5.2l 10-cyl. 4v Engine Mechanical, Engine Code(s): Bsm Audi S8 D3 рестайлинг

Safety Precautions

Note the following when working on the fuel system

1. Procedures before opening high pressure fuel injection system --> «Before Opening High Pressure Fuel Injection System»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__before-opening-high-pressure-fuel-injection) .

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 the 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/s8/d3-2007-2011/remont/cruise-control-systems/#electrical-equipment) .

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

Before Opening High Pressure Fuel Injection System

1. The fuel injection system is separated into a high-pressure section (max. approximately 120 bar) and a low-pressure section (approximately 6 bar).
2. Before opening high pressure area, fuel pressure must be reduced to a residual pressure of approximately 6 bar. The procedure for this is as follows.

Special tools, testers and auxiliary items required

1. Vehicle diagnostic, testing, and information system VAS 5051B

Procedure

Proceed as follows

Scheme 1

1. Connect vehicle diagnosis, testing and information system VAS 5051B while ignition is switched off.

Scheme 2

Display on VAS 5051B

1. Press Vehicle Self-Diagnosis button - 1 - in the selection.

Scheme 3

Display on VAS 5051B

1. In selection - 1 - , press "01 - Engine electronics" vehicle system and continue by pressing button.

Scheme 4

Display on VAS 5051B

1. In selection - 1 - , press diagnostic function "006 - Basic setting" and continue by pressing button.

Scheme 5

Display on VAS 5051B

1. In button field - 1 - , press 1 4 0 buttons for "Display group 140" and confirm the entry by pressing the Q button.

Scheme 6

Display on VAS 5051B

1. Check display for fuel pressure in fuel rail in display field - 3 -.

Example

3 - 40.63 bar

Scheme 7

1. Disconnect electrical connector - arrow - at Fuel Metering Valve 2 N402 on left high pressure pump.

Scheme 8

1. Disconnect electrical connector - arrow - at Fuel Metering Valve 2 N290 on right high pressure pump.

Display on VAS 5051B

1. Check indication in display field - 3

1. Fuel pressure in fuel rail must sink to approximately 6 bar.

1. Switch off ignition.

The fuel rail will continue to be filled with fuel, but it will no longer be under high pressure.

Now components or lines can be opened.

1. Lay clean cloths around connectors and catch escaping fuel.

Final procedures

1. Reconnect electrical harness connectors.
2. Start "Guided Functions" operating mode.
3. Generate readiness code in ECM.

General Information

> Clean Working Conditions

> Contact Corrosion

> Lines, Routing and Securing

Clean Working Conditions

Even a little contamination can lead to faults. Pay careful attention to the following rules for clean working conditions when working on the fuel supply and injection system

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. Plug open lines and connections immediately with appropriate 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 unpacked (e.g. in tool boxes etc.).

1. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
2. Protect disconnected electrical connectors from dirt and moisture and only connect if dry.

Contact Corrosion

Contact corrosion can occur if incorrect fasteners (bolts, nuts, washers, etc.) are 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.

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.

Lines, Routing and Securing

To prevent mistakes and ensure the original installation location is kept, mark the hydraulic lines, vacuum lines or electrical lines before removing them. If necessary, draw sketches or take pictures.

Engine Data

Scheme 9

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

Scheme 10

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

Note. The engine code is also located on the vehicle data plate.

Engine, Removing

Note. With lock carrier installed, engine is removed downward with transmission and subframe. Drained coolant must be stored in a clean container for disposal or reuse. During installation, reinstall all heat insulation sleeves and heat shields at the same locations. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Special tools, testers and auxiliary items required

Scheme 11

1. Pry Lever - Rmv Outside Mirror 80 - 200
2. Ring screw 3368
3. Old oil collecting and extracting device V.A.G 1782
4. Hose clamp pliers V.A.G 1921

1. Spark plug connector pliers V.A.G 1922
2. Hose clip pliers VAS 6340 (formerly: VAS 5024 A)

Special tools, testers and auxiliary items required

Scheme 12

1. Step ladder VAS 5085
2. Scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10
3. Drip tray for workshop crane VAS 6208
4. Tensioning Strap T10038 qty. 2

1. Ignition Coil Puller T40039

Note. If engine should be separated from transmission after removal, two additional adapter sets VAS 6131/10-12 are needed.

Procedure

Note. So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted. In order for the driveshaft to be able to rotate for removal, the electronic parking brake must be released before disconnecting battery.

Scheme 13

1. Remove cover of right luggage compartment side trim - arrows -.

Scheme 14

1. Remove cover - 1 - above battery.

Note. Ignore - 2 -.

Scheme 15

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Discharge refrigerant circuit --> «87 - AIR CONDITIONING»(/audi/s8/d3-2007-2011/remont/automatic-hvac-system/#refrigerant-r134a-servicing) .

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

Scheme 16

1. Remove cover above coolant reservoir - arrows -.

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

Scheme 17

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

Scheme 18

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Remove front and rear part of left and right front wheel housing liner --> «66 - EXTERIOR EQUIPMENT»(/audi/s8/d3-2007-2011/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 19

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

Scheme 20

1. Remove drain plug - arrow - at front coolant pipe and drain coolant.

Scheme 21

1. Remove coolant hoses - 1 to 3 - and drain coolant.

Scheme 22

1. Disconnect coolant hose next to left driveshaft from coolant pipe - arrow - and drain coolant.

Scheme 23

1. Remove screws - 2 - and - 3 -.
2. Remove front lower coolant pipe from hoses - 1 - and - 4 -.

Scheme 24

1. Remove hoses - 1 - and - 2 - from secondary air injection connecting pipes.

Scheme 25

1. Remove coolant hoses - 1 - and - 2 - from right auxiliary cooler and drain remaining coolant.

Scheme 26

1. Remove nut - 1 - and remove coolant hose - 2 - from right auxiliary cooler.

Scheme 27

1. Disconnect electrical connector - 1 - on Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 and remove vacuum hose - 2 -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 from bracket and lay aside with hose connected.

Scheme 28

1. Remove coolant hose - arrow - from coolant pipe to coolant reservoir.

Scheme 29

1. Disconnect electrical connector - 2 - for Mass Air Flow (MAF) Sensor 2 G246.
2. Disconnect air duct hose - 1 - from intake manifold.
3. Remove bolts - arrows - and remove left upper part of air filter housing.

Scheme 30

1. Remove air duct - 1 -.
2. Remove bolts - arrows -.
3. Tilt lower part of air filter housing and remove air flap vacuum hose.
4. Remove lower part of left air filter housing.

Scheme 31

1. Extract hydraulic oil from power steering reservoir using Used Oil Collecting and Extracting Device V.A.G 1782.

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

1. Disconnect power steering hydraulic pressure line - arrow - at front left on engine.
2. Remove hood seal from lock carrier and from fender edges.

Scheme 32

1. Disconnect vacuum hoses - 1 - and - 2 - and free them up.

Scheme 33

1. Separate electrical connector - 1 - for mass air flow (MAF) sensor G70.
2. Disconnect vacuum hose - 2 - from air guide hose.
3. Loosen hose clamps and lay aside air guide hose - 4 -.

1. Remove bolts - arrows - and remove right upper part of air filter housing.

Scheme 34

1. Remove lower air guide hose - arrow - from right upper part of air filter housing.

Scheme 35

1. Disconnect both vacuum hoses - 1 -.
2. Remove air duct - 2 -.
3. Remove bolts - arrows -.
4. Tilt lower part of air filter housing and disconnect electrical connector - 3 - on Intake Air Switch-Over valve N335.

1. Remove lower part of right air filter housing.

Scheme 36

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

Scheme 37

1. Remove bolt - arrow - at torque support mount.

Scheme 38

1. Remove oxygen sensor electrical connectors - 1 - and - 2 - from right bracket in engine compartment.

Scheme 39

1. Disconnect vacuum hoses - 1 - and - 2 - and free them up.

Scheme 40

1. Disconnect fuel supply line - arrow - on distribution piece.

Scheme 41

1. Disconnect crankcase ventilation hose - 2 -.
2. Disconnect electrical connectors - 1 - and - 5 -.
3. Remove bolts - 3 - and - 4 -.
4. Disconnect electrical connectors to ignition coils in cylinder bank 1 (right) and free up electrical wiring harness.

