

Scheme 20

1. Remove electrical harness connectors - 1 - and - 2 - from bracket and disconnect them.
2. Free up wires to lock carrier.

Scheme 21

1. Disconnect electrical harness connector - arrow - for headlights at both sides of the vehicle.
2. Free up electrical wiring.

Scheme 22

1. Disconnect electrical harness connector - arrow - for left and right airbag sensors on lock carrier.
2. Free up cables.
3. Remove hood cable at lock carrier --> «55 HOOD, LIDS»(ref-278920-S06872438102008020700000) «55 - HOOD, LIDS»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

Scheme 23

1. Disconnect electrical harness connector - arrow - for right fan.

Note. To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

Scheme 24

1. Remove refrigerant line - arrow - leading to A/C compressor.

Scheme 25

1. Remove refrigerant line - arrow - leading to A/C evaporator.

Scheme 26

1. Remove bolts - arrows - at left and right side of bumper.
2. Remove hood seal from lock carrier and fender edges.

Scheme 27

1. Remove bolts at impact absorbers - arrows - at left and right.

Note. A second technician is required to remove lock carrier.

1. Remove lock carrier and set aside so it cannot topple.

Scheme 28

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrows 1 and 2 -.

Scheme 29

1. Remove coolant hoses - 1 - and - 2 -.
2. Remove coolant expansion tank - arrow -.
3. Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch F66 at bottom of expansion tank.

Scheme 30

1. Disconnect vacuum line - arrow - to brake booster at bulkhead.

Scheme 31

1. Unclip coolant hose - arrow - from bracket on bulkhead.

Scheme 32

1. If installed, disconnect vacuum line - arrow - to vacuum reservoir.

Scheme 33

1. Disconnect vacuum hose - arrow - from intake manifold.

Scheme 34

1. Disconnect coolant hose - arrow - to heater core at rear coolant pipe on engine.

Scheme 35

1. If installed, disconnect vacuum line at area designated with - arrow -.

Scheme 36

1. If installed, disconnect electrical harness connector - arrow - for After-Run Coolant Pump V51 (behind auxiliary cooler at left) and free up electrical wire.

Note. Place a rag under separating point to catch escaping hydraulic fluid.

Scheme 37

1. Disconnect hose - 1 - from power steering fluid reservoir.

Note. Ignore - 2 -.

Scheme 38

1. Disconnect coolant hoses at positions indicated by - arrows -.

Scheme 39

1. Disconnect coolant hoses at positions indicated by - arrows -.

Scheme 40

1. Disconnect coolant hose to oil cooler - arrow -.

Scheme 41

1. Disconnect coolant hoses at positions indicated by - arrows -.

Scheme 42

1. Remove bolts - 1 - and - 2 -.
2. Remove right auxiliary cooler together with coolant hoses.

Note. The hose - arrow - can remain connected at auxiliary cooler.

Scheme 43

1. Remove fuel hose from connection on fuel rail line. To do so, counter hold using an open-end wrench at hex head - 1 - and - 3 - and remove union nut - 2 -.

Scheme 44

1. Disconnect electrical harness connector - 2 - from Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.
2. Disconnect electrical harness connector - 3 - at Mass Air Flow (MAF) Sensor G70.
3. Disconnect hose - 1 - to Secondary Air Injection (AIR) pump.
4. Disconnect air guide hose - 4 - at Mass Air Flow (MAF) sensor.

1. Move wiring harness clear at air filter housing.
2. Remove clip - arrow - and remove air filter housing with Mass Air Flow (MAF) sensor.

Scheme 45

1. Disconnect air hose - arrow - at right on engine.

Scheme 46

1. Remove bracket for electrical harness connectors - 1 to 4 - at right from bulkhead.

Scheme 47

1. Remove nut - 1 - and remove fuse strip on battery positive (+) cable terminal clamp.
2. Disconnect battery positive (+) cable - 2 - on battery positive terminal.
3. Pull battery positive (+) cable through bulkhead toward front.
4. Free up wiring harness.

Note. Disregard item - 3 -.

Scheme 48

1. Pry off both covers - 3 - using a screwdriver.
2. Loosen hex-nuts - 4 - by several turns.
3. Loosen wiper arms - 2 - from the respective wiper axle by tilting slightly.
4. Remove nuts completely and remove wiper arms.

1. Disconnect securing clips - 1 - and remove cowl grille - 5 -.

Scheme 49

1. Remove cover for E-Box in plenum chamber - arrows -.

Scheme 50

1. Using a screwdriver, carefully pry off mounting bracket - arrow - and remove Engine Control Module (ECM) from E-Box.

Note. Engine Control Module (ECM) remains connected at wiring harness.

Scheme 51

1. Release retaining hooks - arrows - toward outside and remove retaining bracket.

Scheme 52

1. Disconnect all electrical harness connectors on connector station - 2 - using spark plug connector pliers V.A.G 1922.
2. Remove electrical wire connection - 1 -.

Scheme 53

1. Disengage locking mechanisms - arrows - and remove secondary relay carrier in E-Box toward top.
2. Disengage engine wiring harness at E-Box and bulkhead.

Scheme 54

1. Remove Ground (GND) connection - arrow -.

Scheme 55

1. Remove bracket for electrical harness connectors - 1 to 4 - at left from bulkhead.
2. Free up wiring harness.
3. Set electrical wiring harness on engine and secure Engine Control Module (ECM) against falling down.

Scheme 56

1. Disconnect electrical harness connector - 1 - at Secondary Air Injection (AIR) Pump Motor V101.
2. Remove Ground (GND) wire - 2 - on long member.

Scheme 57

1. Place old oil collecting and extracting device V.A.G 1782 under engine.
2. Disconnect hydraulic pressure line for power-steering - arrow - at left next to oil pan.

Scheme 58

Note. To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

1. Remove bolts - 1 - and - 2 -.
2. Remove right refrigerant line from A/C compressor.

Note. The left refrigerant line will be removed at a later point in time.

1. Seal open connections on A/C compressor using clean plugs.

Scheme 59

1. Remove left bracket for refrigerant line - arrows -.

Scheme 60

1. Remove refrigerant line on bracket - arrow -.

Scheme 61

1. Remove bolt - arrow - and disconnect refrigerant line to A/C compressor.

Scheme 62

1. Have a second technician press brake pedal.

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

Scheme 63

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

Scheme 64

1. Disconnect electrical harness connector at Left Front Level Control System Sensor G78.
2. Unclip operating rod for Left Front Level Control System Sensor G78 at bottom on control arm.
3. Remove outer suspension strut bolt from left and right of engine compartment.

Scheme 65

1. Rotate Lifting Eyebolt 3368 at left and right in suspension strut mount hole from below.

1. Tie up wheel bearing housing at left and right with Tensioning Strap T10038 as shown in illustration.

Scheme 66

1. Remove bolt and remove suspension strut from control arm - arrow -.

Scheme 67

1. Remove expanding clips - arrows -.
2. Remove nut - 1 - and remove cover behind wheel housing.

Scheme 68

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

Scheme 69

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

1. Repeat work procedure on opposite side of the vehicle.

Scheme 70

1. Remove heat shield - 1 - for left drive axle.
2. Remove drive axle from transmission flanged shaft.
3. Swing left wheel bearing housing outward and remove drive axle.
4. Repeat work procedure on opposite side of the vehicle.

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

Scheme 71

1. Disconnect exhaust system at double clamps - arrows -.

Scheme 72

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

Scheme 73

Prepare scissor lift platform

1. Equip scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10 as follows

1. Install attachments on scissor lift table by hand first.
2. Place scissor lift platform VAS 6131 A in horizontal position.

1. Note bubble level (sight glass) on support platform.

1. Drive scissor lift platform VAS 6131 A under engine/transmission subassembly.

Scheme 74

1. Position support elements from VAS 6131/10 at front on engine as shown in illustration.

Scheme 75

1. Position support elements from VAS 6131/10 at left and right on subframe as shown in illustration.

Scheme 76

1. Position support elements from VAS 6131/10 at left and right on tunnel cross member as shown in illustration.
2. Turn all spindles of support elements upward far enough until all support pins make contact at support points.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131 A.

Scheme 77

1. Mark installation position of subframe and of both engine mount plates to long members using a felt-tip marker.
2. Remove bolts - 1 to 4 - in diagonal sequence and in stages.

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

Scheme 78

1. Lower engine/transmission subassembly using scissor lift platform VAS 6131 A first only approx. dimension - a -.

1. Dimension - a - = 100 mm.

Scheme 79

1. Disconnect connecting rod - 2 - of shift rod.
2. Remove socket head bolt of pivot rod - 1 -.

Scheme 80

1. Remove nut - arrow - and remove lever from selector shaft.

Scheme 81

1. Remove clutch slave cylinder - arrow - , do not disconnect lines.
2. Tie up clutch slave cylinder together with shift rods.
3. Lower engine/transmission subassembly downward.
4. Push scissor lift platform VAS 6131 A with engine/transmission subassembly under vehicle.

Engine (vehicles with manual transmission), separating

Special tools, testers and auxiliary items required

1. Support set for Audi VAS 6131/10 and VAS 6131/11

Scheme 82

1. Adapter T40058

Work procedure

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

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. All heat insulation sleeves removed during engine removal must be reinstalled at the same locations during installation.

1. Turn spindles of support elements from VAS 6131/10 at left and right at subframe completely downward.
2. Remove support pins from spindles.
3. Remove subframe to side.

Scheme 83

1. Remove bottom engine/transmission connecting bolts - arrows -.

1. Equip scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10 and VAS 6131/11 as follows

*Support elements remain unchanged.

Scheme 84

1. Position support elements from VAS 6131/10 and VAS 6131/11 at left on engine/transmission as shown in illustration.

Scheme 85

1. Position support elements from VAS 6131/10 and VAS 6131/11 at right on engine/transmission as shown in illustration.
2. Turn spindles of attachments upward far enough until all support pins make contact at support points.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131 A.

1. Remove electrical harness connectors - 1 - and - 4 - from bracket and disconnect.
2. Remove heat insulation sleeve on wiring harness and free up individual wires.

Note. In the illustration, the electrical harness connectors are depicted as installed.

Scheme 86

1. Remove bolt - arrow - at strap for left front exhaust pipe.

Scheme 87

1. Remove nuts - 1 to 3 - for left front exhaust pipe/exhaust manifold.
2. Remove front exhaust pipe with pre- and main catalytic converters.

1. Remove electrical harness connectors - 2 - and - 4 - from bracket and disconnect.
2. Free up wiring harnesses.

Note. In the illustration, the electrical harness connectors are depicted as installed.

Scheme 88

1. Remove bolt - arrow - at strap for right front exhaust pipe.

Scheme 89

1. Remove nuts - 1 to 3 - for right front exhaust pipe/exhaust manifold.
2. Remove front exhaust pipe with pre- and main catalytic converters.

Scheme 90

1. Remove bolt and Engine Speed (RPM) Sensor G28 on transmission - arrow -.

Scheme 91

1. Disconnect electrical harness connector - arrow - at Back-Up Light Switch F4 and free up electrical wire.

Scheme 92

1. Remove engine/transmission threaded connections - 1 to 7 -.

Scheme 93

1. Loosen side clamping bolts - 1 - on scissor lift platform VAS 6131 A and pull rear platform top with transmission toward rear - arrow - , simultaneously push torque converter through opening of drive plate while doing this.

Scheme 94

Special tools, testers and auxiliary items required

1. Shackle 10-222 A/12
2. Lifting tackle 3033
3. Engine and Transmission Holder VAS 6095 with Holder for V8 Engine Audi S4, allroad quattro VAS 6095/1-6 or Holder for V8 Engine Audi S4, allroad quattro VAS 6095/1-6A
4. Shop crane VAS 6100

1. Lift arm extension for workshop crane VAS 6101

Special tools, testers and auxiliary items required

Scheme 95

1. Additional hooks 10-222 A/2

Work procedure

Scheme 96

1. Remove wiring harness bracket at right engine plate - arrows -.

Scheme 97

1. Disconnect electrical harness connector - 1 - at right engine mount.
2. Remove bolts - arrows - and remove right engine mount.

Note. Shown without engine mount plate to provide a better illustration.

1. Repeat work procedure on opposite side of vehicle.

Scheme 98

1. Disconnect vacuum hose - 1 -.
2. Disconnect air guide hose - 2 - from throttle valve control module.

Scheme 99

1. Secure shackle 10-222 A/12 to right rear engine lifting eyelet.
2. Hook additional hook 10-222 A/2 on shackle 10-222 A/12.

Scheme 100

1. Engage engine sling 3033 on additional hook 10-222 A/2 and on workshop crane VAS 6100 with lift arm extension for workshop crane VAS 6101 as shown in the illustration.
2. Lift engine from support elements of scissor lift platform VAS 6131 A.

Scheme 101

1. Secure engine with Holder for V8 Engine Audi S4, allroad quattro VAS 6095/1-6 or Holder for V8 Engine Audi S4, allroad quattro VAS 6095/1-6A tightened to 42 Nm to Engine and Transmission Holder VAS 6095 as shown in the illustration.

Engine (vehicles with manual transmission), installing

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

1. When installing a new clutch disc in combination with a used SAC clutch pressure plate (self-adjusting pressure plate), the adjustment ring of the pressure plate must be turned back to impact. Otherwise the pressure plate works with decreased contact pressure (clutch slips) --> «30 CLUTCH»(ref-278904-S05381615532008020700000) .

Note. If clutch disc is not being replaced, the adjustment ring must not be turned back. New SAC-pressure plates are already pre-adjusted and must not be reset.

1. Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant on splines. Do not grease the guide sleeve.
2. If necessary, check centering of clutch drive plate.
3. Check clutch release bearing for wear and replace if necessary.

If plastic ring of clutch release bearing is loose

Scheme 102

1. Adhere clutch release bearing plastic ring to bearing ring, adhesive

1. 3 rectangular tabs - arrows - of plastic ring reach into cutouts of bearing ring.
2. If grooves with depth of more than 0.5 mm are present, the release bearing must be replaced.

1. Make sure alignment sleeves for engine to transmission are installed in cylinder block. Install if necessary.
2. Install intermediate plate between engine and transmission onto alignment bushings.
3. Bolt transmission to engine.

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%.

Engine/transmission, fastening

The rest of installation is in reverse order of removal, note the following

1. Install front exhaust pipes with catalytic converters: Left --> «Left front exhaust pipe with primary and main catalytic converter (vehicles with manual transmission), removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__left-front-exhaust-pipe-with-primary) , right --> «Right front exhaust pipe with primary and main catalytic converter (vehicles with automatic transmission), removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__right-front-exhaust-pipe-with-primary) .
2. Always clean threaded driveshaft bores in transmission flanged shaft of locking fluid residue using a tap before installation.

1. Rotate spindles of support elements downward at left of engine/transmission assembly.
2. Remove both base plates for left support element on scissor lift platform VAS 6131 A.

1. Rotate spindles of support elements downward at right of engine/transmission assembly.
2. Remove both base plates for right support element on Scissor Lift Table VAS 6131 A.

Note. The support points for front of engine and tunnel cross member remain unchanged.

1. Equip scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10 as follows

*Support elements remain unchanged.

*Only install support elements after installing subframe.