Scheme 42

1. Remove ignition coils using Ignition Coil Puller T40039.

Scheme 43

1. Loosen bolts in sequence - 16 to 1 - and remove them.
2. Remove right cylinder head cover.
3. Cover open valvetrain with a clean cloth.

Scheme 44

1. Remove rubber seal - 1 - and remove plenum chamber covers - 2 - and - 3 -.

Scheme 45

1. Pry out cover caps on windshield wiper arms with a screwdriver and loosen nuts - arrows - a few turns.
2. Loosen wiper arms by tilting slightly from windshield wiper axle.
3. Remove nuts completely and remove wiper arms.

Scheme 46

1. Remove dust and pollen filter by opening 4 quick-release fasteners.

Note. Cover the air duct at air conditioning housing with a clean rag so that nothing can fall in.

1. Remove bolts - arrows - at left and right for cowl grill - 1 -.
2. Carefully pull the cowl grill off from the retainers at the windshield.

Scheme 47

1. Remove suspension strut crossmember - arrow -.

Scheme 48

1. Remove bolts - 1 - and - 2 - and remove retaining bracket.
2. Release retaining tabs - arrows - and remove both engine control modules (ECM).

Note. Electrical harnesses remains connected.

Scheme 49

1. Remove Air Quality Sensor G238 by rotating approximately 90 counter-clockwise - arrow - and removing from bracket.
2. Release retaining clips - 1 to 4 -.
3. Fold cover for the E-box in plenum chamber open slightly and pull off toward the front.

Scheme 50

1. Disconnect multi-pin harness connectors - arrows - using spark plug connector pliers V.A.G 1922.
2. Disengage engine wiring harness at E-Box and bulkhead.
3. Lay wiring harness aside on the engine with engine control modules (ECM) connected.

Note. Protect the engine control modules from falling off.

Scheme 51

1. Remove right A-pillar trim --> «70 - INTERIOR TRIM»(/audi/s8/d3-2007-2011/remont/gauges-instrument-panels/#body-interior) .
2. Fold floor covering back.
3. Remove protective cover above main fuse holder.
4. Fold cap - 2 - aside.

1. Remove nut - 4 -.
2. Remove terminal 30 wire to starter.

Note. Ignore - 1 - and - 3 -.

Scheme 52

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

Scheme 53

1. Disconnect electrical connector - 2 -.
2. Remove Ground (GND) wire - 1 - on longmember.
3. Remove wiring harness bracket on longmember - arrows -.
4. Free up wiring harness.

Scheme 54

1. Disconnect electrical harness connector - 2 - at Level Control System Sensor.
2. Disconnect connecting link - 1 - from control arm.
3. Repeat procedure on opposite side of the vehicle.

Scheme 55

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

1. Remove bolts - 1 - and - 2 -.
2. Disconnect refrigerant lines from A/C compressor.

Note. Seal open lines and connections at A/C compressor with suitable sealing caps (to prevent dirt and moisture from entering).

Scheme 56

1. Remove bolts - arrows - on climate control system reservoir bracket.

Note. Climate control system reservoir remains in installation location.

Scheme 57

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

1. Remove hydraulic hose - arrow - from power steering fluid reservoir.

Scheme 58

1. Have a second technician press brake pedal.

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

Scheme 59

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

Scheme 60

1. Insert left and right Lifting Eyebolt 3368 from below into hole in strut tower.
2. Secure Lifting Eyebolt 3368 with a nut - 2 - with washer - 1 - over several threads (do not install nut all the way down on threads).
3. Tie up wheel bearing housing at left and right with Tensioning Strap T10038 as shown in illustration.

Scheme 61

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

Scheme 62

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

Scheme 63

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

1. Repeat work procedure on opposite side of the vehicle.
2. Remove drive axle from transmission flanged shaft.

1. Swing wheel bearing housing outward and remove drive shaft.
2. Repeat work procedure on opposite side of the vehicle.

Scheme 64

1. Remove front transverse beam - arrows -.

Scheme 65

Note. Do not bend the flex joint in front of the exhaust pipe more than 10 or it could be damaged.

1. Loosen clamping sleeves - 1 - and - 2 -.

Scheme 66

1. Remove heat shield - A - for drive shaft - arrows -.
2. Remove bolts on transmission/driveshaft connection.
3. Slide driveshaft back to rear final drive; constant velocity joints can move axially.

Scheme 67

1. Tie driveshaft up and to the side against heat shield - arrow -.

Prepare scissor lift platform

Scheme 68

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 table VAS 6131 A under engine/transmission subassembly.

Scheme 69

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

Scheme 70

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

Scheme 71

1. Remove bracket for oxygen sensor electrical connectors - 1 - and - 2 - from tunnel crossmember - arrows -.

Note. Electrical connectors remain connected.

Scheme 72

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

Scheme 73

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

Scheme 74

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

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

Scheme 75

1. First lower engine/transmission assembly using scissor lift platform VAS 6131 A only approximately by dimension - a -.

1. Dimension - a - = approximately 300 mm.

Scheme 76

1. Press ball socket - 2 - of selector lever cable from selector shaft lever using Pry Lever - Rmv Outside Mirror 80 - 200.
2. Unclip locking plate - 1 - from selector lever cable bracket.
3. Remove selector lever cable.
4. Lower engine/transmission subassembly downward.

1. Push scissor lift platform VAS 6131 A with engine/transmission subassembly under vehicle.

Engine and Transmission, Separating

Special tools, testers and auxiliary items required

1. Adapter VAS 6131/10-12 qty. 2

Scheme 77

1. Adapter T40058

Procedure

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

Scheme 78

1. Remove bracket for oxygen sensor electrical connectors - 1 to 4 - from subframe - arrow -.
2. Remove electrical harness connectors from bracket and disconnect it.

1. Remove oxygen sensor electrical connectors - 1 - and - 2 - from bracket and disconnect them.

Note. Ignore - arrows -.

Scheme 79

1. Remove bolts - 2 - and - 3 -.
2. Pull oil dipstick guide tube upward and off - arrow -.
3. Loosen hose clamps - 1 - and - 4 - and remove left coolant pipe from coolant hoses.

Scheme 80

1. Remove bolt - arrow - at left exhaust tract strap.

Scheme 81

1. Remove nuts - arrows -.

Scheme 82

1. Remove nuts in sequence - 9 to 1 - and remove left front exhaust manifold with catalytic converter.

1. Disconnect electrical harness connectors - 1 - and - 2 - for oxygen sensors.

Note. Electrical connectors are shown in the installation position in the illustration.

Scheme 83

1. Remove nuts in sequence - 6 to 1 - and remove left rear exhaust manifold with catalytic converter.

Scheme 84

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

Scheme 85

1. Remove bolts - 1 through 5 - and remove torque support bracket.

Scheme 86

1. Remove bolts - 2 - and - 3 -.
2. Loosen hose clamps - 1, 4, 5 - and remove right coolant pipe from coolant hoses.

Scheme 87

1. Remove bolt - arrow - at right exhaust tract strap.

Scheme 88

1. Remove nuts - arrows -.

Scheme 89

1. Remove nuts in sequence - 9 to 1 - and remove right front exhaust manifold with catalytic converter.

Scheme 90

1. Remove nuts in sequence - 6 to 1 - and remove right rear exhaust manifold with catalytic converter.

Scheme 91

1. Also place a support element from Support Set VAS 6131/10 at right rear of transmission as shown in illustration.

1. Fastening point on scissor lift table VAS 6131 A : "G15".

1. Rotate support element spindle upward until support pin comes into contact with support point.
2. Tighten support element base plate to 20 Nm on the scissor lift table VAS 6131 A.

Scheme 92

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

Scheme 93

1. Rotate left and right support element spindles - 2 - on subframe completely down.
2. Remove support pins from spindles.
3. Remove both base plates of the subframe support elements from Scissor Lift Table VAS 6131 A.
4. Remove subframe - 3 - to the side.

1. Rotate left and right support element spindles - 1 - on engine carrier - 4 - completely down.

Scheme 94

1. Remove engine bracket bolts at left and right - arrows -.
2. Remove engine carrier.
3. Remove both base plates of the subframe support elements from Scissor Lift Table VAS 6131 A.

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

Scheme 95

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

1. Equip Scissor Lift Table VAS 6131 A with Support Set VAS 6131/10 as well as 3 Adapters VAS 6131/10-12 as follows

Scheme 96

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

Scheme 97

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

Scheme 98

1. Remove left driveshaft heat shield from transmission - arrows -.

1. Remove coolant hoses - arrows -.

1. Remove left transmission mount heat shield - arrow -.

Scheme 99

1. Disconnect electrical connector at left on transmission by turning the twist lock counterclockwise - arrow -.
2. Free up wiring harness.

Scheme 100

1. Disconnect electrical connector - arrow - on Engine Speed (RPM) Sensor G28.
2. Free up electrical wiring.

Scheme 101

1. Remove electrical wiring bracket from right engine support - arrow -.

Scheme 102

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

Scheme 103

1. Insert Socket T40058 adapter so that small diameter - arrow 2 - points to engine. Large diameter - arrow 1 - points to socket.

Scheme 104

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

Note. Disregard - arrow -.

Scheme 105

1. Remove 6 torque converter bolts - arrows - in opening on removed starter (turn crankshaft 1 / 3 rotation in each case).

Scheme 106

1. Remove engine/transmission connecting bolts - 3 to 7 -.

Note. Ignore - A -.

Scheme 107

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, Securing to Engine and Transmission Holder

Special tools, testers and auxiliary items required

Scheme 108

1. Lifting tackle 3033
2. Engine and transmission holder VAS 6095 with bracket VAS 6095/1-7
3. Shop crane VAS 6100
4. Lift arm extension for workshop crane VAS 6101

Procedure

Scheme 109

1. Disconnect electrical harness connector - arrow - at left engine mount.
2. Remove bolts - 1 to 4 - and remove engine support from engine mount.
3. Disconnect electrical harness connector - arrow - at right engine mount.

Scheme 110

1. Remove bolts - 1, 2, 3 - and remove engine support from engine mount.

Scheme 111

1. Engage Lifting Tackle 3033 on engine lifting eyes and on Shop Crane VAS 6100 with Lift Arm Ext./Workshop Hoist VAS 6101 as shown in the illustration.
2. Lift engine from support elements of Scissor Lift Table VAS 6131 A.

Scheme 112

1. Secure the engine to the engine and transmission holder VAS 6095/1-7 using Holder VAS 6095 , and tighten to 40 Nm as shown in the illustration.

Engine, 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 with hose clamps appropriate for the model . During installation, reinstall all heat insulation sleeves and heat shields at the same locations. During installation, all cable ties must be re-installed at the same location.

1. Install left and right engine supports.
2. Make sure alignment sleeves for engine to transmission are installed in cylinder block. Install if necessary.

Scheme 113

1. On a vehicle with automatic transmission, check whether bearing bushing - arrow - is inserted at rear of crankshaft. Drive in bushing if necessary.

1. Before guiding the engine and transmission together, rotate the torque converter and the engine drive plate so the holes and the threaded holes are at the same height as the opening on the removed starter - arrows -.
2. Use new ribbed bolts to secure the torque converter to the drive plate .
3. Bolt transmission to engine.

Note. Tightening 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

Scheme 114

1. Before installing an exchanged engine, check whether O-ring - arrow - is inserted in power steering pump input shaft.
2. Install starter --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/s8/d3-2007-2011/remont/cruise-control-systems/#electrical-equipment) .
3. Always clean threaded driveshaft bores in transmission flanged shaft of locking fluid residue using a tap before installation.

1. Rotate attachment spindles at left of engine/transmission assembly downward.
2. Remove both left support element base plates from Scissor Lift Table VAS 6131 A.

1. Rotate attachment spindles at right of engine/transmission assembly downward.
2. Remove both right support element base plates from 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

1. Position subframe on both attachments VAS 6131/10-8.
2. Twist 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.

1. Tighten left and right transmission mount bolts - arrows -.

1. Remove additional support element VAS 6131/10-10 with VAS 6131/10-4 on right rear of transmission.
2. Install wiring harness and coolant hose system on engine/transmission assembly.
3. Install left drive shaft heat shield.
4. Install left exhaust system tract --> «Left Exhaust System Tract, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-exhaust-system-tract-removing-and) .

1. Install right exhaust system tract --> «Right Exhaust System Tract, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-exhaust-system-tract-removing-and) .
2. Install left coolant pipe --> «Left Coolant Pipe, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-coolant-pipe-removing-and-installing) .
3. Install right coolant pipe --> «Right Coolant Pipe, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-coolant-pipe-removing-and-installing) .
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 - = max. 300 mm.

1. Install selector lever cable and check adjustment if necessary --> «37 - CONTROLS, HOUSING»(/audi/s8/d3-2007-2011/remont/automatic-trans/#6-speed-automatic-transmission-09e-awd) .

1. Align subframe according to the markings on the longitudinal members.
2. Tighten bolts for subframe only to specified torque. Do not tighten further (tighten bolts only after axle alignment).

1. 50 Nm
2. 150 Nm
3. 150 Nm

1. Tighten bolts - 4 - for engine carrier.

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

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

1. Install driveshaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/s8/d3-2007-2011/remont/differentials-drive-axles/#rear-final-drive-0ar) .
2. Align exhaust system --> «Exhaust System, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__exhaust-system-installing) .
3. Install driveshafts --> «40 - FRONT SUSPENSION»(/audi/s8/d3-2007-2011/remont/axle-shafts/#suspension-wheels-and-steering) .
4. Install guide control arm, control arm and stabilizer --> «40 - FRONT SUSPENSION»(/audi/s8/d3-2007-2011/remont/axle-shafts/#suspension-wheels-and-steering) .

1. Install refrigerant lines --> «87 - AIR CONDITIONING»(/audi/s8/d3-2007-2011/remont/automatic-hvac-system/#refrigerant-r134a-servicing) .
2. Install right cylinder head cover --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-cylinder-head-cover-removing-and) .
3. Install suspension strut crossmember --> «40 - FRONT SUSPENSION»(/audi/s8/d3-2007-2011/remont/axle-shafts/#suspension-wheels-and-steering) .

Scheme 115

1. Before tightening specifications support, adjust torque support mount.
2. Turn adjustment ring - 1 - counter-clockwise until it comes into contact with torque support bracket.
3. Then, turn adjustment ring one rotation clockwise again.

1. Tighten bolt - arrow - on torque support mount.
2. Electrical connections and routing --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.
3. Observe safety precautions after connecting battery --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/s8/d3-2007-2011/remont/cruise-control-systems/#electrical-equipment) .
4. Install wiper arms and adjust --> «92 - WINDSHIELD WIPER AND WASHER SYSTEM»(/audi/s8/d3-2007-2011/remont/cruise-control-systems/#electrical-equipment) .

1. Before starting engine for the first time, fill power steering vacuum reservoir with hydraulic oil.

Note. Power-steering pump must not run dry.

1. Check oil level --> «Oil Level, Checking»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-level-checking) .
2. Fill with coolant --> Filling under «Cooling System, Draining and Filling»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__cooling-system-draining-and-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/s8/d3-2007-2011/remont/automatic-hvac-system/#refrigerant-r134a-servicing) .
2. Perform alignment --> «44 - WHEELS, TIRES AND WHEEL ALIGNMENT»(/audi/s8/d3-2007-2011/remont/axle-shafts/#suspension-wheels-and-steering) .

Tightening Specifications

Note. Tightening 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%.