1. Position subframe on both attachments VAS 6131/10-8.
2. Turn spindles of support elements upward on both sides.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131 A.
4. Using scissor lift platform VAS 6131 A , slowly guide engine/transmission unit with subframe into body from below.

1. Lift engine/transmission subassembly using scissor lift platform VAS 6131 A until dimension - a - is reached.

1. Dimension - a - = 100 mm.

1. Secure clutch slave cylinder with a new bolt - arrow -.

1. Install lever for selector shaft - arrow -.

1. Install connecting rod - 2 - of shift rod.
2. Install socket head bolt of pivot rod - 1 -.

1. Align subframe, engine bearing plated and tunnel cross member according to markings applied on long members during removal.
2. Tighten bolts for subframe, engine mount plates as well as tunnel cross member only to specified torque. Do not tighten further (tighten bolts only after axle alignment).

1. 65 Nm
2. 110 Nm
3. 110 Nm
4. 75 Nm

1. Install driveshafts --> «40 - FRONT SUSPENSION»(/audi/s4/b8-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .
2. Install guide control arm, control arm, stabilizer bar and suspension strut --> «40 - FRONT SUSPENSION»(/audi/s4/b8-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .
3. Install driveshaft --> 39 - FINAL DRIVE, DIFFERENTIAL for 5 SPD. AUTOMATIC TRANSMISSION 01V 39 - FINAL DRIVE, DIFFERENTIAL for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING 39 FINAL DRIVE, DIFFERENTIAL for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 39 FINAL DRIVE, DIFFERENTIAL for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 39 FINAL DRIVE, DIFFERENTIAL for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «39 FINAL DRIVE, DIFFERENTIAL»(ref-278904-S16737983372008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .
4. Align exhaust system free of tension --> «Exhaust system, installing free of tension»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__exhaust-system-installing-free-of-tension) .

1. Install refrigerant lines --> «87 AIR CONDITIONING»(/audi/s4/b8-2008-2011/remont/ac-compressor/#heating-air-conditioning) .

1. Secure fuel hose to connection on fuel rail line. To do so, counter hold using an open-end wrench at each hex head - 1 - and - 3 - and tighten union nut - 2 - to 22 Nm.
2. Install lock carrier with attachments --> «50 BODY, FRONT»(ref-278920-S31853902272008020700000) «50 - BODY - FRONT»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

Scheme 103

1. Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(ref-278920-S18413101412008020700000) «63 - BUMPERS»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Electrical connections and routing --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.
4. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/s4/b8-2008-2011/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

1. Mount wiper arms and adjust --> «92 WINDSHIELD WIPER WASHER SYSTEM»(/audi/s4/b8-2008-2011/remont/cruise-control-systems/#electrical-equipment) 92 WINDSHIELD WIPER & WASHER SYSTEM for ELECTRICAL EQUIPMENT, CABRIOLET .
2. Check oil level --> «Oil level, checking»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__oil-level-checking) .
3. Before starting engine for the first time, fill power steering reservoir with hydraulic oil --> «48 - STEERING»(/audi/s4/b8-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .

Note. Power-steering pump must not run dry.

1. Fill with coolant «Filling»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__filling) .

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

1. Fill refrigerant circuit --> «87 - AIR CONDITIONING»(/audi/s4/b8-2008-2011/remont/automatic-hvac-system/#refrigerant-r134a-servicing) .
2. Align subframe and both engine bearing plates --> «40 - FRONT SUSPENSION»(/audi/s4/b8-2008-2011/remont/axle-shafts/#suspension-wheels-steering)
3. Perform axle alignment --> «44 - WHEELS, TIRES, VEHICLE ALIGNMENT»(/audi/s4/b8-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .

1. Check headlight adjustment --> «01 - MAINTENANCE»(ref-278933-S06026331132008020700000) «01 - MAINTENANCE»(/audi/s4/b8-2008-2011/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

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%.

* Insert using locking compound; locking compound .

*Replace screw.

Engine (vehicles with automatic transmission), removing

Note. With lock carrier removed, engine is removed downward with transmission and subframe.

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782
2. Hose clamp pliers V.A.G 1921
3. Spark plug connector pliers V.A.G 1922
4. Step ladder VAS 5085

1. Scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10
2. Drip tray for workshop crane VAS 6208

Note. If engine and transmission are to be separated after removal, Supplementary Set, Audi A8 > 2002 VAS 6131/11 and Supplementary Set, Audi A6 > 2005 VAS 6131/12 will also be required.

Special tools, testers and auxiliary items required

1. Lifting Eyebolt 3368

1. Tension strap T10038

Work procedure

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. Drained coolant must be stored in a clean container for disposal or reuse.

1. Remove plenum chamber cover rubber seal.

1. Remove plenum chamber cover - 1 - toward front - arrows -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Discharge refrigerant circuit --> «87 - AIR CONDITIONING»(/audi/s4/b8-2008-2011/remont/automatic-hvac-system/#refrigerant-r134a-servicing) .
3. Extract hydraulic oil for power-steering from reservoir using old oil collecting and extracting device V.A.G 1782.

1. Open cap of coolant expansion tank.
2. Remove both front wheels.

1. Remove quick-release fasteners - 1 - , remove screws - 2 - and remove noise insulation.

1. Remove bracket for noise insulation - arrows -.
2. Remove left and right front wheel housing liners --> «66 EXTERIOR EQUIPMENT»(ref-278920-S32431341132008020700000) «66 - EXTERIOR EQUIPMENT»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Remove front bumper cover --> «63 BUMPER»(ref-278920-S18413101412008020700000) «63 - BUMPERS»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Remove left air guide - arrow - in front of auxiliary cooler.

1. Remove right air guide - arrow - in front of auxiliary cooler.

1. Place drip tray for workshop crane VAS 6208 under engine.
2. Remove drain plug - arrow - on coolant thermostat housing and drain coolant from engine.

1. Disconnect lower coolant hose from radiator - arrow - and drain residual coolant.
2. Place old oil collecting and extracting device V.A.G 1782 under engine.

1. Disconnect hydraulic lines to cooling coil at left rear of bumper - arrows -.

Scheme 104

Note. Observe the rules of cleanliness for working on automatic transmissions --> 00 TECHNICAL DATA .

1. Place old oil collecting and extracting device V.A.G 1782 under engine.
2. Loosen union nuts - arrows - and disconnect ATF lines.

1. Remove cover - 1 - in engine compartment (left side).

1. Remove cover - 1 - in engine compartment (right side).

1. Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - from air guide.
2. Remove bolts - arrows -.
3. Remove air duct - 2 -.

1. Disconnect top coolant hose - arrow - from radiator.

1. Remove electrical harness connectors - 1 - and - 2 - from bracket and disconnect them.
2. Free up wires to lock carrier.

1. Disconnect electrical harness connector - arrow - for headlights at both sides of vehicle.
2. Free up electrical wiring.

1. Disconnect electrical harness connector - arrow - for left and right airbag sensors on lock carrier.
2. Free up cables.
3. Remove hood cable at lock carrier --> «55 HOOD, LIDS»(ref-278920-S06872438102008020700000) «55 - HOOD, LIDS»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Disconnect electrical harness connector - arrow - for right fan.

Note. To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

1. Remove refrigerant line - arrow - leading to A/C compressor.

1. Remove refrigerant line - arrow - leading to A/C evaporator.

1. Remove bolts - arrows - at left and right side of bumper.
2. Pull off hood seal from lock carrier and fender edges.

1. Remove bolts at impact absorbers - arrows - at left and right.

Note. A second technician is required to remove the lock carrier.

1. Remove lock carrier and set aside so it cannot topple.

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrows 1 and 2 -.

1. Remove coolant hoses - 1 - and - 2 -.
2. Remove coolant expansion tank - arrow -.
3. Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch F66 at bottom of expansion tank.

1. Disconnect vacuum line - arrow - to brake booster at bulkhead.

1. Unclip coolant hose - arrow - from bracket on bulkhead.

1. If installed, disconnect vacuum line - arrow - to vacuum reservoir.

1. Disconnect vacuum hose - arrow - from intake manifold.

1. Disconnect coolant hose - arrow - to heater core at rear coolant pipe on engine.

1. If installed, disconnect vacuum line at area designated with - arrow -.

1. If installed, disconnect electrical harness connector - arrow - for After-Run Coolant Pump V51 (behind auxiliary cooler at left) and free up electrical wire.

Note. Place a rag under separating point to catch escaping hydraulic fluid.

1. Disconnect hose - 1 - from power steering fluid reservoir.

Note. Ignore - 2 -.

1. Disconnect coolant hoses at positions indicated by - arrows -.

1. Disconnect coolant hoses at positions indicated by - arrows -.

1. Disconnect coolant hose to oil cooler - arrow -.

1. Disconnect coolant hoses at positions indicated by - arrows -.

1. Remove bolts - 1 - and - 2 -.
2. Remove right auxiliary cooler together with coolant hoses.

Note. The hose - arrow - can remain connected at auxiliary cooler.

1. Remove fuel hose from connection on fuel rail line. To do so, counter hold using an open-end wrench at hex head - 1 - and - 3 - and remove union nut - 2 -.

1. Disconnect electrical harness connector - 2 - from Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.
2. Disconnect electrical harness connector - 3 - at Mass Air Flow (MAF) Sensor G70.
3. Disconnect hose - 1 - to Secondary Air Injection (AIR) pump.
4. Disconnect air guide hose - 4 - at Mass Air Flow (MAF) sensor.

1. Move wiring harness clear at air filter housing.
2. Remove clip - arrow - and remove air filter housing with Mass Air Flow (MAF) sensor.

1. Disconnect air hose - arrow - at right on engine.

1. Remove bracket for electrical harness connectors - 1 to 4 - at right from bulkhead.

1. Remove nut - 1 - and remove fuse strip on plus wire terminal clamp.
2. Disconnect battery positive (+) cable - 2 - on battery positive terminal.
3. Pull battery positive (+) cable through bulkhead toward front.
4. Free up the wiring harness.

Note. Disregard item - 3 -.

1. Pry off both covers - 3 - using a screwdriver.
2. Loosen hex-nuts - 4 - by several turns.
3. Loosen wiper arms - 2 - from respective wiper axle by tilting slightly.
4. Remove nuts completely and remove wiper arms.

1. Disconnect securing clips - 1 - and remove cowl grille - 5 -.

1. Remove cover for E-Box in plenum chamber - arrows -.

1. Using a screwdriver, carefully pry off mounting bracket - arrow - and remove Engine Control Module (ECM) from E-Box.

Note. Engine Control Module (ECM) remains connected at wiring harness.

1. Release retaining hooks - arrows - toward outside and remove retaining bracket.

1. Disconnect all electrical harness connectors on connector station - 2 - using spark plug connector pliers V.A.G 1922.
2. Remove electrical wire connection - 1 -.

1. Disengage locking mechanisms - arrows - and remove secondary relay carrier in E-Box toward top.
2. Disengage engine wiring harness at E-Box and bulkhead.

1. Remove Ground (GND) connection - arrow -.

1. Remove bracket for electrical harness connectors - 1 to 4 - at left from bulkhead.
2. Free up wiring harness.
3. Set electrical wiring harness on engine and secure Engine Control Module (ECM) against falling down.

1. Disconnect electrical harness connector - 1 - at Secondary Air Injection (AIR) Pump Motor V101.
2. Remove Ground (GND) wire - 2 - on long member.

1. Place old oil collecting and extracting device V.A.G 1782 under engine.
2. Disconnect hydraulic pressure line for power-steering - arrow - at left next to oil pan.

Note. To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

1. Remove bolts - 1 - and - 2 -.
2. Remove right refrigerant line from A/C compressor.

Note. The left refrigerant line will be removed at a later point in time.

1. Seal open connections on A/C compressor using clean plugs.

1. Remove left bracket for refrigerant line - arrows -.

1. Remove refrigerant line on bracket - arrow -.

1. Remove bolt - arrow - and disconnect refrigerant line to A/C compressor.

1. Have a second technician press brake pedal.

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

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

1. Disconnect electrical harness connector at Level Control System Sensor.
2. Unclip operating rod for Left Front Level Control System Sensor G78 at bottom on control arm.
3. Remove outer suspension strut bolt from left and right of engine compartment.

1. Rotate Lifting Eyebolt 3368 at left and right in suspension strut mount hole from below.

1. Tie up wheel bearing housing at left and right with Tensioning Strap T10038 as shown in illustration.

1. Remove bolt and remove suspension strut from control arm - arrow -.

1. Remove expanding clips - arrows -.
2. Remove nut - 1 - and remove cover behind wheel housing.

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

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

1. Repeat work procedure on opposite side of vehicle.

1. Remove heat shield - 1 - for left drive axle.
2. Remove drive axle from transmission flanged shaft.
3. Swing left wheel bearing housing outward and remove drive axle.
4. Repeat work procedure on opposite side of vehicle.

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

1. Disconnect exhaust system at double clamps - arrows -.

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

Note. Mark the installation position of bracket for selector lever cable using a felt-tip marker.

Scheme 105

1. Press ball socket - 1 - of selector lever cable from selector shaft lever.
2. Remove bracket on transmission - arrows -.
3. Move selector lever cable clear.

Note. To improve clarity, the transmission supports are shown removed in the illustration.

Prepare scissor lift platform

1. Equip scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10 as follows

1. Install attachments on scissor lift table by hand first.
2. Place scissor lift platform VAS 6131 A in horizontal position.

1. Note bubble level (sight glass) on support platform.

1. Drive scissor lift platform VAS 6131 A under engine/transmission subassembly.

1. Position support elements from VAS 6131/10 at front on engine as shown in illustration.

1. Position support elements from VAS 6131/10 at left and right on subframe as shown in illustration.

Scheme 106

1. Position support elements from VAS 6131/10 at rear on transmission as shown in illustration.
2. Turn all spindles of support elements upward far enough until all support pins make contact at support points.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131 A.

1. Turn both spindles at subframe 2 rotations upward.

1. Turn both spindles at transmission 4 rotations upward.

Scheme 107

1. Remove bolts - 1 -.
2. Mark installation position of subframe and of both engine mount plates to long members using a felt-tip marker.
3. Remove bolts - 2 - , - 3 - and - 4 - 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. Push scissor lift platform VAS 6131 A with engine/transmission subassembly under vehicle.

Engine and transmission (vehicles with automatic transmission), separating

Special tools, testers and auxiliary items required

1. Support set for Audi VAS 6131/10 , VAS 6131/11 and VAS 6131/12

1. Adapter T40058

Work procedure

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

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. All heat insulation sleeves removed during engine removal must be reinstalled at the same locations during installation.

Scheme 108

1. Remove bolts - arrows - for left and right transmission mount.

1. Turn spindles of support elements from VAS 6131/10 at left and right at subframe completely downward.
2. Remove support pins from spindles.
3. Remove subframe to side.

1. Equip scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10 , VAS 6131/11 and VAS 6131/12 as follows

*Support elements remain unchanged.

Scheme 109

1. Position support elements from VAS 6131/11 and VAS 6131/12 at left on engine/transmission as shown in illustration.

Scheme 110

1. Position support elements from VAS 6131/10 and VAS 6131/11 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 support elements to 20 Nm on scissor lift platform VAS 6131 A.

1. Remove electrical harness connectors - 1 - and - 4 - from bracket and disconnect.
2. Remove heat insulation sleeve on wiring harness and free up individual wires.