Servicing, Belt Pulley Side

> Ribbed Belt Drive, Component Overview

> Ribbed Belt, Removing and Installing

> Vibration Damper, Removing and Installing

> Crankshaft Seal, Belt Pulley Side, Replacing

Scheme 116

1 - 22 Nm

2 - 22 Nm

3 - Tensioning device for ribbed belt

4 - 22 Nm

5 - Generator

1. Removing and installing --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/s8/d3-2007-2011/remont/cruise-control-systems/#electrical-equipment)

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/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__vibration-damper-removing-and-installing)

12 - Bolt

1. Replace
2. Only use original equipment bolts, Bolt class 12.9
3. Insert bolts that are not self-locking with locking compound; Locking compound .
4. Tightening order --> «Vibration Damper, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__vibration-damper-removing-and-installing)

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. A reversed turning in direction can cause damage to the ribbed belt under operating conditions
4. Removing and installing --> «Ribbed Belt, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__ribbed-belt-removing-and-installing)

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

17 - Threaded bushing

Ribbed Belt, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 117

1. Torque Wrench V.A.G 1332

Scheme 118

1. Socket AF 16 mm V.A.G 1332/14

Removing

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

1. Remove hood seal from lock carrier and from fender edges.
2. Disconnect vacuum hoses - 1 - and - 2 - and free them up.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and remove front noise insulation.

Scheme 119

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

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

Installing

Installation is in reverse order of removal, note the following

Scheme 120

1. Place ribbed belt - 2 - over belt pulley in the specified sequence.

1 - Generator

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 121

1. Position torque wrench with the 16 mm socket V.A.G 1332/14 on the tensioning roller hex head and tension the ribbed belt to 70 Nm.
2. At the same time, tighten the tensioning bolt - arrow - to 25 Nm.
3. Start engine and check running belt.

Vibration Damper, Removing and Installing

Removing

1. Drain coolant --> «Cooling System, Draining and Filling»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__cooling-system-draining-and-filling) .
2. Remove radiator --> «Radiator, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__radiator-removing-and-installing) .
3. Remove fan shroud --> «Fan Shroud, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__fan-shroud-removing-and-installing) .

Scheme 122

1. Loosen 8 bolts - arrow - on vibration damper several turns by counterholding on generator belt pulley central nut with open end wrench.

Note. Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the ribbed 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 the vibration damper bolts with new original bolts . Insert bolts that are not self-locking with locking compound; Locking compound . The vibration damper can only be installed in one position - note the alignment bushing.

1. Tighten vibration damper bolts - arrow - diagonally in 3 stages.
2. Using torque wrench, tighten to 15 Nm.
3. Using torque wrench, tighten to 22 Nm.
4. With Torx key, 90 ( 1 / 4 turn) additional turn.
5. Install ribbed belt --> «Ribbed Belt, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__ribbed-belt-removing-and-installing) .
6. Install fan shroud --> «Fan Shroud, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__fan-shroud-removing-and-installing) .
7. Install radiator --> «Radiator, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__radiator-removing-and-installing) .
8. Fill with coolant --> Filling under «Cooling System, Draining and Filling»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__cooling-system-draining-and-filling) .

Crankshaft Seal, Belt Pulley Side, Replacing

Special tools, testers and auxiliary items required

Scheme 123

1. Seal remover T40019

Scheme 124

1. Assembly tool T40048

Procedure

1. Drain coolant --> «Cooling System, Draining and Filling»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__cooling-system-draining-and-filling) .
2. Remove radiator --> «Radiator, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__radiator-removing-and-installing) .
3. Remove fan shroud --> «Fan Shroud, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__fan-shroud-removing-and-installing) .
4. Remove vibration damper --> «Vibration Damper, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__vibration-damper-removing-and-installing) .

Scheme 125

1. Position inner part of Oil Seal Extractor T40019 flush with outer part and secure inner part with knurled thumb screw.
2. Lubricate threaded head of the seal remover, place against seal, and with strong force screw into the seal as far as possible.
3. Loosen knurled screw and turn inner portion against crankshaft until oil seal is pulled out.
4. Tension seal extractor in a vise at mounting points and remove seal with pliers.

1. Clean operating and sealing surfaces.

Scheme 126

1. Position assembly device T40048/1 on pull sleeve T40048/2 and slide seal - A - onto pull sleeve.
2. Remove assembly device.

Scheme 127

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 128

1. Position pressure sleeve T40048/3 with 2 M8x55 mm bolts - arrows - on crankshaft.
2. Then install 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/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__vibration-damper-removing-and-installing) .
2. Install ribbed belt --> «Ribbed Belt, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__ribbed-belt-removing-and-installing) .
3. Install fan shroud --> «Fan Shroud, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__fan-shroud-removing-and-installing) .
4. Install radiator --> «Radiator, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__radiator-removing-and-installing) .

1. Fill with coolant --> Filling under «Cooling System, Draining and Filling»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__cooling-system-draining-and-filling) .

Servicing, Timing Chain Side

> Drive Plate, Component Overview

> Drive Plate, Removing and Installing

> Crankshaft Seal, Timing Chain Side, Replacing

> Timing Chain Covers, Component Overview

> Left and Right Timing Chain Covers, Removing and Installing

> Lower Timing Chain Cover, Removing and Installing

> Camshaft Timing Chain, Component Overview

> Camshaft Timing Chain, Removing from Camshaft

> Camshaft Timing Chain, Removing and Installing

> Timing Mechanism Drive Chain, Component Overview

> Timing Mechanism Drive Chain, Removing and Installing

> Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Component Overview

> Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing

> Power Take-Off, Component Overview

> Power Take-Off Seals, Replacing

> Spur Gear Unit, Removing and Installing

> Balancing Shaft, Component Overview

> Balancing Shaft, Removing and Installing

Scheme 129

1 - Drive plate

1. Removing and installing --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing)
2. Mark for re-installation

2 - Washer

1. 3.4 mm thick
2. Mark for re-installation

3 - 60 Nm plus additional 90 ( 1 / 4 turn)

1. Replace

4 - Crankshaft

5 - Centering bushing

1. For torque converter
2. Check availability

6 - Crankshaft seal, timing chain side

1. Replacing --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__crankshaft-seal-timing-chain-side-replacing) .

7 - Spacer washer

1. 1.5 mm thick
2. Mark for re-installation

Drive Plate, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 130

1. Counter-holder tool 10 - 201

Removing

1. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
2. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-and-transmission-separating) .
3. Leave engine on scissor lift table VAS 6131 A or secure engine to the engine and transmission holder --> «Engine, Securing to Engine and Transmission Holder»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-securing-to-engine-and-transmission) .

Scheme 131

1. Insert counterhold tool 10 - 201 to loosen bolts.
2. Mark installation position on drive plate to crankshaft using a felt-tip marker.
3. Remove drive plate.
4. Remove spacer washer behind.

Installing

Installation is in reverse order of removal, note the following

1. Install drive plate with spacer washer.
2. Use new bolts when securing.
3. Turn over counterhold tool 10 - 201 to tighten bolts.
4. Install engine --> «Engine, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-installing) .

Tightening specifications

Crankshaft Seal, Timing Chain Side, Replacing

Special tools, testers and auxiliary items required

Scheme 132

1. Pulling fixture T10122

Scheme 133

1. Extractor hook T20143

Procedure

1. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
2. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-and-transmission-separating) .
3. Leave engine on scissor lift table VAS 6131 A or secure engine to the engine and transmission holder --> «Engine, Securing to Engine and Transmission Holder»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-securing-to-engine-and-transmission) .
4. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .

Scheme 134

1. Pry out sealing ring using pulling hook T20143/2.
2. Clean operating and sealing surfaces.

Scheme 135

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

Scheme 136

1. Install pull sleeve T10122/2 with seal - 1 - on crankshaft.

Scheme 137

1. Press seal evenly and flush all around with thrust piece T10122/3.

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

1. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .
2. Install engine --> «Engine, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-installing) .

Scheme 138

1 - Bolt

1. M6 - 8 Nm plus an additional 90 ( 1 / 4 turn); replace
2. M8 - 22 Nm
3. Note tightening sequence --> see scheme 185.

2 - Crankshaft seal, timing chain side

1. Replacing --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__crankshaft-seal-timing-chain-side-replacing) .

3 - Alignment bushing

1. 2 pieces

4 - Left cylinder head gasket

5 - 9 Nm

1. Observe sequence when tightening: Left --> see scheme 171; right --> see scheme 173.

6 - Left timing chain cover

1. Removing and installing --> «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-and-right-timing-chain-covers)

7 - O-ring

1. Replace

8 - Left coolant intermediate pipe

1. Drive out with suitable drift

9 - O-ring

1. Replace

10 - 9 Nm

1. Note tightening sequence --> see scheme 173.

11 - Right timing chain cover

1. Removing and installing --> «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-and-right-timing-chain-covers)

12 - O-ring

1. Replace

13 - Right coolant intermediate pipe

1. Drive out with suitable drift

14 - O-ring

1. Replace

15 - Right cylinder head gasket

16 - Alignment bushing

1. 2 pieces

17 - Lower timing chain cover

1. Removing and installing --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__lower-timing-chain-cover-removing-and)

Left and Right Timing Chain Covers, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 139

1. Hose clamp pliers V.A.G 1921
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Sealant

Removing

Note. During installation, reinstall all heat insulation sleeves and heat shields at the same locations. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

1. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
2. Leave engine with transmission installed on the scissor lift platform VAS 6131 A.

1. Remove bolts - 2 - and - 3 -.
2. Pull oil dipstick guide tube upward and off - arrow -.
3. Loosen hose clamps - 1 - and - 4 - and remove left coolant pipe from coolant hoses.

1. Remove bolts - 2 - and - 3 -.
2. Loosen hose clamps - 1, 4, 5 - and remove right coolant pipe from coolant hoses.

Scheme 140

1. Remove nuts - 2 - and - 4 - and remove connector bracket from rear coolant pipe.
2. Free up engine wiring harness on rear coolant pipe.
3. Disconnect electrical connector - 3 - on Engine Coolant Temperature (ECT) Sensor G62.
4. Disconnect coolant hose - 5 - from rear coolant pipe.

1. Remove screws - 1 - and - 6 - and remove rear coolant pipe.

Scheme 141

1. Remove screws - 1 to 8 - and remove left timing chain cover.

Scheme 142

1. Remove screws - 1 to 8 - and remove right timing chain cover.

Installing

Note. Replace O-rings. Secure all hose connections with hose clamps appropriate for the model . During installation, reinstall all heat insulation sleeves and heat shields at the same locations. During installation, all cable ties must be re-installed at the same location.

Scheme 143

1. Remove sealant residue on timing chain covers and cylinder head, e.g. with a rotating plastic brush.

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

Scheme 144

1. Cut off nozzle on the tube of sealant at the front mark (diameter of nozzle approximately 2 mm).

Scheme 145

1. Drive left coolant intermediate pipe - 2 - out of left timing chain cover with a suitable drift.
2. Replace O-rings - 1 - at coolant intermediate pipe - 2 -.
3. Insert coolant intermediate pipe in left timing chain cover.
4. Apply sealant bead - arrow - on clean sealing surfaces of left timing chain cover, as shown in illustration.

1. Thickness of sealant bead: 2.5 mm.

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

1. Position left timing chain cover and tighten screws in sequence - 1 to 8 -.

1. Drive right coolant intermediate pipe - 2 - out of right timing chain cover with a suitable drift.
2. Replace O-rings - 1 - at coolant intermediate pipe - 2 -.
3. Insert coolant intermediate pipe in right timing chain cover.
4. Apply sealant bead - arrows - on clean sealing surfaces of right timing chain cover, as shown in illustration.

1. Thickness of sealant bead: 2.5 mm.

1. Position right timing chain cover and tighten screws in sequence - 1 to 8 -.

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

1. Install rear coolant pipe --> «Rear Coolant Pipe, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__rear-coolant-pipe-removing-and-installing) .
2. Install left coolant pipe --> «Left Coolant Pipe, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-coolant-pipe-removing-and-installing) .
3. Install right coolant pipe --> «Right Coolant Pipe, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-coolant-pipe-removing-and-installing) .
4. Install engine --> «Engine, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-installing) .

Tightening specifications

Lower Timing Chain Cover, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 146

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. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
4. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-and-transmission-separating) .

1. Leave engine on scissor lift table VAS 6131 A or secure engine to the engine and transmission holder --> «Engine, Securing to Engine and Transmission Holder»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-securing-to-engine-and-transmission) .
2. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .
3. Remove left and right timing chain covers --> «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-and-right-timing-chain-covers) .
4. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .

1. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .

Scheme 147

1. Remove bolts - arrows -.
2. Remove screws - 1 to 13 - and remove lower timing chain cover.
3. Press crankshaft seal timing chain side out of lower timing chain cover.

Installing

Installation is in reverse order of removal, note the following

1. Pull alignment bushing out of top right of cylinder block.

Scheme 148

1. Chamfer alignment bushing with a file, as shown in the illustration.

1. Dimension - x - = 6.5 mm.
2. Dimension - y - = 8 mm.

1. Install alignment bushing into cylinder block so that the chamfered side faces upward.

Note. The chamfer simplifies installation of the lower timing chain cover with cylinder head installed.

1. Remove sealant residue in timing chain cover and cylinder block, e.g. with a rotating plastic brush.

1. Clean sealing surfaces so they are completely free of any oil or grease.

Scheme 149

1. Clean old sealant from holes - arrow - in the cylinder head gaskets.

Note. With the cylinder head installed only half of the holes in the cylinder head gasket are visible.

Scheme 150

1. Bend ends of the cylinder head gaskets very slightly downward - arrows - until upper sealing surface of the gasket and cylinder head can be cleaned.
2. Clean both cylinder head gaskets, top and bottom, so they are completely free of any oil or grease.

1. Cut off nozzle on the tube of sealant at the front mark (diameter of nozzle approximately 2 mm).

1. Coat sealing surfaces of the cylinder head gaskets, top and bottom, with a thin layer of sealant, to do this, slightly bend the cylinder head gaskets downward again - arrows -.
2. To coat the surface between the cylinder head and gasket, use a flat object, e.g. a feeler gauge.

Scheme 151

1. Apply sealant beads - 1 to 9 - on clean sealing surfaces of lower timing chain cover, as shown in illustration.

1. Thickness of sealant beads: 2.5 mm.

Note. Timing chain cover must be installed within 5 minutes of applying sealant.

1. Set lower timing chain cover in place, guiding cover at an angle from below onto cylinder block sealing surface and cylinder head.

1. Tighten bolts in 6 stages as follows
2. Tighten bolts - arrows - to 5 Nm using a torque wrench.
3. Tighten bolts - 1 to 13 - in a diagonal sequence to 8 Nm using a torque wrench.
4. Tighten bolts - arrows - to 8 Nm using a torque wrench.

1. Tighten bolts - 2, 4, 8, 9, 10 - in a diagonal sequence to 22 Nm using a torque wrench.
2. Tighten bolts - 1, 3, 5, 6, 7, 11, 12, 13 - an additional 90 ( 1 / 4 turn) in a diagonal sequence using a rigid wrench.
3. Tighten bolts - arrows - 90 ( 1 / 4 additional turn) using a rigid wrench.

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/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__crankshaft-seal-timing-chain-side-replacing) .
2. Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
3. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .
4. Install left and right timing chain covers --> Installing under «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .

1. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .
2. Install engine --> «Engine, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-installing) .
3. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-level-checking) .