Note. In the illustration, the electrical harness connectors are depicted as installed.

Scheme 111

1. Remove bolt - arrow - at strap for left front exhaust pipe.

1. Remove nuts - 1 to 3 - for left front exhaust pipe/exhaust manifold.
2. Remove front exhaust pipe with pre- and main catalytic converters.

1. Remove electrical harness connectors - 2 - and - 4 - from bracket and disconnect.
2. Free up the wiring harnesses.

Note. In the illustration, the electrical harness connectors are depicted as installed.

Scheme 112

1. Remove bolt - arrow - at strap for right front exhaust pipe.

1. Remove nuts - 1 to 3 - for right front exhaust pipe/exhaust manifold.
2. Remove front exhaust pipe with pre- and main catalytic converters.

Scheme 113

Note. Observe rules of cleanliness for working on automatic transmissions --> 00 TECHNICAL DATA .

1. Remove bracket - arrow - for ATF lines at right on oil pan.

Scheme 114

1. Remove bracket - arrow - for ATF lines at bottom on transmission.

Scheme 115

1. Remove bolt - arrow -.
2. Disconnect ATF lines from transmission.

1. Remove bolt and Engine Speed (RPM) Sensor G28 on transmission - arrow -.

Scheme 116

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

1. Remove wiring harness bracket at right engine plate - arrows -.

1. Disconnect electrical harness connector - 1 - at right engine mount.
2. Remove bolts - arrows - and remove right engine mount.

Note. Shown without engine mount plate to provide a better illustration.

Scheme 117

1. Remove Ground (GND) wire - 1 -.
2. Disconnect electrical wires - 3 - and - 4 - on starter.
3. Remove bolts - 2 - and - 5 - and remove starter.

Scheme 118

1. Insert guide pin of adapter T40058 so that small diameter - arrow 2 - points to engine. Large diameter - arrow 1 - points to adapter.

Scheme 119

1. To loosen torque converter bolts, counter hold crankshaft using adapter T40058.

Note. Disregard - arrow -.

Scheme 120

1. Remove 3 torque converter bolts - arrows - in opening on removed starter (turn crankshaft 1 / 3 rotation in each case).

Scheme 121

1. Remove engine/transmission threaded connections - 3 to 10 -.

1. Loosen side clamping bolts - 1 - on scissor lift platform VAS 6131 A and pull rear platform top with transmission toward rear - arrow - , simultaneously push torque converter through opening of drive plate while doing this.

Engine (vehicles with automatic transmission), securing to assembly stand

Special tools, testers and auxiliary items required

1. Shackle 10-222 A/12
2. Lifting tackle 3033
3. Engine and Transmission Holder VAS 6095 with Holder for V8 Engine Audi S4, allroad quattro VAS 6095/1-6 or Holder for V8 Engine Audi S4, allroad quattro VAS 6095/1-6A
4. Shop crane VAS 6100

1. Lift arm extension for workshop crane VAS 6101

Special tools, testers and auxiliary items required

1. Additional hooks (2) 10-222 A/2

Work procedure

1. Disconnect vacuum hose - 1 -.
2. Disconnect air guide hose - 2 - from throttle valve control module.

1. Secure shackle 10-222 A/12 to right rear engine lifting eyelet.
2. Hook additional hook 10-222 A/2 on shackle 10-222 A/12.

1. Engage engine sling 3033 on additional hook 10-222 A/2 and on workshop crane VAS 6100 with lift arm extension for workshop crane VAS 6101 as shown in the illustration.
2. Lift engine from support elements of scissor lift platform VAS 6131 A.
3. Remove engine mount with left engine support.

1. Secure engine with Holder for V8 Engine Audi S4, allroad quattro VAS 6095/1-6 or Holder for V8 Engine Audi S4, allroad quattro VAS 6095/1-6A tightened to 42 Nm to Engine and Transmission Holder VAS 6095 as shown in the illustration.

Engine (vehicles with automatic transmission), installing

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

Scheme 122

Installation dimension for torque converter, checking

When torque converter is installed correctly, distance between contact surface of threaded holes at torque converter and contact surface of converter housing on Automatic Transmission 09L is approx. 19 mm.

1. Before connecting engine and transmission, rotate torque converter and engine drive plate so that one hole or one threaded hole stands at height of opening of removed starter - arrow -.
2. To secure torque converter to drive plate, use new original ribbed bolts .
3. Bolt transmission to engine.

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%.

Engine/transmission, fastening

The rest of installation is in reverse order of removal, note the following

1. Install front exhaust pipes with catalytic converters: Left --> «Left front exhaust pipe with primary and main catalytic converter (vehicles with manual transmission), removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__left-front-exhaust-pipe-with-primary) , right --> «Right front exhaust pipe with primary and main catalytic converter (vehicles with automatic transmission), removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__right-front-exhaust-pipe-with-primary) .
2. Install ATF lines --> «37 CONTROLS, HOUSING»(ref-278909-S00033401322008020700000) .
3. Always clean threaded driveshaft bores in transmission flanged shaft of locking fluid residue using a tap before installation.

1. Rotate spindles of support elements downward at left of engine/transmission assembly.
2. Remove both base plates for left support element on scissor lift platform VAS 6131 A.

1. Rotate spindles of support elements downward at right of engine/transmission assembly.
2. Remove both base plates for right support element on Scissor Lift Table VAS 6131 A.

Note. The support points for front of engine and rear of transmission remain unchanged.

1. Equip scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10 as follows

*Support elements remain unchanged.

*Only install support elements after installing subframe.

1. Position subframe on both attachments VAS 6131/10-8.
2. Turn spindles of support elements upward on both sides.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131 A.
4. Install left and right transmission mounts --> «37 CONTROLS, HOUSING»(ref-278909-S00033401322008020700000) .

1. Using scissor lift platform VAS 6131 A , slowly guide engine/transmission unit with subframe into body from below.

1. Align subframe and engine bearing plates according to markings applied on long members during removal.
2. Tighten bolts for subframe and engine mount plates only to specified torque. Do not tighten further (tighten bolts only after axle alignment).

1. 65 Nm
2. 110 Nm
3. 110 Nm
4. 75 Nm

The rest of installation is in reverse order of removal, note the following

1. Install selector lever cable, adjust if necessary --> «37 CONTROLS, HOUSING»(ref-278909-S00033401322008020700000) .
2. Install drive axles --> «40 - FRONT SUSPENSION»(/audi/s4/b8-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .
3. Install guide control arm, control arm, stabilizer bar and suspension strut --> «40 - FRONT SUSPENSION»(/audi/s4/b8-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .
4. Align exhaust system free of tension --> «Exhaust system, installing free of tension»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__exhaust-system-installing-free-of-tension) .

1. Install refrigerant lines --> «87 AIR CONDITIONING»(/audi/s4/b8-2008-2011/remont/ac-compressor/#heating-air-conditioning) .

1. Secure fuel hose to connection on fuel rail line. To do so, counter hold using an open-end wrench at each hex head - 1 - and - 3 - and tighten union nut - 2 - to 22 Nm.
2. Install lock carrier with attachments --> «50 BODY, FRONT»(ref-278920-S31853902272008020700000) «50 - BODY - FRONT»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Install ATF lines --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(ref-278909-S00033401322008020700000) for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE .

1. Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(ref-278920-S18413101412008020700000) «63 - BUMPERS»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Electrical connections and routing --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.
4. Observe safety precautions after connecting battery --> «97 WIRING»(/audi/s4/b8-2008-2011/remont/cruise-control-systems/#electrical-equipment) 97 WIRING for ELECTRICAL EQUIPMENT, CABRIOLET .

1. Mount wiper arms and adjust --> «92 WINDSHIELD WIPER WASHER SYSTEM»(/audi/s4/b8-2008-2011/remont/cruise-control-systems/#electrical-equipment) 92 WINDSHIELD WIPER & WASHER SYSTEM for ELECTRICAL EQUIPMENT, CABRIOLET .
2. Check oil level --> «Oil level, checking»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__oil-level-checking) .
3. Before starting engine for the first time, fill power steering reservoir with hydraulic oil --> «48 - STEERING»(/audi/s4/b8-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .

1. Fill with coolant «Filling»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__filling) .

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

1. Fill refrigerant circuit --> «87 - AIR CONDITIONING»(/audi/s4/b8-2008-2011/remont/automatic-hvac-system/#refrigerant-r134a-servicing) .
2. Align subframe and both engine mount plate --> «40 - FRONT SUSPENSION»(/audi/s4/b8-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .
3. Perform axle alignment --> «44 - WHEELS, TIRES, VEHICLE ALIGNMENT»(/audi/s4/b8-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .

1. Check headlight adjustment --> «01 - MAINTENANCE»(ref-278933-S06026331132008020700000) «01 - MAINTENANCE»(/audi/s4/b8-2008-2011/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

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%.

*Replace bolts.

*Insert bolts with locking fluid.

Scheme 123

1 - 40 Nm

2 - Support tool 3369

1. Tighten to 10 Nm

3 - 10 Nm

4 - 10 Nm

5 - 10 Nm

6 - 10 Nm

7 - Support tool 3369

1. Tighten to 10 Nm

8 - 40 Nm

Lock carrier, moving into service position

Special tools, testers and auxiliary items required

Scheme 124

1. Support tool 3369

Work procedure

1. Remove quick-release fasteners - 1 - , remove screws - 2 - and remove noise insulation.
2. Remove both front wheels.
3. Loosen left and right wheel housing liners in front area.
4. Remove front bumper cover --> «63 BUMPER»(ref-278920-S18413101412008020700000) «63 - BUMPERS»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Remove cover - 1 - in engine compartment (left side).

1. Remove electrical harness connectors - 1 - and - 2 - from bracket.
2. Free up wires to lock carrier.

1. Remove cover - 1 - in engine compartment (right side).

1. Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - from air guide.
2. Remove bolts - arrows -.
3. Remove air duct - 2 -.

1. Remove left air guide - arrow - in front of auxiliary cooler.

1. Remove right air guide - arrow - in front of auxiliary cooler.

1. Remove bolts - arrows - at left and right side of bumper.
2. Pull off hood seal from lock carrier and fender edges.

Scheme 125

1. Thread support tool 3369 into empty bores at left and right.
2. Remove bolts at impact absorbers - arrows - at left and right.
3. Carefully pull lock carrier toward front.

Installing

Installation is in reverse order of removal, note the following

1. Install lock carrier with attachments --> «50 BODY, FRONT»(ref-278920-S31853902272008020700000) «50 - BODY - FRONT»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
2. Install the front bumper cover --> «63 BUMPER»(ref-278920-S18413101412008020700000) «63 - BUMPERS»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(ref-278933-S06026331132008020700000) «01 - MAINTENANCE»(/audi/s4/b8-2008-2011/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

Scheme 126

1 - 22 Nm

2 - 22 Nm

3 - Ribbed belt tensioner

4 - 22 Nm

5 - Generator

1. Removing and installing --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/s4/b8-2008-2011/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET

6 - M8 - 22 Nm; M10 - 46 Nm

7 - Alignment bushing

1. For generator bracket
2. 2 pieces

8 - Generator bracket

9 - 10 Nm

10 - Idler roller holder

11 - Vibration damper

1. Removing and installing --> «Vibration damper, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__vibration-damper-removing-and-installing)

12 - 22 Nm plus an additional 45 ° ( 1 / 8 turn)

1. Replace

13 - Idler roller for ribbed belt

14 - 22 Nm

15 - Cover cap

16 - Ribbed belt

1. Check for wear
2. Do not kink
3. Before removing, mark direction of rotation using chalk or felt-tip marker. Reversing direction of rotation of a run-in belt can destroy the belt
4. Removing and installing --> «Ribbed belt, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__ribbed-belt-removing-and-installing)

1. When installing ribbed belt, make sure it is seated correctly on pulleys

17 - Threaded bushing

Ribbed belt, removing and installing

Special tools, testers and auxiliary items required

Scheme 127

1. Torque wrench V.A.G 1332

Removing

1. Bring lock carrier into service position --> «Lock carrier, moving into service position»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__lock-carrier-moving-into-service-position) .

Note. Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

Scheme 128

1. Loosen tensioning bolt - arrow - and remove ribbed belt.

Scheme 129

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

1. Generator
2. Ribbed belt
3. Idler roller
4. Vibration damper
5. Tensioning roller

Note. When installing the ribbed belt, make sure it is seated correctly on the pulleys.

Scheme 130

1. Position torque wrench on belt tensioner hex bolt and pre-tighten ribbed belt to 70 Nm.
2. At the same time, tighten tensioning bolt - arrow - to 22 Nm.

The rest of installation is in reverse order of removal, note the following

1. Install lock carrier with attachments --> «50 BODY, FRONT»(ref-278920-S31853902272008020700000) «50 - BODY - FRONT»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
2. Start engine and check belt running.

1. Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
2. Install the front bumper cover --> «63 BUMPER»(ref-278920-S18413101412008020700000) «63 - BUMPERS»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(ref-278933-S06026331132008020700000) «01 - MAINTENANCE»(/audi/s4/b8-2008-2011/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

Vibration damper, removing and installing

Removing

1. Bring lock carrier into service position --> «Lock carrier, moving into service position»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__lock-carrier-moving-into-service-position) .

Note. To loosen and tighten vibration damper, counter hold on center nut of generator belt pulley using open end wrench.

Scheme 131

1. Loosen 8 mounting bolts - arrow - on vibration damper a few turns.

Note. Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

1. Loosen tensioning bolt - arrow - and remove ribbed belt.
2. Remove vibration damper.

Installing

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque. Installation of vibration damper is only possible in one position - note alignment bushing.

1. Install ribbed belt «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__installing) .
2. Install lock carrier with attachments --> «50 BODY, FRONT»(ref-278920-S31853902272008020700000) «50 - BODY - FRONT»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(ref-278920-S18413101412008020700000) «63 - BUMPERS»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(ref-278933-S06026331132008020700000) «01 - MAINTENANCE»(/audi/s4/b8-2008-2011/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

* 45 ° corresponds to a 1/8 turn

*Replace bolts.

Crankshaft seal (ribbed belt side), replacing

Special tools, testers and auxiliary items required

Scheme 132

1. Oil Seal Extractor T40019

Scheme 133

1. Assembly tool T40048

Removing

1. Bring lock carrier into service position --> «Lock carrier, moving into service position»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__lock-carrier-moving-into-service-position) .
2. Remove vibration damper --> «Vibration damper, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__vibration-damper-removing-and-installing) .
3. Place inner part of Oil Seal Extractor T40019 flush with outer part and secure using knurled-head screw.

Scheme 134

1. Lubricate threaded head of Oil Seal Extractor T40019 , position and with forced pressure screw into oil seal as far as possible.
2. Loosen knurled thumb screw and turn inner portion against crankshaft until seal is pulled out.
3. Clamp seal extractor at mounting points in a vise.
4. Remove seal using pliers.

Installing

1. Clean operating and sealing surfaces.

Scheme 135

1. Insert assembly device T40048/1 onto pull sleeve T40048/2 and slide seal - 1 - onto pull sleeve.
2. Remove assembly device.

Scheme 136

1. Place pull sleeve T40048/2 on crankshaft and slide seal - 1 - into sealing surface on engine.

Note. Pull sleeve remains on crankshaft for pressing in.

Scheme 137

1. Position pressure sleeve T40048/3 with bolts M8x55 mm - arrows - on crankshaft.
2. Then tighten bolts by hand.
3. Tighten bolts each 1 / 2 rotation by alternating sides to press in seal until it reaches stop.

The rest of installation is in reverse order of removal, note the following

1. Install vibration damper --> «Vibration damper, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__vibration-damper-removing-and-installing) .
2. Install lock carrier with attachments --> «50 BODY, FRONT»(ref-278920-S31853902272008020700000) «50 - BODY - FRONT»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(ref-278920-S18413101412008020700000) «63 - BUMPERS»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(ref-278933-S06026331132008020700000) «01 - MAINTENANCE»(/audi/s4/b8-2008-2011/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

Scheme 138

1 - Dual mass flywheel

1. Removing and installing --> «Dual-mass flywheel, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__dual-mass-flywheel-removing-and-installing)

2 - Needle bearing

1. Pulling out and driving in --> «Dual-mass flywheel needle bearings, pulling out and driving in»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__dual-mass-flywheel-needle-bearings-pulling-out)

3 - Special bolt

1. Replace
2. Tightening torque «Torque specification»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__torque-specification)

4 - Crankshaft

5 - Sealing ring for crankshaft -timing chain side

1. Replacing --> «Crankshaft seal (timing chain side), replacing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__crankshaft-seal-timing-chain-side-replacing) .

Dual-mass flywheel, removing and installing

Special tools, testers and auxiliary items required

Scheme 139

1. Counter-holder tool 10-201

1. Transmission removed.

1. Remove clutch pressure plate --> «30 CLUTCH»(ref-278904-S05381615532008020700000) .
2. Mark dual mass flywheel to crankcase.

Scheme 140

1. Insert counterhold tool 10-201 to loosen bolts.

Scheme 141

Note. To prevent damage to dual-mass flywheel when removing, bolts - B - must not be removed using an air-powered or impact wrench. Only removing bolts by hand is permitted.

1. Rotate dual-mass flywheel - A - so that bolts stand centered to holes - arrows -.
2. When removing bolts, make sure that no bolt head makes contact on dual-mass flywheel because it will otherwise be damaged when further installing the bolt.

Installing

Installation is in reverse order of removal, note the following

Note. Needle bearing is located in the flywheel and must be driven in when flywheel is replaced --> Dual-mass flywheel needle bearings, pulling out and driving in .

1. Use new bolts when securing.
2. Turn over counterhold tool 10-201 to tighten bolts.
3. Install clutch pressure plate --> «30 CLUTCH»(ref-278904-S05381615532008020700000) .

Torque specification

* 90 ° corresponds to one quarter rotation.

*Replace bolts.

Dual-mass flywheel needle bearings, pulling out and driving in

Special tools, testers and auxiliary items required

Scheme 142

1. Bearing driver 3264

Scheme 143

1. 1 - Internal puller Kukko 21/1
2. 4 - Counter-support Kukko 22/1

Work procedure

1. Transmission removed.

1. Remove clutch pressure plate --> «30 CLUTCH»(ref-278904-S05381615532008020700000) .

Scheme 144

1. Pull out needle bearing using internal puller Kukko 21/1 and support Kukko 22/1.

Scheme 145

1. Drive in needle bearing using bearing driver 3264 into dual-mass flywheel until it reaches stop.
2. Install clutch pressure plate --> «30 CLUTCH»(ref-278904-S05381615532008020700000) .

Scheme 146

1 - Drive plate

1. Removing and installing --> «Drive plate, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__drive-plate-removing-and-installing)

2 - Washer

1. Mark for re-installation

3 - Special bolt

1. Replace
2. Tightening torque «Torque specification»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

4 - Shim

1. Mark for re-installation

5 - Sealing ring for crankshaft - timing chain side

1. Removing and installing --> «Crankshaft seal (timing chain side), replacing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__crankshaft-seal-timing-chain-side-replacing)

6 - Crankshaft

Drive plate, removing and installing

Special tools, testers and auxiliary items required

1. Counter-holder tool 10-201

1. Transmission removed.

1. Mark drive plate and washer to crankshaft.

Scheme 147

1. Insert counterhold tool 10-201 to loosen bolts.
2. Remove drive plate.

Installation is in reverse order of removal, note the following

1. Install drive plate with washer.
2. Use new bolts when securing.
3. Turn over counterhold tool 10-201 to tighten bolts.

* 90 ° corresponds to one quarter rotation.

*Replace bolts.

Crankshaft seal (timing chain side), replacing

Special tools, testers and auxiliary items required

Scheme 148

1. Assembly Tool T10122

Scheme 149

1. Pulling Hook T20143

Work procedure

1. Transmission removed.

1. Remove dual-mass flywheel --> «Dual-mass flywheel, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__dual-mass-flywheel-removing-and-installing) , drive plate --> «Drive plate, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__drive-plate-removing-and-installing) .

Scheme 150

1. Pry out sealing ring using Pulling Hook T20143/2.
2. Clean operating and sealing surfaces.

Scheme 151

1. Insert assembly device T10122/1 onto pull sleeve T10122/2 and slide seal - A - onto pull sleeve.
2. Remove assembly device.

Scheme 152

1. Install pull sleeve T10122/2 with sealing ring - 1 - onto crankshaft.

Scheme 153

1. Press in seal evenly all around until it reaches stop using T10122/3.

The rest of installation is in reverse order of removal, note the following

1. Install dual-mass flywheel --> «Dual-mass flywheel, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__dual-mass-flywheel-removing-and-installing) , drive plate --> «Drive plate, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__drive-plate-removing-and-installing) .

Scheme 154

1 - M6 - 10 Nm; M8 - 22 Nm

1. Note tightening sequence Position lower cover for timing chain and tighten bolts as follows. under «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

2 - Seal

1. for crankshaft - timing chain side
2. Removing and installing --> «Crankshaft seal (timing chain side), replacing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__crankshaft-seal-timing-chain-side-replacing)

3 - Shim

1. For vehicles with automatic transmission
2. Mark for re-installation

4 - Alignment bushing

1. 2 pieces

5 - Heat shield

6 - 10 Nm

7 - Seal

1. Replace

8 - 10 Nm

9 - Sealing flange

10 - 10 Nm

11 - Camshaft position (CMP) sensor 2 G163

12 - O-ring

1. Replace

13 - 10 Nm

1. Note tightening sequence Position left cover for timing chain and tighten bolts as follows. under «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

14 - 10 Nm

1. Note tightening sequence Position left cover for timing chain and tighten bolts as follows. under «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

15 - Left timing chain cover

16 - Gasket

1. Replace

17 - 4 Nm

1. Insert using locking compound; locking compound .

18 - 10 Nm

19 - Camshaft Position (CMP) sensor G40

20 - O-ring

1. Replace

21 - 10 Nm

1. Note tightening sequence Position right cover for timing chain and tighten bolts as follows. under «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

22 - Right timing chain cover

23 - Gasket

1. Replace

24 - 4 Nm

1. Insert using locking compound; locking compound .

25 - 10 Nm

1. Note tightening sequence Position right cover for timing chain and tighten bolts as follows. under «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

26 - Heat shield

27 - 10 Nm

28 - Seal

1. Replace

29 - Sealing flange

30 - 10 Nm

31 - Alignment bushing

1. 2 pieces

32 - Lower timing chain cover

Timing chain covers (All), removing and installing

Special tools, testers and auxiliary items required

Scheme 155

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

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

1. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
2. Remove engine: --> «Engine (vehicles with manual transmission)»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) , --> «Engine (vehicles with automatic transmission), removing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-removing) .
3. Disconnect engine and transmission: --> «Engine (vehicles with manual transmission), separating»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-manual-transmission-separating) , --> «Engine and transmission (vehicles with automatic transmission), separating»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-and-transmission-vehicles-with-automatic) .
4. Leave engine on Scissor Lift Table VAS 6131 A or secure engine to engine and transmission holder: --> «Engine (vehicles with manual transmission), securing to engine and transmission holder»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) , --> «Engine (vehicles with automatic transmission), securing to assembly stand»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-securing) .

1. Remove dual-mass flywheel --> «Dual-mass flywheel, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__dual-mass-flywheel-removing-and-installing) , drive plate --> «Drive plate, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__drive-plate-removing-and-installing) .

Scheme 156

1. Disconnect electrical connection - 1 - at throttle valve control module J338.
2. Disconnect crankcase ventilation hose - 3 - at intake pipe.

Note. Ignore - 2 -.

Scheme 157

1. Remove electrical harness connectors - 1 - , - 2 - , - 5 - and - 6 - toward front from brackets on intake line.
2. Separate the electrical connectors - 3 - and - 4 -.

Scheme 158

1. Disconnect vacuum hose - arrow - at T-piece.

Scheme 159

1. Disconnect connector strips - 1 - and - 5 - at fuel injectors.
2. For vehicles with fuel return line, disconnect vacuum line - 4 - on fuel pressure regulator.
3. Remove retaining bolts - 2 - and - 3 - for fuel rail line.
4. Remove fuel rail line together with fuel injectors from intake manifold uniformly upward.

Note. Carefully protect the removed fuel injectors from contamination.

Scheme 160

1. Remove left rear engine lifting eye - arrows -.

Scheme 161

1. Remove intake manifold bolts - arrows - and remove it.

Note. Plug the intake ports of the cylinder head with clean rags.

Scheme 162

1. Remove cap - arrow - for oil filter housing.
2. Remove oil filter element.
3. Extract engine oil using old oil collecting and extracting device V.A.G 1782 from oil filter housing.

Note. Place a rag around oil filter housing to catch escaping engine oil.

Scheme 163

1. Remove bolts - arrows -.
2. Remove oil filter housing.

Scheme 164

1. Remove bolts - 1 - and - 2 -.
2. Place old oil collecting and extracting device V.A.G 1782 underneath.
3. Remove return line from power-steering pump - arrow -.

Scheme 165

1. Remove bolt - arrow - from oil dipstick guide tube at cylinder head, pull up and remove guide tube.

Scheme 166

1. Remove bolts - 1 - and - 2 -.
2. Loosen hose clamps - arrows - and remove left coolant pipe from coolant hoses.

Scheme 167

1. Remove bolts - 1 - and - 2 -.
2. Loosen hose clamps - arrows - and remove right coolant pipe from coolant hoses.

Scheme 168

1. Disconnect electrical harness connector - 2 - on Engine Coolant Temperature (ECT) Gauge Sensor G2/G62.
2. Remove nut - 1 - and remove electrical wiring harness at rear of coolant pipe.

Scheme 169

1. Remove bolts - 2 to 5 -.
2. Remove rear coolant pipe.

Note. Ignore - 1 - and - 6 -.

Scheme 170

1. Remove mounting bolts - 1 to 4 - of combination valves for Secondary Air Injection (AIR) system.

Scheme 171

1. Remove nuts - 1 to 12 - and remove left exhaust manifold.

Scheme 172

1. Remove left heat shield - arrows -.

Scheme 173

1. Remove nuts - 1 to 12 - and remove right exhaust manifold.

Scheme 174

1. Remove right heat shield - arrows -.

Scheme 175

1. Remove bolts - 5 - and - 6 - on left cylinder head.
2. Disconnect electrical harness connectors - 1 to 4 -.
3. Remove ignition coils - arrows -.

Note. Extractor T40039 can be used for removal.

Scheme 176

1. Disconnect hose of crankshaft housing ventilation - arrow -.
2. Remove left cylinder head cover bolts in sequence - 15 to 1 -.
3. Remove cylinder head cover.

Scheme 177

1. Remove bolts - 5 - and - 6 - on right cylinder head.
2. Disconnect electrical harness connectors - 1 to 4 -.
3. Remove ignition coils - arrows -.

Note. Extractor T40039 can be used for removal.

Scheme 178

1. Disconnect hose of crankshaft housing ventilation - arrow -.
2. Remove right cylinder head cover screws in sequence - 15 to 1 -.
3. Remove cylinder head cover.

Scheme 179

1. Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor 2 G163 on left cylinder head.
2. Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor G40 on right cylinder head.

Scheme 180

1. Remove Ground (GND) cable on right cylinder head - arrow -.
2. Set wiring harness aside.

Scheme 181

1. Remove bolts - 1 to 6 - and remove left timing chain cover.

Scheme 182

1. Remove bolts - 1 to 6 - and remove right timing chain cover.

Scheme 183

1. Remove bolts - 1 to 13 - and remove lower timing chain cover.

Scheme 184

1. Press sealing ring for crankshaft at rear out of cover.

Note. Replace gaskets, seals and O-rings. During installation, all cable ties must be re-installed at the same location.

Scheme 185

1. Using e.g. a rotating plastic brush, remove sealant residue on covers for timing chain and on cylinder block and head.

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

Scheme 186

1. Cut off nozzle on the tube of sealant at front mark (dia. of nozzle approx. 1 mm).

Note. Covers for timing chain must be installed within 5 minutes after applying sealant.

Scheme 187

1. Apply sealant beads - 1 to 6 - , as shown in illustration, on clean sealing surfaces of lower cover for timing chain.

1. Thickness of sealant bead: 1.5 to 2.0 mm.

1. Check whether 2 alignment bushings are present in cylinder block, install if necessary.

1. Position lower cover for timing chain and tighten bolts as follows.

1. Tighten bolts 11 , 12 , 13 to 10 Nm
2. Tighten bolts 1 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 to 10 Nm
3. Tighten bolts 4 , 8 , 9 , 10 to 22 Nm
4. Tighten bolts 2 for power-steering pump to 22 Nm

Scheme 188

1. Remove sealing flanges for camshaft adjuster on left and right covers for timing chain - arrows -.

Scheme 189

1. Apply sealant bead - arrow - , as shown in illustration, on clean sealing surfaces of left cover for timing chain.

1. Groove on lower sealing surface - arrow 1 - must be completely filled with sealant. Sealant bead must stand 1.5 to 2.0 mm above sealing surface.
2. Sealant bead on front sealing surface - arrows 2 - must be 1.5 to 2.0 mm thick.

1. Install new seal - 3 - on left cover for timing chain.

1. Position left cover for timing chain and tighten bolts as follows.

1. Tighten bolts to 1 to 4 to 5 Nm
2. Tighten bolts to 6 to 10 Nm
3. Tighten bolts to 5 to 10 Nm
4. Tighten bolts to 1 to 4 to 10 Nm

Scheme 190

1. Apply sealant beads - arrow - , as shown in illustration, on clean sealing surfaces of right cover for timing chain.

1. Groove on lower sealing surface - arrow 1 - must be completely filled with sealant. Sealant bead must stand 1.5 to 2.0 mm above sealing surface.
2. Sealant bead on front sealing surface - arrows 2 - must be 1.5 to 2.0 mm thick.

1. Install new seal - 3 - on right cover for timing chain.

1. Position right cover for timing chain and tighten bolts as follows.

1. Tighten bolts 2 , 3 , 5 , 6 to 5 Nm
2. Tighten bolts to 1 to 10 Nm
3. Tighten bolts to 4 to 10 Nm
4. Tighten bolts 2 , 3 , 5 , 6 to 10 Nm

1. Install sealing flanges for camshaft adjuster with new sealing rings on left and right covers for timing chain - arrows -.