Tightening Specifications

Scheme 152

1 - Camshaft adjuster for exhaust camshaft

1. Identification "Exhaust"
2. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-and-installing)

2 - Camshaft bolt

1. Replace
2. Initial tightening specifications: 60 Nm
3. Final tightening specifications: 80 Nm plus an additional 90 ( 1 / 4 turn)

3 - Camshaft bolt

1. Replace
2. Initial tightening specifications: 60 Nm
3. Final tightening specifications: 80 Nm plus an additional 90 ( 1 / 4 turn)

4 - Camshaft adjuster for intake camshaft

1. Identification "Intake"
2. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-and-installing)

5 - Left camshaft timing chain

1. Before removing, mark direction of rotation with paint. Reversing the rotation direction of a used chain can destroy it
2. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-and-installing)

6 - 5 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

7 - Guide piece

8 - Chain tensioner for left camshaft timing chain

1. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-and-installing)

9 - Oil strainer

1. Set into chain tensioner
2. Observe locating tabs on circumference

10 - Gasket

1. Replace
2. Clipped onto chain tensioner

11 - Mounting bracket for drive sprocket

12 - 9 Nm

13 - Drive sprocket for left camshaft timing chain

14 - Thrust washer for drive sprocket

15 - 22 Nm

Scheme 153

1 - Pivot pin for drive sprocket

1. For right camshaft timing chain
2. Asymmetrical version
3. Installed location --> «Location of mounting pins for camshaft timing chain drive sprocket»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

2 - 42 Nm

3 - Camshaft adjuster for exhaust camshaft

1. Identification "Exhaust"
2. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-and-installing)

4 - Camshaft bolt

1. Replace
2. Initial tightening specifications: 60 Nm
3. Final tightening specifications: 80 Nm plus an additional 90 ( 1 / 4 turn)

5 - Camshaft bolt

1. Replace
2. Initial tightening specifications: 60 Nm
3. Final tightening specifications: 80 Nm plus an additional 90 ( 1 / 4 turn)

6 - Camshaft adjuster for intake camshaft

1. Identification "Intake"
2. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-and-installing)

7 - Right camshaft timing chain

1. Before removing, mark direction of rotation with paint. Reversing rotation direction of a used chain can destroy it
2. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-and-installing)

8 - Chain tensioner for right camshaft timing chain

1. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-and-installing)

9 - Guide piece

10 - Oil strainer

1. Set into chain tensioner
2. Installation position: Observe locating tabs on circumference

11 - Gasket

1. Replace
2. Clipped onto the chain tensioner

12 - 5 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

13 - Thrust washer for drive sprocket

14 - Drive sprocket for right camshaft timing chain

Scheme 154

1. Alignment bushings in right camshaft timing chain drive sprocket mounting pins - 3 - must engage in holes in thrust washer - 1 - and cylinder block.

2 - Drive sprocket for right camshaft timing chain

4 - Bolt - 42 Nm

Camshaft Timing Chain, Removing from Camshaft

Special tools, testers and auxiliary items required

Scheme 155

1. Locking pin 3242
2. Torque Wrench V.A.G 1332
3. Assembly tool V.A.G 1332/9
4. Adapter T40058

1. Camshaft locator T40070 (qty. 2)
2. Securing pin T40071 (qty. 2)

Special tools, testers and auxiliary items required

Scheme 156

1. Wrench T40079

Removing

Note. According to the following description, the timing chains for camshafts remain on engine.

1. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
2. Leave engine with transmission installed on the scissor lift platform VAS 6131 A.
3. Remove cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-cylinder-head-cover-removing-and) .
4. Remove left and right timing chain covers --> «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-and-right-timing-chain-covers) .

1. Insert Socket T40058 adapter so that small diameter - arrow 2 - points to engine. Large diameter - arrow 1 - points to socket.

1. Using Socket T40058 , rotate crankshaft in direction of engine rotation - arrow - to "TDC".

Scheme 157

1. The threaded holes - arrows - in the camshafts must face upward.

Scheme 158

1. Mount camshaft locating tool T40070 on both cylinder heads and tighten bolts - arrows - to 25 Nm.

1. The camshaft locating tool T40070 is correctly positioned when the holes for the cylinder head bolts remain free.

Scheme 159

1. Remove locking bolt - arrow - from upper part of oil pan.

Scheme 160

1. Install crankshaft holder 3242 in the hole and tighten to 20 Nm. If necessary, rotate the crankshaft back and forth slightly to completely center the holder.

Scheme 161

1. Press left camshaft timing chain tensioner glide track inward with a screwdriver - 1 - as far as stop and secure chain tensioner with Locking Pin T40071.

Note. The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.

Scheme 162

1. Press right camshaft timing chain tensioner glide track inward with a screwdriver - 1 - as far as stop and secure chain tensioner with Locking Pin T40071.

Note. The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.

Scheme 163

1. For re-installation, identify installation location of camshaft adjuster with paint.
2. Remove bolts - 1 - and - 2 - on left cylinder head and remove both camshaft adjusters.

Scheme 164

1. For re-installation, identify installation location of camshaft adjuster with paint.
2. Remove bolts - 1 - and - 2 - on right cylinder head and remove both camshaft adjusters.

Installing

Note. Replace bolts which have been tightened to torque.

Scheme 165

1. Drive chain for timing mechanism installed --> «Timing Mechanism Drive Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__timing-mechanism-drive-chain-removing-and) .
2. Secure crankshaft in "TDC" position using Crankshaft Holder 3242.

1. Camshaft Clamp T40070 mounted on both cylinder heads and fastened to 25 Nm - arrows -.

Note. Reinstall left camshaft adjuster according to the mark applied during removal.

1. Replace camshaft bolts.
2. Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in bolts - 1 - and - 2 -.

1. Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

1. Remove Locking Pin T40071.

Note. Reinstall right camshaft adjuster according to the mark applied during removal.

1. Replace camshaft bolts.
2. Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in the bolts - 1 - and - 2 -.

1. Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

1. Remove Locking Pin T40071.

Scheme 166

Note. A 2nd technician is needed for further work.

1. Position Key T40079 on intake camshaft adjuster at left cylinder head.
2. Position Torque Wrench V.A.G 1332 with Open Ring Spanner Insert V.A.G 1332/9 on Key T40079.
3. Pre-tension camshaft adjuster in direction of - arrow - to 40 Nm and maintain tension.
4. Tighten bolts - 1 - on exhaust camshaft simultaneously to initial torque.

1. Tightening Specifications 60 Nm.

1. Continue holding pretension on exhaust camshaft and pre-torque bolt - 2 - on exhaust camshaft.

1. Tightening Specifications: 60 Nm.

Scheme 167

1. Position Key T40079 on exhaust camshaft adjuster at right cylinder head.
2. Position Torque Wrench V.A.G 1332 with Open Ring Spanner Insert V.A.G 1332/9 on Key T40079.
3. Pre-tension camshaft adjuster in direction of - arrow - to 40 Nm and maintain the tension.
4. Tighten bolts - 1 - on intake camshaft simultaneously to initial torque.

1. Tightening Specifications: 60 Nm.

1. Continue holding pretension on exhaust camshaft and pre-torque bolt - 2 - on exhaust camshaft.

1. Tightening Specifications: 60 Nm.

1. Remove Key T40079.
2. Remove Camshaft Clamps T40070 on both cylinder heads - arrows -.

Scheme 168

1. First tighten camshaft bolt - 1 - and then camshaft bolt - 2 - on left cylinder head to final torque.

1. Tightening Specifications: 80 Nm plus an additional 90 ( 1 / 4 turn).

Scheme 169

1. First tighten camshaft bolt - 1 - and then camshaft bolt - 2 - on right cylinder head to final torque.

1. Tightening Specifications 80 Nm plus an additional 90 ( 1 / 4 turn).

1. Remove crankshaft holder 3242.

1. Using Socket T40058 turn crankshaft two complete rotations in direction of engine rotation - arrow - until crankshaft stands at "TDC" again.

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

1. The threaded holes - arrows - in the camshafts must face upward.

1. Mount camshaft locating tool T40070 on both cylinder heads and tighten bolts - arrows - to 25 Nm.

1. The camshaft locating tool T40070 is correctly positioned when the holes for the cylinder head bolts remain free.

1. Install crankshaft holder 3242 in the bore or groove and tighten it to 20 Nm.

1. The crankshaft holder 3242 must engage in the locating hole or groove on the crankshaft - 1 -. Repeat adjustment if it does not.

1. Remove camshaft locating tools on both cylinder heads.
2. Remove crankshaft holder 3242.
3. Install "TDC" mark sealing plug with new seal in upper part of oil pan.

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

1. Install left and right timing chain covers --> Installing under «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
2. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-cylinder-head-cover-removing-and) .
3. Install engine --> «Engine, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-installing) .

Tightening Specifications

Camshaft Timing Chain, Removing and Installing

Special tools, testers and auxiliary items required

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

Removing

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
4. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-and-transmission-separating) .

1. Leave engine on scissor lift table VAS 6131 A or secure engine to the engine and transmission holder --> «Engine, Securing to Engine and Transmission Holder»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-securing-to-engine-and-transmission) .
2. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .
3. Remove cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-cylinder-head-cover-removing-and) .
4. Remove left and right timing chain covers --> «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-and-right-timing-chain-covers) .

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .
2. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
3. Remove lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__lower-timing-chain-cover-removing-and) .
4. Remove camshaft timing chains from camshafts --> «Camshaft Timing Chain, Removing from Camshaft»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-from-camshaft) .

Scheme 170

1. Mark running direction of left camshaft timing chain with paint.
2. Remove bolts - 1 - and - 2 - and remove left chain tensioner and left camshaft timing chain.

Scheme 171

1. Mark running direction of right camshaft timing chain with paint.
2. Remove bolts - 1 - and - 2 - and remove right chain tensioner and right camshaft timing chain.

Installing

Note. If the tensioning element is to be removed from the chain tensioner, observe the installed position: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail. Replace bolts which have been tightened to torque.

Scheme 172

1. Press left and right camshaft timing chain guide rail inward - arrow - as far as stop and secure chain tensioner with Locking Pin T40071.

Scheme 173

1. Clean oil strainer - 2 - in both chain tensioners if necessary.
2. Place a new gasket - 3 - onto rear of the chain tensioner - 1 -.

1. Insert chain tensioner in left cylinder head and position camshaft timing chain according to mark applied during removal, as shown in illustration.
2. Tighten bolts - 1 - and - 2 -.

1. Insert chain tensioner in right cylinder head and position camshaft timing chain according to mark applied during removal, as shown in illustration.
2. Tighten bolts - 1 - and - 2 -.

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

1. Position camshaft timing chains on camshafts --> Installing under «Camshaft Timing Chain, Removing from Camshaft»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
2. Install lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__lower-timing-chain-cover-removing-and) .
3. Install crankshaft seal, timing chain side --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__crankshaft-seal-timing-chain-side-replacing) .
4. Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .

1. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .
2. Install left and right timing chain covers --> Installing under «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
3. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-cylinder-head-cover-removing-and) .
4. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .

1. Install engine --> «Engine, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-installing) .
2. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-level-checking) .

Tightening specifications

Scheme 174

1 - Guide rail

2 - 10 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

3 - 22 Nm

4 - Thrust washer for drive sprocket

5 - Drive sprocket for left timing chain

6 - 10 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

7 - Timing Mechanism Drive Chain

1. Before removing, mark direction of rotation with paint. Reversing the rotation direction of a used chain can destroy it.
2. Removing and installing --> «Timing Mechanism Drive Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__timing-mechanism-drive-chain-removing-and)

8 - Guide rail

9 - 10 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

10 - 9 Nm

11 - Pivot pin for drive sprocket

1. For right camshaft timing chain
2. Asymmetrical version
3. Installed location --> «Location of mounting pins for the camshaft timing chain drive sprocket»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__location-of-mounting-pins-for-the)

12 - Thrust washer

13 - Drive sprocket for right timing chain

14 - Pivot pin for drive sprocket

15 - 42 Nm

16 - O-ring

1. Replace

17 - Chain tensioner

18 - 5 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

19 - Crankshaft

20 - 10 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

Location of mounting pins for the camshaft timing chain drive sprocket

1. Alignment bushings in right camshaft timing chain drive sprocket mounting pins - 3 - must engage in holes in thrust washer - 1 - and cylinder block.

2 - Drive sprocket for right camshaft timing chain

4 - Bolt - 42 Nm

Timing Mechanism Drive Chain, Removing and Installing

Special tools, testers and auxiliary items required

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

Scheme 175

1. Securing pin T40071

Removing

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
4. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-and-transmission-separating) .

1. Leave engine on scissor lift table VAS 6131 A or secure engine to the engine and transmission holder --> «Engine, Securing to Engine and Transmission Holder»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-securing-to-engine-and-transmission) .
2. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .
3. Remove cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-cylinder-head-cover-removing-and) .
4. Remove left and right timing chain covers --> «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-and-right-timing-chain-covers) .

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .
2. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
3. Remove lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__lower-timing-chain-cover-removing-and) .
4. Remove camshaft timing chains --> «Camshaft Timing Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-and-installing) .

1. Remove oil pump drive chain and balance shaft --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__power-take-off-oil-pump-and-balancing) .

Scheme 176

1. Push drive chain tensioner guide rail in direction of - arrow - and secure chain tensioner using Locking Pin T40071.
2. Mark drive chain running direction with paint.
3. Remove bolts - 1 - and remove guide rail.
4. Remove bolts - 2 to 4 - and remove chain tensioner.

1. Remove timing mechanism drive chain.

Installing

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque.

1. Route timing mechanism drive chain according to marks applied to drive chain sprockets during removal.
2. Install guide rail and tighten bolts - 1 -.
3. Install chain tensioner and tighten screws - 2 -.
4. Press drive chain tensioner guide rail in direction of - arrow - and remove Locking Pin T40071 from chain tensioner.

1. Install oil pump drive chain and balance shaft --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__power-take-off-oil-pump-and-balancing) .
2. Install camshaft timing chains --> Installing under «Camshaft Timing Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-and-installing) .
3. Install lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__lower-timing-chain-cover-removing-and) .
4. Install crankshaft seal, timing chain side --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__crankshaft-seal-timing-chain-side-replacing) .

1. Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
2. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .
3. Install left and right timing chain covers --> Installing under «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
4. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-cylinder-head-cover-removing-and) .

1. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .
2. Install engine --> «Engine, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-installing) .
3. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-level-checking) .

Tightening Specifications

Scheme 177

1 - 9 Nm

2 - Chain tensioner

1. With glide track

3 - Gasket

1. Replace

4 - Spring

5 - 42 Nm

6 - Chain sprocket for balance shaft

7 - Bearing cap

8 - Differential shaft

1. Removing and installing --> «Balancing Shaft, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__balancing-shaft-removing-and-installing)

9 - 9 Nm

10 - Drive chain for power take-off, oil pump and balance shaft

1. Before removing, mark direction of rotation with paint. Reversing the rotation direction of a used chain can destroy it.
2. Removing and installing --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__power-take-off-oil-pump-and-balancing)

11 - Crankshaft

12 - Drive chain for power take-off and oil pump

13 - Circlip

Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 178

1. Locking pin 3242
2. Old oil collecting and extracting device V.A.G 1782
3. Adapter T40058
4. Securing pin T40071

1. Setting gauge T40128

Removing

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
4. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-and-transmission-separating) .

1. Leave engine on scissor lift table VAS 6131 A or secure engine to the engine and transmission holder --> «Engine, Securing to Engine and Transmission Holder»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-securing-to-engine-and-transmission) .

1. Insert Socket T40058 adapter so that small diameter - arrow 2 - points to engine. Large diameter - arrow 1 - points to socket.

1. Using Socket T40058 , rotate crankshaft in direction of engine rotation - arrow - to "TDC".

1. Remove locking bolt - arrow - from upper part of oil pan.

1. Install crankshaft holder 3242 in the hole and tighten to 20 Nm. If necessary, rotate crankshaft back and forth slightly to completely center the holder.
2. Remove vibration damper --> «Vibration Damper, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__vibration-damper-removing-and-installing) .
3. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .
4. Remove left and right timing chain covers --> «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-and-right-timing-chain-covers) .

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .
2. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
3. Remove lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__lower-timing-chain-cover-removing-and) .