The rest of installation is in reverse order of removal, note the following

1. Install crankshaft seal, timing chain side --> «Crankshaft seal (timing chain side), replacing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__crankshaft-seal-timing-chain-side-replacing) .
2. Install cylinder head cover: --> «Left cylinder head cover, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__left-cylinder-head-cover-removing-and) , --> «Right cylinder head cover, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__right-cylinder-head-cover-removing-and) .
3. Install exhaust manifold: --> «Left exhaust manifold, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__left-exhaust-manifold-removing-and-installing) , --> «Right exhaust manifold, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__right-exhaust-manifold-removing-and-installing) .
4. Install combination valve for Secondary Air Injection (AIR) system: --> «Left combination valve for Secondary Air Injection, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__left-combination-valve-for-secondary-air) , --> «Right combination valve for Secondary Air Injection, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__right-combination-valve-for-secondary-air) .

1. Install rear coolant pipe --> «Rear coolant pipe, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__rear-coolant-pipe-removing-and-installing) .
2. Install left and right coolant pipe --> «Right coolant pipe, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) and --> «Left coolant pipe, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__left-coolant-pipe-removing-and-installing) .
3. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__oil-filter-housing-removing-and-installing) .
4. Install intake manifold --> «Intake manifold, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__intake-manifold-removing-and-installing) .

1. Install dual-mass flywheel --> «Dual-mass flywheel, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__dual-mass-flywheel-removing-and-installing) , --> «Drive plate, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__drive-plate-removing-and-installing) .
2. Install engine: --> «Engine (vehicles with manual transmission), installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-manual-transmission-installing) , --> «Engine (vehicles with automatic transmission), installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-installing) .
3. Add engine oil and check oil level --> «Oil level, checking»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__oil-level-checking) .

* Insert using locking compound; locking compound .

Left camshaft timing chain

Note. Before removing timing chain, mark direction of travel with paint. Reversing the rotation direction of a used chain can destroy it.

Scheme 191

1 - Pivot pin -10 Nm

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

1. Replace

3 - Washer

1. Note installation position

4 - Camshaft bolt

1. Replace
2. Initial tightening torque: 40 Nm
3. Final tightening torque: 100 Nm plus an additional 1 / 4 turn (90 °)

5 - Chain sprocket

1. For exhaust camshaft

6 - Camshaft bolt

1. Replace
2. Initial tightening torque: 40 Nm
3. Final tightening torque: 100 Nm plus an additional 1 / 4 turn (90 °)

7 - Hall sensor wheel

1. When installing timing chain, adjust using setting gauge T40047

8 - Camshaft adjuster

1. For intake camshaft

9 - Diamond disc

1. Replace

10 - Chain tensioner

1. For left timing chain

11 - Left camshaft timing chain

1. Removing and installing --> «Camshaft timing chain, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

12 - Guide rail

1. Can be replaced separately

13 - Control housing

1. For camshaft adjuster

14 - Gasket

1. Replace

15 - Camshaft

16 - Alignment bushing

1. 2 pieces

17 - 5 Nm plus an additional 1 / 4 turn (90 °)

1. Replace

18 - Bracket

1. For drive sprocket

19 - 10 Nm

20 - Drive sprocket

1. For left timing chain

21 - Thrust washer

1. For drive sprocket

22 - 5 Nm plus an additional 1 / 4 turn (90 °)

1. Replace

23 - Guide rail

Right camshaft timing chain

Note. Before removing timing chain, mark direction of travel with paint. Reversing the rotation direction of a used chain can destroy it.

Scheme 192

1 - Chain tensioner

1. For right timing chain

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

1. Replace

3 - Mounting pin

1. For drive sprocket

4 - Washer

5 - 42 Nm

6 - Camshaft bolt

1. Replace
2. Initial tightening torque: 40 Nm
3. Final tightening torque: 100 Nm plus an additional 1 / 4 turn (90 °)

7 - Hall sensor wheel

1. When installing timing chain, adjust using setting gauge T40047

8 - Camshaft adjuster

1. For intake camshaft

9 - Diamond disc

1. Replace

10 - Pivot pin -10 Nm

11 - Guide rail

12 - Thrust washer

1. For drive sprocket

13 - Right camshaft timing chain

1. Removing and installing --> «Camshaft timing chain, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

14 - Control housing

1. For camshaft adjuster

15 - Gasket

1. Replace

16 - Camshaft

17 - Alignment bushing

1. 2 pieces

18 - Guide rail

1. Can be replaced separately

19 - 5 Nm plus an additional 1 / 4 turn (90 °)

1. Replace

20 - Chain sprocket

1. For exhaust camshaft

21 - Washer

1. Note installation position

22 - Camshaft bolt

1. Replace
2. Initial tightening torque: 40 Nm
3. Final tightening torque: 100 Nm plus an additional 1 / 4 turn (90 °)

23 - Drive sprocket

1. For right timing chain

24 - Guide rail

1. For timing chain

25 - Pivot pin -10 Nm

Scheme 193

Special tools, testers and auxiliary items required

1. Crankshaft Holder 3242
2. Trim removal wedge 3409 (2x)
3. Old oil collecting and extracting device V.A.G 1782
4. Multi-point socket T10035

1. Camshaft locator T40046 (qty. 2)
2. Setting gauge T40047

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782

Scheme 194

1. Key T40049
2. Drill 3.3 mm diameter (2x)

1. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
2. Remove engine: Vehicles with manual transmission --> «Engine (vehicles with manual transmission)»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), removing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-removing) .
3. Disconnect engine and transmission: Vehicles with manual transmission --> «Engine (vehicles with manual transmission), separating»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-manual-transmission-separating) , vehicles with automatic transmission --> «Engine and transmission (vehicles with automatic transmission), separating»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-and-transmission-vehicles-with-automatic) .
4. Leave engine on Scissor Lift Table VAS 6131 A or secure engine to the engine and transmission holder: Vehicles with manual transmission --> «Engine (vehicles with manual transmission), securing to engine and transmission holder»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), securing to assembly stand»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-securing) .

1. Remove covers for timing chains --> «Timing chain covers (All), removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__timing-chain-covers-all-removing-and) .

Scheme 195

1. Install key T40049 at rear on crankshaft e.g. using 2 old bolts for dual-mass flywheel.
2. Rotate crankshaft in direction of engine rotation - arrow - to TDC ignition timing.

Scheme 196

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

Scheme 197

1. Rotate camshafts at hex head slightly back or forth if necessary so that camshaft locator T40046 can be inserted.
2. If camshaft locator T40046 cannot be inserted, rotate crankshaft 1 rotation (360 °) further.
3. Remove camshaft locator T40046 again.

Scheme 198

1. Remove drain plug from upper section of oil pan.
2. Install Crankshaft Holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

Scheme 199

1. Push glide track of chain tensioner for left timing chain in direction of - arrow - and pull off chain tensioner using a drill bit 3.3 mm dia. - 1 -.

Scheme 200

1. Mark running direction of left timing chain with paint.
2. Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket T10035.
3. Remove camshaft chain sprocket, camshaft adjuster and timing chain.

Scheme 201

1. Push glide track of chain tensioner for right timing chain in direction of - arrow - and pull off chain tensioner using a drill bit 3.3 mm dia. - 1 -.
2. Mark running direction of right timing chain with paint.

Scheme 202

1. Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket T10035.
2. Remove camshaft chain sprocket, camshaft adjuster and timing chain.

1. Secure crankshaft in TDC position using Crankshaft Holder 3242.
2. Drive chain for timing mechanism installed --> «Drive chain for timing mechanism, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__drive-chain-for-timing-mechanism-removing) .

Note. Always replace bolts that are tightened to torque as well as O-rings and gaskets. When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged.

Scheme 203

1. Rotate inner part and outer part of both camshaft adjusters against each other up to lock position - arrows -.

1. Inner part and outer part must not be able to be against each other in lock position (slight play can still be felt).

1. Check whether camshafts of both cylinder heads stand in TDC position.

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Insert camshaft locator T40046 into camshafts of left cylinder head, to do so rotate camshafts back or forth at hex head if necessary.

Scheme 204

1. Insert camshaft locator T40046 into camshafts of right cylinder head, to do so rotate camshafts back or forth at hex head if necessary.
2. Replace all four camshaft bolts.
3. Replace diamond disc between camshaft and left cylinder head camshaft adjuster.
4. Assemble left timing chain with chain sprocket and camshaft adjuster.

1. Loosely install bolts - 1 - and - 2 -.

1. Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip.

1. Replace diamond disc between camshafts and right cylinder head camshaft adjuster.
2. Assemble right timing chain with chain sprocket and camshaft adjuster.

1. Loosely install bolts - 1 - and - 2 -.

1. Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip.

1. Remove Crankshaft Holder 3242.

Scheme 205

1. Using key T40049 , rotate crankshaft approx. 30 ° in opposite direction of engine rotation - arrow -.
2. Pull drill bit out of alignment hole, which loosens left chain tensioner.

Scheme 206

1. Insert trim removal wedge 3409 as shown in illustration and bring chain tensioner into contact with trim removal wedge 3409.

1. Lightly pressing in an extra 0.5 mm is permitted.

1. Pull drill bit out of alignment hole, which loosens right chain tensioner.

Scheme 207

1. Insert trim removal wedge 3409 as shown in illustration and bring chain tensioner into contact with trim removal wedge 3409.

1. Lightly pressing in an extra 0.5 mm is permitted.

1. Using key T40049 , rotate crankshaft in direction of engine rotation - arrow - to TD ignition timing.

Note. If rotated unintentionally beyond TDC, turn back crankshaft again approx. 30 ° and set to TDC again.

1. Install Crankshaft Holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

Scheme 208

1. Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to initial tightening torque.

1. Torque specification: 40 Nm.

Scheme 209

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
2. Place setting gauge T40047 on bolt - 1 -.
3. Tighten camshaft bolt - 2 - on intake camshaft to initial tightening torque.

1. Torque specification: 40 Nm.

Scheme 210

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
2. Place setting gauge T40047 on bolt - 2 -.
3. Tighten camshaft bolt - 1 - on intake camshaft to initial tightening torque.

1. Torque specification: 40 Nm.

1. Remove setting gauge T40047.

Scheme 211

1. Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to initial tightening torque.

1. Torque specification: 40 Nm.

Note. Camshaft locators T40046 must not be used as counter holder for final tightening of camshaft bolts.

1. Remove camshaft locators T40046 on both cylinder heads.

1. Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to final tightening torque.

1. Torque specification: 100 Nm plus an additional 1 / 4 turn (90 °).

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
2. Place setting gauge T40047 on bolt - 1 -.
3. Tighten camshaft bolt - 2 - on intake camshaft to final tightening torque.

1. Torque specification: 100 Nm plus an additional 1 / 4 turn (90 °).

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
2. Place setting gauge T40047 on bolt - 2 -.
3. Tighten camshaft bolt - 1 - on intake camshaft to final tightening torque.

1. Torque specification: 100 Nm plus an additional 1 / 4 turn (90 °).

1. Remove setting gauge T40047.

1. Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to final tightening torque.

1. Torque specification: 100 Nm plus an additional 1 / 4 turn (90 °).

1. Remove Crankshaft Holder 3242.

1. Using key T40049 turn crankshaft two complete rotations in direction of engine rotation - arrow - until crankshaft stands at TDC again.

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Install Crankshaft Holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

1. Insert camshaft locator T40046 into camshafts of left cylinder head.

1. Insert camshaft locator T40046 into camshafts of right cylinder head.

If camshaft locators cannot be inserted

1. Repeat adjustment.
2. Pull out trim removal wedge 3409.
3. Remove camshaft locator T40046 on both cylinder heads.
4. Remove Crankshaft Holder 3242.

1. Install sealing plug of TDC marking with new sealing ring into upper section of oil pan.

The rest of installation is in reverse order of removal, note the following

1. Install covers for timing chains «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .
2. Install engine: Vehicles with manual transmission --> «Engine (vehicles with manual transmission), installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-manual-transmission-installing) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-installing) .
3. Add engine oil and check oil level --> «Oil level, checking»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__oil-level-checking) .

* 90 ° corresponds to one quarter rotation.

*Replace bolts.

Camshaft timing chains, removing from camshafts

Note. For the removal of the cylinder head or camshafts, it is sufficient to remove camshaft timing chains only from the camshafts. Chains remain on the engine; only the top covers at left and right are removed. Even if work is performed only on one of the cylinder heads, the procedure described must be followed, since then the valve timing at both cylinder heads must be adjusted.

Special tools, testers and auxiliary items required

1. Crankshaft Holder 3242
2. Trim removal wedge 3409 (2x)
3. Old oil collecting and extracting device V.A.G 1782
4. Multi-point socket T10035

1. Camshaft locator T40046 (qty. 2)
2. Setting gauge T40047

Old oil collecting and extracting device V.A.G 1782

Drill bit 3.3 mm dia. (2x)

Work procedure

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

1. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
2. Remove engine: Vehicles with manual transmission --> «Engine (vehicles with manual transmission)»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), removing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-removing) .
3. Leave engine with transmission installed on scissor lift platform VAS 6131 A.

1. Disconnect electrical connection - 1 - at throttle valve control module J338.
2. Disconnect crankcase ventilation hose - 3 - at intake pipe.

Note. Disregard item - 2 -.

1. Remove electrical harness connectors - 1 - , - 2 - , - 5 - and - 6 - toward front from brackets on intake line.
2. Disconnect electrical connectors - 3 - and - 4 -.

1. Disconnect vacuum hose - arrow - at T-piece.

1. Disconnect connector strips - 1 - and - 5 - at fuel injectors.
2. For vehicles with fuel return line, disconnect vacuum line - 4 - on fuel pressure regulator.
3. Remove retaining bolts - 2 - and - 3 - for fuel rail line.
4. Remove fuel rail line together with fuel injectors from intake manifold uniformly upward.

Note. Carefully protect the removed fuel injectors from contamination.

1. Remove left rear engine lifting eye - arrows -.

1. Remove intake manifold bolts - arrows - and remove it.

Note. Plug intake ports of the cylinder head with clean rags.

1. Remove cap - arrow - for oil filter housing.
2. Remove oil filter element.
3. Extract engine oil using old oil collecting and extracting device V.A.G 1782 from oil filter housing.

Note. Place a rag around oil filter housing to catch escaping engine oil.

1. Remove bolts - arrows -.
2. Remove oil filter housing.

1. Remove bolts - 1 - and - 2 -.
2. Place old oil collecting and extracting device V.A.G 1782 underneath.
3. Remove return line from power-steering pump - arrow -.

1. Remove guide pipe bolt - arrow - for oil dipstick at cylinder head, pull up and remove.

1. Remove bolts - 1 - and - 2 -.
2. Loosen hose clamps - arrows - and remove left coolant pipe from coolant hoses.

1. Remove bolts - 1 - and - 2 -.
2. Loosen hose clamps - arrows - and remove right coolant pipe from coolant hoses.

1. Disconnect electrical harness connector - 2 - on Engine Coolant Temperature (ECT) Gauge Sensor G2/G62.
2. Remove nut - 1 - and remove electrical wiring harness at rear coolant pipe.

1. Remove bolts - 2 to 5 -.
2. Remove rear coolant pipe.

Note. Ignore - 1 - and - 6 -.

1. Remove mounting bolts - 1 to 4 - of combination valves for Secondary Air Injection (AIR) system.

1. Remove nuts - 1 to 12 - and remove left exhaust manifold.

1. Remove left heat shield - arrows -.

1. Remove nuts - 1 to 12 - and remove right exhaust manifold.

1. Remove right heat shield - arrows -.

1. Remove bolts - 5 - and - 6 - on left cylinder head.
2. Disconnect electrical harness connectors - 1 to 4 -.
3. Remove ignition coils - arrows -.

Note. Extractor T40039 can be used for removal.

1. Disconnect hose of crankshaft housing ventilation - arrow -.
2. Remove left cylinder head cover bolts in sequence - 15 to 1 -.
3. Remove cylinder head cover.

1. Remove bolts - 5 - and - 6 - on right cylinder head.
2. Disconnect electrical harness connectors - 1 to 4 -.
3. Remove ignition coils - arrows -.

Note. Extractor T40039 can be used for removal.

1. Disconnect hose of crankshaft housing ventilation - arrow -.
2. Remove right cylinder head cover bolts in sequence - 15 to 1 -.
3. Remove cylinder head cover.

1. Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor 2 G163 on left cylinder head.

1. Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor G40 on right cylinder head.

1. Remove Ground (GND) wire on right cylinder head - arrow -.
2. Set wiring harness aside.

1. Remove bolts - 1 to 6 - and remove left timing chain cover.

1. Remove bolts - 1 to 6 - and remove right timing chain cover.

Scheme 212

1. Rotate crankshaft in direction of engine rotation - arrow - to TDC ignition timing.

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Rotate camshafts at hex head slightly back and forth if necessary so that camshaft locator T40046 can be inserted.
2. If camshaft locator T40046 cannot be inserted, rotate crankshaft 1 rotation (360 °) further.
3. Remove camshaft locator T40046 again.
4. Remove drain plug from upper section of oil pan.

1. Install Crankshaft Holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

1. Push glide track of chain tensioner for left timing chain in direction of - arrow - and pull off chain tensioner using a drill bit - 1 - 3.3 mm in dia.

Note. In the following illustration, the timing mechanism is depicted with covers completely removed.

1. Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket T10035.
2. Remove camshaft chain sprocket and camshaft adjuster.

Note. Camshaft timing chain remains on engine. Also, if only one of the two cylinder heads is removed, bolts for camshaft gears must be loosened at both cylinder heads.

1. Push glide track of chain tensioner for right timing chain in direction of - arrow - and pull off chain tensioner using a drill bit - 1 - 3.3 mm in dia.

1. Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket T10035.
2. Remove camshaft chain sprocket and camshaft adjuster.

Note. Camshaft timing chain remains on engine. Also, if only one of the two cylinder heads is removed, bolts for camshaft gears must be loosened at both cylinder heads.

Installing

1. Secure crankshaft in TDC position using Crankshaft Holder 3242.

Note. Always replace bolts that are tightened to torque as well as O-rings and gaskets. When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged. During installation, all cable ties must be re-installed at the same location.

1. Rotate inner part and outer part of both camshaft adjusters against each other up to lock position - arrows -.

1. Inner part and outer part must not be able to be against each other in lock position (slight play can still be felt).

1. Check whether camshafts of both cylinder heads stand in TDC position.

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Insert camshaft locator T40046 into camshafts of left cylinder head, to do so rotate camshafts back and forth at hex head if necessary.

1. Insert camshaft locator T40046 into camshafts of right cylinder head, to do so rotate camshafts back and forth at hex head if necessary.
2. Replace all four camshaft bolts.
3. Replace diamond disc between camshaft and left cylinder head camshaft adjuster.
4. Assemble left timing chain with chain sprocket and camshaft adjuster.

1. Loosely install bolts - 1 - and - 2 -.

1. Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip.

1. Replace diamond disc between camshafts and right cylinder head camshaft adjuster.
2. Assemble right timing chain with chain sprocket and camshaft adjuster.

1. Loosely install bolts - 1 - and - 2 -.

1. Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip

1. Remove Crankshaft Holder 3242.

Scheme 213

1. Rotate crankshaft 30 ° in opposite direction of engine rotation - arrow -.
2. Pull drill out of alignment hole, which loosens left chain tensioner.

1. Insert trim removal wedge 3409 as shown in illustration and bring chain tensioner into contact with trim removal wedge 3409.

1. Lightly pressing in an extra 0.5 mm is permitted.

1. Pull drill out of alignment hole, which loosens right chain tensioner.

1. Insert trim removal wedge 3409 as shown in illustration and bring chain tensioner into contact with trim removal wedge 3409.

1. Lightly pressing in an extra 0.5 mm is permitted.

1. Rotate crankshaft in direction of engine rotation - arrow - to TDC ignition timing.

Note. If rotated unintentionally beyond TDC, turn back crankshaft again approx. 30 ° and set to TDC again.

1. Install Crankshaft Holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

1. Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to initial tightening torque.

1. Torque specification: 40 Nm.

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
2. Place setting gauge on bolt - 1 -.
3. Tighten camshaft bolt - 2 - on intake camshaft to initial tightening torque.

1. Torque specification: 40 Nm.

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
2. Place setting gauge on bolt - 2 -.
3. Tighten camshaft bolt - 1 - on intake camshaft to initial tightening torque.

1. Torque specification: 40 Nm.

1. Remove setting gauge.

1. Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to initial tightening torque.

1. Torque specification: 40 Nm.

Note. Camshaft locators must not be used as counter holder for final tightening of camshaft bolts.

1. Remove camshaft locators T40046 on both cylinder heads.

1. Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to final tightening torque.

1. Torque specification: 100 Nm plus an additional ( 1 / 4 turn (90 °).

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
2. Place locator on bolt - 1 -.
3. Tighten camshaft bolt - 2 - on intake camshaft to final tightening torque.

1. Torque specification: 100 Nm plus an additional ( 1 / 4 turn (90 °).

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
2. Place setting gauge T40047 on bolt - 2 -.
3. Tighten camshaft bolt - 1 - on intake camshaft to final tightening torque.

1. Torque specification: 100 Nm plus an additional ( 1 / 4 turn (90 °).

1. Remove setting gauge T40047.

1. Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to final tightening torque.

1. Torque specification: 100 Nm plus an additional ( 1 / 4 turn (90 °).

1. Remove Crankshaft Holder 3242.

1. Turn crankshaft two complete rotations in direction of engine rotation - arrow - until crankshaft stands at TDC again.

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Install Crankshaft Holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

1. Insert camshaft locator T40046 into camshafts of left cylinder head.

1. Insert camshaft locator T40046 into camshafts of right cylinder head.

If camshaft locators cannot be inserted

1. Repeat adjustment.
2. Pull out trim removal wedge 3409.
3. Remove camshaft locator T40046 on both cylinder heads.
4. Remove Crankshaft Holder 3242.

1. Install sealing plug of TDC marking with new sealing ring into upper section of oil pan.

The rest of installation is in reverse order of removal, note the following

1. Install covers for timing chains «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .
2. Install engine: Vehicles with manual transmission --> «Engine (vehicles with manual transmission), installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-manual-transmission-installing) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-installing) .
3. Add engine oil and check oil level --> «Oil level, checking»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__oil-level-checking) .

Torque specifications

* 90 ° corresponds to one quarter rotation.

*Replace bolts.

Drive chain for timing mechanism - component overview

Note. Before removing timing chain, mark direction of travel with paint. Reversing the rotation direction of a used chain can destroy it.

Scheme 214

1 - Pivot pin for drive sprocket

2 - Washer

3 - 42 Nm

4 - Pivot pin -10 Nm

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

1. Replace

6 - Thrust washer for drive sprocket

7 - Drive sprocket for left timing chain

8 - Pivot pin -10 Nm

9 - Drive chain for timing mechanism

10 - Guide rail

11 - Pivot pin -10 Nm

12 - 10 Nm

13 - Mounting bracket for drive sprocket

14 - O-ring

1. Replace

15 - Thrust washer

16 - Drive sprocket for right timing chain

17 - Pivot pin -10 Nm

18 - O-ring

1. Replace

19 - Chain tensioner

20 - 10 Nm

21 - Glide track for chain tensioner

22 - Crankshaft

23 - Guide rail

24 - Pivot pin -10 Nm

Drive chain for timing mechanism, removing and installing

Removing

1. Remove camshaft timing chains --> «Camshaft timing chain, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .
2. Remove chain for power take-off --> «Chain for power take-off, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__chain-for-power-take-off-removing-and) .

Scheme 215

1. Remove glide track - 1 - at left cylinder head.
2. Remove chain tensioner - 2 -.

Scheme 216

1. Remove glide track - 1 - at right cylinder head.
2. Remove chain tensioner - 2 -.

Scheme 217

1. Push glide track of chain tensioner for chain drive in direction of - arrow - and pull off chain tensioner using a drill bit - 4 - 3.3 mm dia.
2. Mark running direction of timing chain with paint.
3. Remove bolts - 2 - and - 3 - and remove chain sprockets with drive chain and glide track - 1 -.

Installing

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque.

1. Install chain for power take-off --> «Chain for power take-off, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__chain-for-power-take-off-removing-and) .
2. Install camshaft timing chains «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

Torque specifications

*Replace bolts.

* 90 ° corresponds to one quarter turn.

Scheme 218

1 - 10 Nm

2 - Chain tensioner

1. With glide track

3 - 42 Nm

4 - Washer

5 - Pivot pin for idler sprocket

6 - Idler sprocket for chain for power take-off

7 - 10 Nm

8 - Mounting bracket for idler chain sprocket

9 - Chain for power take-off

1. Removing and installing --> «Chain for power take-off, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__chain-for-power-take-off-removing-and)

10 - Crankshaft

11 - Drive sprocket for power take-off

12 - 62 Nm

Chain for power take-off, removing and installing

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782

Removing

1. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
2. Remove engine: Vehicles with manual transmission --> «Engine (vehicles with manual transmission)»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), removing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-removing) .
3. Disconnect engine and transmission: Vehicles with manual transmission --> «Engine (vehicles with manual transmission), separating»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-manual-transmission-separating) , vehicles with automatic transmission --> «Engine and transmission (vehicles with automatic transmission), separating»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-and-transmission-vehicles-with-automatic) .
4. Leave engine on Scissor Lift Table VAS 6131 A or secure engine to engine and transmission holder: Vehicles with manual transmission --> «Engine (vehicles with manual transmission), securing to engine and transmission holder»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), securing to assembly stand»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-securing) .

1. Remove covers for timing chains --> «Timing chain covers (All), removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__timing-chain-covers-all-removing-and) .

Scheme 219

1. Push glide track of chain tensioner in direction of - arrow - and pull off chain tensioner using a drill bit - 1 - 3.3 mm dia.

Note. If chain sprocket for power take-off is to be removed, mounting bolt must be loosened before removing chain.

1. Mark running direction of chain for power take-off with paint.
2. Remove bolts - 2 to 5 - and remove chain tensioner.
3. Remove chain for power take-off.

Installing

Installation is in reverse order of removal, note the following

1. First install chain for power take-off.
2. Install chain tensioner starting at top on engine.
3. Install covers for timing chains «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .
4. Install engine: Vehicles with manual transmission --> «Engine (vehicles with manual transmission), installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-manual-transmission-installing) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-installing) .

1. Add engine oil and check oil level --> «Oil level, checking»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__oil-level-checking) .

Torque specifications

Scheme 220

1 - 62 Nm

2 - Spring

3 - Drive sprocket

1. For power take-off

4 - Drive spur gear

1. For power take-off

5 - 22 Nm

6 - Spur gear unit

7 - O-ring

1. Replace

8 - Seal

1. For A/C compressor drive
2. Replacing --> «Power take-off seals, replacing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

9 - Protective dust cap

1. For A/C compressor drive

10 - Input shaft

1. For air conditioning compressor
2. Tighten to 60 Nm

11 - Seal

1. For power steering pump drive
2. Replacing --> «Power take-off seals, replacing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

12 - Power-steering pump

13 - Input shaft

1. For oil pump

14 - Circlip

15 - Thrust washer

16 - O-ring

1. Replace

17 - Shaft for drive spur gear

18 - Bolt -22 Nm

Scheme 221

Special tools, testers and auxiliary items required

1. Pulling Hook T20143
2. Pressure piece T40051
3. Pressure piece T40052

Work procedure

1. Remove air conditioning compressor --> «87 AIR CONDITIONING»(/audi/s4/b8-2008-2011/remont/ac-compressor/#heating-air-conditioning) .
2. Remove power steering pump --> «48 - STEERING»(/audi/s4/b8-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 222

1. Pry out sealing ring for A/C compressor drive using pulling hook T20143/1.

Scheme 223

1. Pry out power-steering pump drive seal using pulling hook T20143/1.

Scheme 224

1. Drive in sealing ring for A/C compressor drive using thrust piece T40051.

Scheme 225

1. Drive in sealing ring for power-steering pump drive using thrust piece T40052.

The rest of installation is in reverse order of removal, note the following

1. Install the power steering pump --> «48 - STEERING»(/audi/s4/b8-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .
2. Install A/C compressor --> «87 AIR CONDITIONING»(/audi/s4/b8-2008-2011/remont/ac-compressor/#heating-air-conditioning) .

Spur gear unit, removing and installing

Special tools, testers and auxiliary items required

1. Pulling Hook T20143
2. Pressure piece T40051
3. Pressure piece T40052
4. Sealant

Special tools, testers and auxiliary items required

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

Removing

1. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
2. Remove engine: Vehicles with manual transmission --> «Engine (vehicles with manual transmission)»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), removing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-removing) .
3. Disconnect engine and transmission: Vehicles with manual transmission --> «Engine (vehicles with manual transmission), separating»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-manual-transmission-separating) , vehicles with automatic transmission --> «Engine and transmission (vehicles with automatic transmission), separating»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-and-transmission-vehicles-with-automatic) .
4. Leave engine on Scissor Lift Table VAS 6131 A or secure engine to engine and transmission holder: Vehicles with manual transmission --> «Engine (vehicles with manual transmission), securing to engine and transmission holder»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), securing to assembly stand»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-securing) .

1. Remove covers for timing chains --> «Timing chain covers (All), removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__timing-chain-covers-all-removing-and) .
2. Remove power-steering pump from cylinder block.

Scheme 226

1. Loosen bolt - 1 - on drive sprocket - 2 - a few turns.
2. Remove chain for power take-off --> «Chain for power take-off, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__chain-for-power-take-off-removing-and) .
3. Remove drive sprocket for power take-off.

Scheme 227

1. Remove bolts - 1 to 6 -.
2. Remove spur gear unit.

Scheme 228

1. Remove compression spring - 2 - between spur gear unit - 1 - and oil pump input shaft - 3 -.

Scheme 229

1. Remove drive shaft - arrow - for oil pump.

Installing

Note. Replace seals and O-rings.

Scheme 230

1. Remove A/C compressor drive seal - 2 - and power steering pump drive seal - 3 - using pulling hook T20143/1.
2. Remove O-ring - 1 -.
3. Remove sealant residue on spur gear unit and cylinder block.
4. Clean sealing surfaces so they are completely free of any oil or grease.

Scheme 231

1. Drive in sealing ring for A/C compressor drive using thrust piece T40051.
2. Drive in sealing ring for power-steering pump drive using thrust piece T40052.

1. Insert drive shaft - arrow - for oil pump into guide on oil pump.

Note. To guarantee that the drive shaft engages correctly in the oil pump, insert the drive shaft into the oil pump separately, do not install together with the front bearing cap.

1. Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 1.5 mm).

Scheme 232

1. Apply sealant beads - arrows - to clean sealing surfaces of spur gear unit as shown in illustration.

1. Thickness of sealant beads: 2.0 mm.

1. Position O-ring - 1 - and secure it with some grease.

Note. The spur gear unit must be installed within 5 minutes after application of sealant.

1. Position compress spring - 2 - for input shaft - 3 - in spur gear unit - 1 -.

1. Position spur gear unit and tighten bolts - 1 to 6 - in a diagonal sequence in stages.

1. Hand tighten power take-off drive sprocket - 2 -.
2. Install chain for power take-off --> «Chain for power take-off, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__chain-for-power-take-off-removing-and) .
3. Tighten power take-off drive sprocket bolt - 1 -.
4. Slide power steering pump with new O-ring onto spur gear for power-steering pump drive.

The rest of installation is in reverse order of removal, note the following

1. Install covers for timing chains «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .
2. Install engine: Vehicles with manual transmission --> «Engine (vehicles with manual transmission), installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-manual-transmission-installing) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-installing) .
3. Add engine oil and check oil level --> «Oil level, checking»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__oil-level-checking) .

Torque specifications

Crankshaft, component overview

Note. To perform assembly work, secure engine with Holder for V8 Engine Audi S4, allroad quattro VAS 6095/1-6 or Holder for V8 Engine Audi S4, allroad quattro VAS 6095/1-6A to Engine and Transmission Holder VAS 6095 --> Engine (vehicles with automatic transmission), securing to assembly stand .

Scheme 233

1 - Seals

1. Replace

2 - Seal for crankshaft - ribbed belt side

1. Replacing --> «Crankshaft seal (ribbed belt side), replacing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__crankshaft-seal-ribbed-belt-side-replacing) .

3 - Alignment bushing

1. 3 pieces
2. Insert into guide frame
3. Installed location «Sealant applied on cylinder block (for guide frame)»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

4 - Screws

1. For guide frame
2. Replace
3. Different bolt sizes
4. Tightening order «Installing guide frame»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

5 - Bolt

1. For sealing surfaces of cylinder block/guide frame
2. Different bolt lengths
3. Tightening order «Installing guide frame»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

6 - Bearing bracket

1. Sealant applied on cylinder block (for guide frame) «Sealant applied on cylinder block (for guide frame)»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)
2. Tightening sequence for manifold mounting bolts «Installing guide frame»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

7 - Thrust washer

1. Only at 4th crankshaft bearing
2. Lubricating grooves face outward
3. Note locating point in guide frame
4. Measuring crankshaft axial clearance --> «Axial clearance, measuring»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__axial-clearance-measuring)

8 - Bearing shell

1. For guide frame without lubricating groove
2. Do not interchange used bearing shells (mark)
3. Insert new bearing shells for guide frame with proper color marking --> «Allocation of main bearing shells for new crankshafts»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) or --> «Allocation of main bearing shells for used and reworked crankshafts»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__allocation-of-main-bearing-shells-for)

9 - Crankshaft

1. Measuring axial play --> «Axial clearance, measuring»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__axial-clearance-measuring)
2. Radial clearance, measuring --> «Radial clearance, measuring»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__radial-clearance-measuring)
3. Do not turn crankshaft when measuring radial play
4. Crankshaft dimensions --> «Crankshaft dimensions»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__crankshaft-dimensions)

10 - Thrust washer

1. Only at 4th crankshaft bearing
2. Lubricating grooves face outward
3. Measuring crankshaft axial clearance --> «Axial clearance, measuring»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__axial-clearance-measuring)

11 - 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 main bearing shells for new crankshafts»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) or --> «Allocation of main bearing shells for used and reworked crankshafts»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__allocation-of-main-bearing-shells-for)

12 - Gasket

1. Replace

13 - Cylinder block

1. Sealant applied on cylinder block (for guide frame) «Sealant applied on cylinder block (for guide frame)»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

Scheme 234

1. Clean sealing surfaces, they must be free of oil and grease.
2. Apply sealant beads - arrows - on clean sealing surfaces of guide frame as shown in illustration.

1. Thickness of sealant beads: 1.5 to 2.0 mm.

1. Install seals - 1 to 3 -.

Scheme 235

1. Check whether alignment bushings - arrows - are inserted at locations in guide frame as shown in the illustration.

Scheme 236

1. Replace bolts - 1 to 20 -.
2. Tighten bolts for guide frame as follows
3. Tighten bolts - 1 to 10 - to 30 Nm with torque wrench.
4. Tighten bolts - 11 to 20 - to 20 Nm with torque wrench.

1. Tighten bolts - 1 to 10 - to 50 Nm with torque wrench.
2. Tighten bolts - 11 to 20 - to 30 Nm with torque wrench.
3. Tighten bolts - 1 to 10 - 90 ° ( 1 / 4 additional turn) using a rigid wrench.
4. Tighten bolts - 11 to 20 - 90 ° ( 1 / 4 additional turn) using a rigid wrench.

1. Tighten bolts for sealing surfaces of cylinder block/guide frame - dark hatching in the illustration - to 9 Nm in diagonal sequence.

Scheme 237

Allocation of crankshaft bearing shells for cylinder block

1. Bearing shells with correct thickness are allocated to cylinder block in factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
2. Allocation of bearing shells to cylinder block is marked by one letter each at left front on cylinder block (can be read from outside) as shown in the illustration.

Note. In addition, the letters are also stamped on the guide frame.

Scheme 238

Allocation of crankshaft bearing shells for guide frame - crankshaft manufactured by Alfing

1. Bearing shells with correct thickness are allocated to guide frame in the factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
2. Allocation of bearing shells to guide frame is marked by one colored dot each on crankshaft counterweight as shown in the illustration.
3. Crankshafts manufactured by Alfing have no manufacturers identification.

Scheme 239

Allocation of crankshaft bearing shells for guide frame - crankshaft manufactured by Weber

1. Bearing shells with correct thickness are allocated to guide frame in the factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
2. Allocation of bearing shells to guide frame is marked by one colored dot each on front crankshaft counterweight as shown in the illustration. The "X" marks the end of the letter series and stand next to color identification for bearing 1 (belt pulley side).
3. Crankshafts manufactured by Weber have a manufacturers identification - A - on front crankshaft counterweight.

Note. The letter series begins at left with bearing 5 (flywheel side).

Allocation of main bearing shells for used and reworked crankshafts

Allocation of crankshaft bearing shells for cylinder block

1. Bearing shells are allocated to cylinder block corresponding to color markings stamped into cylinder block.
2. For used and reworked crankshafts, the main crankshaft journals must be measured in order to allocate matching bearing shells.
3. Basic dimension of main crankshaft journals = 65 mm dia.
4. Repair stage of main crankshaft journals = 64.75 mm dia.

1. Thicker over-sized bearing shells are available for reworked crankshafts. These have the same color markings as the original-size bearing shells.

Allocation of crankshaft bearing shells for guide frame

1. For used and reworked crankshafts, the main crankshaft journals must be measured in order to allocate the matching bearing shells.
2. Any other markings on the crankshaft are invalid when reworking crankshafts.
3. Allocate bearing shells to determined diameter of main crankshaft journals according to the following table.

*Colored markings on bearing shells do not indicate if they are for new or used crankshafts.

Crankshaft dimensions

Axial clearance, measuring

Special tools, testers and auxiliary items required

Scheme 240

1. Dial gauge holder VW 387

Scheme 241

1. Dial gauge VAS 6079

Work procedure

Scheme 242

1. Attach dial indicator VAS 6079 together with dial gauge holder VW 387 to cylinder block and set indicator against crankshaft counterweight.
2. Press crankshaft against dial indicator by hand, set indicator to "0".
3. Press crankshaft off dial indicator and read off value

1. Axial clearance: 0.090 to 0.251 mm.

Radial clearance, measuring

Special tools, testers and auxiliary items required

1. Plastigage

Work procedure

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

1. Remove guide frame and clean journals.
2. Place Plastigage over entire width of bearing journal or into bearing shells.

1. Plastigage must rest in center of bearing shell.

1. Install guide frame and tighten to 30 Nm. Do not turn crankshaft.
2. Remove guide frame again.
3. Compare width of Plastigage with measuring scale

1. Radial clearance, new: 0.010 to 0.039 mm.
2. Radial clearance wear limit: 0.08 mm.

Piston and connecting rod, component overview

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

Scheme 243

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

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/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)
3. When installing bearing cap, observe: The wide thrust flange - A - must point to same side on connecting rod and connecting rod bearing cap
4. Installation position of connecting rod pairs «Connecting rod, installed location»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

3 - Bearing shells

1. Check that retaining tabs are secured
2. Do not interchange used bearing shells (mark, but not on running surface)
3. Radial clearance, measuring --> «Connecting rod radial clearance, measuring»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__connecting-rod-radial-clearance-measuring)
4. Over-sized bearings are available for reworked crankshaft connecting rod journals

4 - Connecting rod

1. Only replace as set
2. Mark allocation to cylinder with paint - B - «Mark connecting rod»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)
3. When installing bearing cap, observe: The wide thrust flange - A - must point to the same side on connecting rod and connecting rod bearing cap
4. Installation position of connecting rod pairs «Connecting rod, installed location»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

1. Axial play for each new connecting rod pair: 0.20 to 0.38 mm
2. Axial play wear limit: 0.60 mm
3. Radial clearance, measuring --> «Connecting rod radial clearance, measuring»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__connecting-rod-radial-clearance-measuring)

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»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)
2. Piston and cylinder dimensions --> «Piston and cylinder dimensions»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__piston-and-cylinder-dimensions)
3. Checking «Checking piston»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)
4. Install with piston ring compressor

1. Measuring cylinder bore «Measuring cylinder bore»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

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. Measuring end cap «Measuring piston ring gap»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

1. Measuring side clearance «Measuring piston ring side clearance»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

Scheme 244

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 245

1. Clean ring groove of piston before checking.

Scheme 246

1. Measure approx. 10 mm from the lower edge, at a 90 ° angle to piston pin axis using an external micrometer 75 to 100 mm.

1. Maximum deviation from nominal dimension: 0.04 mm.

Nominal dimension --> Piston and cylinder dimensions .

Scheme 247

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 248

1. Mark allocation to cylinder on piston head using chalk or water-proof felt pen.

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. Valve recesses - 1 - point toward center of engine.

Scheme 249

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 with paint - arrow -.

Scheme 250

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

Scheme 251

1. Oil injector jet (opening pressure 2 to 2.4 bar positive pressure)
2. Bolts - 9 Nm. Insert using locking compound; locking compound

Piston and cylinder dimensions

Matching pistons are allocated to the different manufacturing stages of the cylinder block.

*Dimension with graphite coating (thickness = 0.01 mm). The graphite coating wears off.

Connecting rod radial clearance, measuring

Special tools, testers and auxiliary items required

1. Plastigage

Test sequence

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

1. Remove connecting rod bearing caps again.
2. Compare width of Plastigage with measuring scale

1. Radial clearance, new: 0.028 to 0.077 mm.
2. Radial clearance wear limit: 0.12 mm.

1. Replace bolts for connecting rod bearings.

Cylinder head, component overview

Note. Right cylinder head is shown in illustration.

Scheme 252

1 - Cylinder head gasket

1. Replacing --> «Cylinder head, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .
2. Installed location: Part Number, points to cylinder head
3. After replacing, change coolant and engine oil

2 - Lifting eye

3 - 22 Nm

4 - Gasket

1. Replace if damaged or leaking

5 - Cylinder head cover gasket

1. Replace if damaged or leaking

6 - Cylinder head cover

1. Removing and installing left cylinder head cover --> «Left cylinder head cover, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__left-cylinder-head-cover-removing-and)
2. Removing and installing right cylinder head cover --> «Right cylinder head cover, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__right-cylinder-head-cover-removing-and)

7 - Ignition coil

1. Extractor T40039 can be used for removal.

8 - Special bolt - 10 Nm

1. Replace if damaged or leaking
2. Observe sequence for tightening Tighten cylinder head cover in sequence under «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

9 - Cylinder head cover gaskets

1. Replace if damaged or leaking

10 - Cylinder head cover gasket

1. Replace if damaged or leaking

11 - Semicircular seal

1. Replace if damaged or leaking

12 - Cylinder head bolt

1. Replace
2. Observe sequence for loosening Loosen cylinder head bolts in the sequence under «Cylinder head, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)
3. Observe sequence for tightening --> see scheme 490

13 - Cylinder head

1. Removing --> «Cylinder head, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)
2. Check for distortion Checking cylinder head for distortion under «Cylinder head, component overview»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__cylinder-head-component-overview)
3. Reworking dimension «Reworking dimension of cylinder head»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)
4. Installing «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

1. After replacing, change coolant and engine oil

Scheme 253

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

1. Max. permissible distortion: 0.1 mm

Scheme 254

1. It is only permitted to reface cylinder head to minimum dimension - a -.

1. Minimum dimension: - a - = 139.25 mm.

Left cylinder head cover, removing and installing

Special tools, testers and auxiliary items required

Scheme 255

1. Hose clamps up to 25 mm diameter 3094

1. Remove front engine cover - arrows 1 and 2 -.

1. Remove rear engine cover - arrows -.

1. Remove cover - 1 - in engine compartment (left side).

1. Clamp off coolant hose - 2 - using Hose clamps up to 25 mm diameter 3094 and disconnect from coolant expansion tank.
2. Seal connection using a plug that fits.
3. Remove coolant expansion tank - arrow -.
4. Disconnect electrical wire to Engine Coolant Level (ECL) Warning Switch F66 at bottom on expansion tank and set aside coolant expansion tank with coolant hose - 1 - connected.

1. Remove bolt - arrow - at oil dipstick guide tube.

Note. Guide tube remains inserted in upper part of oil pan.

1. Remove bolts - 5 - and - 6 -.
2. Disconnect electrical harness connectors - 1 to 4 -.
3. Remove ignition coils - arrows -.

Note. Extractor T40039 can be used for removal.

1. Disconnect hose of crankshaft housing ventilation - arrow -.
2. Remove left cylinder head cover screws in sequence - 15 to 1 -.
3. Remove cylinder head cover.

Installation is in reverse order of removal, note the following

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

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

Scheme 256

1. Coat semicircular seals - arrows - lightly with oil and insert.

1. Tighten cylinder head cover in sequence - 1 to 15 -.

* Insert using locking compound; locking compound .

Right cylinder head cover, removing and installing

Removing

1. Remove rear engine cover - arrows -.

1. Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - from air guide.
2. Remove bolts - arrows -.
3. Remove air duct - 2 -.

1. Remove fuel hose from connection on fuel rail line. To do so, counter hold using an open-end wrench at hex head - 1 - and - 3 - and remove union nut - 2 -.

1. Disconnect electrical harness connector - 2 - from Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.
2. Disconnect electrical harness connector - 3 - at Mass Air Flow (MAF) Sensor G70.
3. Disconnect hose - 1 - to Secondary Air Injection (AIR) pump.
4. Disconnect air guide hose - 4 - at Mass Air Flow (MAF) Sensor G70.

1. Move wiring harness clear at air filter housing.
2. Remove clip and remove air filter housing with Mass Air Flow (MAF) Sensor G70.

1. Disconnect vacuum hose - 1 -.
2. Disconnect air guide hose - 2 - from Throttle Valve Control Module J338.

1. Remove bolts - 5 - and - 6 - on right cylinder head.
2. Disconnect electrical harness connectors - 1 to 4 -.
3. Remove ignition coils - arrows -.

Note. Extractor T40039 can be used for removal.

1. Disconnect hose of crankshaft housing ventilation - arrow -.
2. Remove right cylinder head cover bolts in sequence - 15 to 1 -.
3. Remove cylinder head cover.

Installing

Installation is in reverse order of removal, note the following

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

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

1. Coat semicircular seals - arrows - lightly with oil and insert.

1. Tighten cylinder head cover in sequence - 1 to 15 -.

1. Secure fuel hose to connection on fuel rail line. To do so, counter hold using an open-end wrench at each hex head - 1 - and - 3 - and tighten union nut - 2 - to 22 Nm.

Torque specifications

* Insert using locking compound; locking compound .

Cylinder head, removing and installing

Removing

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

1. Remove engine: Vehicles with manual transmission --> «Engine (vehicles with manual transmission)»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), removing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-removing) .
2. Leave engine with transmission installed on scissor lift platform VAS 6131 A.
3. Remove camshaft timing chains from camshafts --> «Camshaft timing chains, removing from camshafts»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__camshaft-timing-chains-removing-from-camshafts) .

1. Remove glide track - 1 - at left cylinder head.
2. Remove chain tensioner - 2 -.

1. Remove glide track - 1 - at right cylinder head.
2. Remove chain tensioner - 2 -.

Scheme 257

1. Loosen cylinder head bolts in the sequence - 1 to 10 -.
2. Remove cylinder head and place it on a soft surface (foam).

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 roller rocker levers and cam lubricating surfaces after installing cylinder head. Do not remove plastic bases protecting exposed valves until immediately before installing cylinder head. Cylinder heads with cracks between the valve seats, or between the valve seat and the spark plug threads, can continue to be used without reducing the service life, as long as the cracks have a width of max. 0.3 mm, or only the first 4 threads of the spark plug threads are cracked. Only unpack new cylinder head gasket immediately prior to installation. Handle gasket with extra care. 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 . When replacing the cylinder head or cylinder head seal, all of the coolant and engine oil must be replaced. 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. During installation, all cable ties must be re-installed at the same location.

1. Check whether camshafts of both cylinder heads stand in TDC position.

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Crankshaft holder 3242 must be installed.

Scheme 258

1. Position cylinder head gasket.

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. Install cylinder head.
2. Insert new cylinder head bolts and tighten by hand.

Scheme 259

1. Tighten cylinder head bolts in 4 stages in tightening sequence shown as follows
2. Using torque wrench, tighten to 30 Nm.
3. Using torque wrench, tighten to 60 Nm.
4. With Torx key, 90 ° ( 1 / 4 turn) additional turn.

1. With Torx key, 90 ° ( 1 / 4 turn) additional turn.

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

The rest of installation is in reverse order of removal, note the following

1. Install camshaft timing chains «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .
2. Install engine: Vehicles with manual transmission --> «Engine (vehicles with manual transmission), installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-manual-transmission-installing) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-installing) .
3. Change engine oil --> «01 - MAINTENANCE»(ref-278933-S06026331132008020700000) «01 - MAINTENANCE»(/audi/s4/b8-2008-2011/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .
4. Replace coolant «Filling»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__filling) .

Torque specifications

*Replace bolts.

* 90 ° corresponds to one quarter turn.

Scheme 260

1 - Intake manifold

1. Removing and installing --> «Intake manifold, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

2 - O-rings for fuel injectors

1. Replace

3 - 10 Nm

4 - Fuel return line

5 - Fuel supply line

1. Tighten union nut to 22 Nm

6 - Fuel rail

7 - Vacuum line

8 - Crankcase housing ventilation pressure regulator valve

9 - 10 Nm

1. Fasten in diagonal sequence in steps

10 - Lifting eye

11 - 23 Nm

12 - Gasket for intake manifold

1. Replace

13 - Locking pin - 0.6 Nm

Scheme 261

1 - Intake manifold

1. Removing and installing --> «Intake manifold, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

2 - O-rings for fuel injectors

1. Replace

3 - 10 Nm

4 - Secure the fuel line from the connector flange of the fuel tank using hose clamps appropriate for the model type

1. Loosening and tightening union nut --> «Loosening and tightening union nut for fuel hose»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__loosening-and-tightening-union-nut-for)

5 - Fuel rail

6 - Pressure regulator valve

1. For crankcase ventilation

7 - 10 Nm

1. Fasten diagonally in steps

8 - Lifting eye

9 - 23 Nm

10 - Gasket

1. For intake manifold
2. Replace

11 - Locking pin - 0.6 Nm

Loosening and tightening union nut for fuel hose

Loosening

1. Remove fuel hose from connection on fuel rail line. To do so, counter hold using an open-end wrench at each hex head - 1 - and - 3 - and remove union nut - 2 -.

Tightening

1. Secure fuel hose to connection on fuel rail line. To do so, counter hold using an open-end wrench at each hex head - 1 - and - 3 - and tighten union nut - 2 - to 22 Nm.

Intake manifold, removing and installing

Removing

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

1. Bring lock carrier into service position --> «Lock carrier, moving into service position»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__lock-carrier-moving-into-service-position) .

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrows 1 and 2 -.

1. Disconnect vacuum line - arrow - to brake booster at bulkhead.

1. If installed, disconnect vacuum line - arrow - to vacuum reservoir.

1. Disconnect vacuum hose - arrow - from intake manifold.

Scheme 262

1. Disconnect electrical connection - 1 - at throttle valve control module J338.
2. Disconnect vacuum hose - 2 -.
3. Remove air guide hose - 3 -.
4. Disconnect crankcase ventilation hose - 4 - at intake pipe.

1. If installed, disconnect vacuum line at area designated with - arrow -.

1. Remove electrical harness connectors - 1 to 4 - toward front from brackets on intake pipe.

Note. The electrical connections must not be separated.

1. Disconnect vacuum hose - arrow - at T-piece.

1. Disconnect connector strips - 1 - and - 5 - at fuel injectors.
2. For vehicles with fuel return line, disconnect vacuum line - 4 - on fuel pressure regulator.
3. Remove retaining bolts - 2 - and - 3 - for fuel rail line.
4. Remove fuel distributor together with fuel injectors from intake manifold simultaneously upward and place it on a clean rag in engine compartment.

Note. Carefully protect the removed fuel injectors from contamination.

1. Remove bolts - arrows - for left rear engine lifting eye.

1. Remove intake manifold bolts - arrows - and remove manifold.

Note. Plug intake ports of cylinder head with clean rags.

Installing

Installation is in reverse order of removal, note the following

Note. Replace gaskets and O-rings. 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.

Scheme 263

1. Replace intake manifold gaskets, thereby removing locking bolt - 1 -.
2. Be aware of alignment pins - 2 - when setting intake manifold in place.

Scheme 264

1. Tighten intake manifold bolts - arrows - in a diagonal sequence and in steps.

Tightening torque: 11 Nm

1. Install lock carrier with attachments --> «50 BODY, FRONT»(ref-278920-S31853902272008020700000) «50 - BODY - FRONT»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(ref-278920-S18413101412008020700000) «63 - BUMPERS»(/audi/s4/b8-2008-2011/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Run engine for 5 minutes.
4. Retighten intake manifold bolts in sequence shown.

Tightening torque: 11 Nm

1. Check headlight adjustment --> «01 - MAINTENANCE»(ref-278933-S06026331132008020700000) «01 - MAINTENANCE»(/audi/s4/b8-2008-2011/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

Compression pressures, checking

Special tools, testers and auxiliary items required

Scheme 265

1. Spark plug removal tool 3122 B

Scheme 266

1. Compression tester V.A.G 1763

Test conditions

1. Engine oil temperature min. 30 ° C
2. Battery voltage at least 12.5 V

Test sequence

1. Switch off ignition.

Scheme 267

1. Remove fuse for Fuel Pump (FP) from socket - 28 -.

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrows 1 and 2 -.

1. Remove cover - 1 - in engine compartment (left side).

1. Remove coolant expansion tank - arrow -.
2. Disconnect electrical wire from Engine Coolant Level (ECL) Warning Switch F66 and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

1. Remove bolt - arrow - at oil dipstick guide tube.

Note. Guide tube remains inserted in upper part of oil pan.

1. Remove cover - 1 - in engine compartment (right side).

1. Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - from air guide.
2. Remove bolts - arrows -.
3. Remove air duct - 2 -.

1. Remove fuel hose from connection on fuel rail line. To do so, counter hold using an open-end wrench at hex head - 1 - and - 3 - and remove union nut - 2 -.

1. Disconnect electrical harness connector - 2 - from Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.
2. Disconnect electrical harness connector - 3 - at Mass Air Flow (MAF) Sensor G70.
3. Disconnect hose - 1 - to Secondary Air Injection (AIR) pump.
4. Disconnect air guide hose - 4 - at Mass Air Flow (MAF) sensor.

1. Move wiring harness clear at air filter housing.
2. Remove clip and remove air filter housing with Mass Air Flow (MAF) sensor.

1. Remove bolts - 5 - and - 6 - on left cylinder head.
2. Disconnect electrical harness connectors - 1 to 4 -.
3. Remove ignition coils - arrows -.

Note. Extractor T40039 can be used for removal.

1. Remove bolts - 5 - and - 6 - on right cylinder head.
2. Disconnect electrical harness connectors - 1 to 4 -.
3. Remove ignition coils - arrows -.

Note. Extractor T40039 can be used for removal.

1. Using spark plug removal tool 3122 B , remove spark plugs.
2. Open throttle valve completely.
3. Check compression using compression tester V.A.G 1763.

Note. Using the compression tester Operating instructions.

1. Have a second technician press accelerator pedal completely and at the same time operate starter long enough until pressure increase no longer appears on tester.

Compression pressure

Assembly is in reverse order of removal, note the following

1. Secure fuel hose to connection on fuel rail line. To do so, counter hold using an open-end wrench at each hex head - 1 - and - 3 - and tighten union nut - 2 - to 22 Nm.
2. Install sparks plugs --> «01 - MAINTENANCE»(ref-278933-S06026331132008020700000) «01 - MAINTENANCE»(/audi/s4/b8-2008-2011/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Faults are saved in the ECM when the electrical connectors are disconnected

1. Connect Vehicle Diagnosis, testing info. system VAS 5051B.
2. Start "Guided Functions" operating mode.
3. Generate readiness code in ECM.

Torque specifications

* Insert using locking compound; locking compound .

Valvetrain, servicing

Note. Cylinder heads with cracks between the valve seats, or between the valve seat and the spark plug threads, can continue to be used without reducing the service life, as long as the cracks have a width of max. 0.3 mm, or only the first 4 threads of the spark plug threads 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 268

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

1. Replace

2 - Housing for camshaft adjustment solenoid valve

3 - Gasket

1. Replace

4 - Valve stem seal

1. Replacing --> «Valve stem seals, replacing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

5 - Valve spring

6 - Valve spring plate

7 - Valve keepers

8 - Hydraulic valve lifter

1. Pressed into roller rocker lever
2. Not removable without being damaged

9 - Roller rocker lever

1. Removing and installing --> «Roller rocker lever, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__roller-rocker-lever-removing-and-installing)

10 - Alignment bushing

1. 2 pieces

11 - Double bearing cap

12 - 5 Nm plus an additional 1 / 4 turn (90 °)

1. Replace

13 - Oil deflector

1. On cylinder head at right between bearing cap E4 and A4
2. On cylinder head at left between bearing cap E2 and A2

14 - 5 Nm plus an additional 1 / 4 turn (90 °)

1. Replace

15 - Bearing cap

1. Note installation position and allocation «Installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)

16 - Intake camshaft

1. Removing and installing --> «Camshafts, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__camshafts-removing-and-installing)
2. Checking axial play --> «Camshaft (axial clearance), checking»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__camshaft-axial-clearance-checking)
3. Check radial clearance using Plastigage (roller rocker lever removed) wear limit 0.1 mm run-out max. 0.01 mm

17 - Exhaust camshaft

1. Removing and installing --> «Camshafts, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__camshafts-removing-and-installing)
2. Checking axial play --> «Camshaft (axial clearance), checking»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__camshaft-axial-clearance-checking)
3. Check radial clearance using Plastigage (roller rocker lever removed) wear limit 0.1 mm run-out max. 0.01 mm

18 - Shaft for roller rocker lever, intake side

1. Removing and installing --> «Roller rocker lever, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__roller-rocker-lever-removing-and-installing)

19 - 10 Nm

20 - Shaft for roller rocker lever, exhaust side

1. Removing and installing --> «Roller rocker lever, removing and installing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__roller-rocker-lever-removing-and-installing)

21 - O-ring for shaft of roller rocker lever

1. Replace

22 - Cylinder head

1. See note --> «Valvetrain, servicing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__valvetrain-servicing)
2. Check valve guides, grind valve seats --> «Valve guides, checking»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__valve-guides-checking)
3. Rework valve seats --> «Valve seats, refacing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__valve-seats-refacing)

23 - Intake valve

1. Do not rework, only lapping is permitted
2. Valve dimensions --> «Valve dimensions»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)
3. Check valve guides, grind valve seats --> «Valve guides, checking»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__valve-guides-checking)

24 - Exhaust valve

1. Do not rework, only lapping is permitted
2. Valve dimensions --> «Valve dimensions»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf)
3. Check valve guides, grind valve seats --> «Valve guides, checking»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__valve-guides-checking)

25 - Alignment bushing

1. 2 pieces

Camshafts, removing and installing

Note. Removal and installation at right cylinder head is depicted in the following description.

1. Remove engine: Vehicles with manual transmission --> «Engine (vehicles with manual transmission)»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) , vehicles with automatic transmission --> «Engine (vehicles with automatic transmission), removing»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-automatic-transmission-removing) .
2. Disconnect engine and transmission: Vehicles with manual transmission --> «Engine (vehicles with manual transmission), separating»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-vehicles-with-manual-transmission-separating) , vehicles with automatic transmission --> «Engine and transmission (vehicles with automatic transmission), separating»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__engine-and-transmission-vehicles-with-automatic) .
3. Remove camshaft timing chains from camshafts --> «Camshaft timing chains, removing from camshafts»(/audi/s4/b8-2008-2011/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf__camshaft-timing-chains-removing-from-camshafts) .

Scheme 269

1. Remove housing for camshaft adjustment solenoid valves - arrows -.

Scheme 270

1. Remove bearing caps - 1 - , - E3 - , - E5 - , - A3 - and - A5 -.
2. Remove oil deflector - arrow -.
3. Loosen and remove bearing caps - E2 - , - E4 - , - A2 - and - A4 - for intake and exhaust camshafts, alternating and in diagonal sequence.
4. Remove intake and exhaust camshaft.

1. Secure crankshaft in TDC position using Crankshaft Holder 3242.

Note. Always replace bolts that are tightened to torque as well as O-rings and gaskets.

1. Install camshafts at TDC position into cylinder head.

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Install bearing caps - E2 - , - E4 - , - A2 - and - A4 -.
2. Install oil deflector - arrow