Scheme 179

1. Mark running direction of power take-off chain with paint.
2. Press tensioning rail in direction of - arrow - and secure chain tensioner with Locking Pin T40071.
3. Remove bolt - 1 - and remove balance shaft chain sprocket.
4. Remove bolts - 2, 3, 4 - and remove chain tensioner.

1. Remove drive chain for power take-off, oil pump and balance shaft.

Installing

Installation is in reverse order of removal, note the following

Note. Replace gaskets, seal and O-rings.

1. Secure crankshaft - 1 - in "TDC" position using crankshaft holder 3242.

Scheme 180

1. Remove bolts - 2 - and - 4 -.
2. Remove balance shaft cover.
3. Remove bolts - 1 - and - 3 -.

Note. Balance shaft front bearing cap remains installed.

Scheme 181

1. Position setting gauge T40128 on balance shaft front bearing cap.

1. Rib on setting gauge T40128 must engage in groove on balance shaft.

1. Fasten setting gauge T40128 to cylinder block with 2 M6x30 bolts - arrows -.

1. Route drive chain for power-take off, oil pump and balance shaft according to marks made during removal.
2. Install chain tensioner and tighten bolts - 2, 3, 4 -.
3. Place drive chain on balance shaft chain sprocket and tighten bolt - 1 -.

1. Remove setting gauge T40128.
2. Tighten bolts - 1 - and - 3 -.
3. Replace balance shaft cover O-ring.
4. Tighten bolts - 2 - and - 4 - on balance shaft cover.

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

1. Install lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__lower-timing-chain-cover-removing-and) .
2. Install crankshaft seal, timing chain side --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__crankshaft-seal-timing-chain-side-replacing) .
3. Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
4. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .

1. Install left and right timing chain covers --> Installing under «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
2. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .
3. Install vibration damper --> «Vibration Damper, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__vibration-damper-removing-and-installing) .
4. Install engine --> «Engine, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-installing) .

1. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-level-checking) .

Tightening Specifications

Scheme 182

1 - Circlip

2 - Spur gear unit

1. Removing and installing --> «Spur Gear Unit, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__spur-gear-unit-removing-and-installing)

3 - 22 Nm

4 - Sealing ring for A/C compressor drive

1. Replacing --> «Power Take-Off Seals, Replacing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__power-take-off-seals-replacing) .

5 - Dust seal cap for A/C compressor drive

6 - Clamp

7 - Drive shaft for A/C compressor

1. Tighten to 60 Nm.

8 - O-ring

1. Replace

9 - Power-steering pump

10 - O-ring

1. Replace

11 - Drive shaft for oil pump

12 - Sealing ring for power-steering pump drive

1. Replacing --> «Power Take-Off Seals, Replacing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__power-take-off-seals-replacing) .

13 - Spring

Power Take-Off Seals, Replacing

Special tools, testers and auxiliary items required

Scheme 183

1. Extractor hook T20143
2. Pressure piece T40051
3. Pressure piece T40052

Procedure

1. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
2. Remove air conditioning compressor --> «87 - AIR CONDITIONING»(/audi/s8/d3-2007-2011/remont/automatic-hvac-system/#refrigerant-r134a-servicing) .
3. Remove power steering pump --> «48 - STEERING»(/audi/s8/d3-2007-2011/remont/axle-shafts/#suspension-wheels-and-steering) .

Scheme 184

1. Pry out A/C compressor drive seal using pulling hook T20143/1.

Scheme 185

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

Scheme 186

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

Scheme 187

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 power steering pump --> «48 - STEERING»(/audi/s8/d3-2007-2011/remont/axle-shafts/#suspension-wheels-and-steering) .
2. Install A/C compressor --> «87 - AIR CONDITIONING»(/audi/s8/d3-2007-2011/remont/automatic-hvac-system/#refrigerant-r134a-servicing) .

Spur Gear Unit, Removing and Installing

Special tools, testers and auxiliary items required

1. Extractor hook T20143
2. Pressure piece T40051
3. Pressure piece T40052

Special tools, testers and auxiliary items required

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

Removing

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
4. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-and-transmission-separating) .

1. Leave engine on scissor lift table VAS 6131 A or secure engine to the engine and transmission holder --> «Engine, Securing to Engine and Transmission Holder»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-securing-to-engine-and-transmission) .
2. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .
3. Remove left and right timing chain covers --> «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-and-right-timing-chain-covers) .
4. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .

1. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
2. Remove lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__lower-timing-chain-cover-removing-and) .
3. Remove power-steering pump from cylinder block.

Scheme 188

1. Remove hose clamp at A/C compressor dust cap - arrow -.
2. Remove power take-off drive chain --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__power-take-off-oil-pump-and-balancing) .

Scheme 189

1. Remove bolts - 1 through 6 - and remove spur gear unit.

Scheme 190

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

Scheme 191

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

Installing

Note. Replace seals and O-rings.

Scheme 192

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 front bearing cap and on cylinder block.
4. Clean sealing surfaces, they must be free of oil and grease.

Scheme 193

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 oil pump, insert drive shaft only into oil pump, do not install together with spur gear unit.

1. Cut off nozzle on the tube of sealant at front mark (diameter of nozzle approximately 1.5 mm).

Scheme 194

1. Apply sealant beads - arrows - on clean sealing surfaces of front bearing cap 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 bearing cap 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. Slide dust seal cap - arrow - with hose clamp already installed onto shaft end of A/C compressor drive spur gear.

1. Position spur gear unit and tighten bolts - 1 to 6 - in a diagonal sequence in stages.
2. Install oil pump drive chain and balance shaft --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__power-take-off-oil-pump-and-balancing) .
3. 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 lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__lower-timing-chain-cover-removing-and) .
2. Install crankshaft seal, timing chain side --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__crankshaft-seal-timing-chain-side-replacing) .
3. Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
4. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .

1. Install left and right timing chain covers --> Installing under «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
2. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .
3. Install engine --> «Engine, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-installing) .
4. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-level-checking) .

Tightening specifications

Scheme 195

1 - Differential shaft

1. Removing and installing --> «Balancing Shaft, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__balancing-shaft-removing-and-installing)

2 - 9 Nm

3 - Rear bearing cap

1. For balance shaft

4 - Seals

1. For balance shaft rear bearing cap
2. Replace

5 - O-rings

1. Replace

6 - Front bearing cap

1. For balance shaft

7 - 9 Nm

8 - Cover

1. For balance shaft

9 - 5 Nm

10 - O-ring

1. Replace

Balancing Shaft, Removing and Installing

Removing

1. Remove oil pump drive chain and balance shaft --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__power-take-off-oil-pump-and-balancing) .

Scheme 196

1. Remove bolts - arrows - and remove balance shaft rear bearing cap.

1. Remove bolts - 2 - and - 4 - and remove balance shaft cover.
2. Remove bolts - 1 - and - 3 - and remove balance shaft front bearing cap.

1. Carefully remove balance shaft from cylinder block.

Installing

Installation is in reverse order of removal, note the following

Note. Replace gaskets and O-rings.

1. Carefully insert balance shaft in cylinder block.

1. Tighten balance shaft rear bearing cap - arrows -.
2. Insert balance shaft in rear bearing cap.

Scheme 197

1. Insert balance shaft front bearing cap - arrow -.

Note. The bolts for the balance shaft front bearing cap are installed later after the balance shaft is adjusted. Balance shaft, adjusting --> Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing .

1. Install oil pump drive chain and balance shaft --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__power-take-off-oil-pump-and-balancing) .

Tightening specifications

Crankshaft, Removing and Installing

> Crankshaft, Component Overview

> Main Bearing Shells, New Crankshafts, Allocating

> Main Bearing Shears, Used and Reworked Crankshafts, Allocating

> Crankshaft Dimensions

> Axial Clearance, Measuring

> Radial Clearance, Measuring

Crankshaft, Component Overview

Note. For performing work, secure engine using bracket VAS 6095/1-7 on Engine and Transmission Holder VAS 6095 --> Engine, Securing to Engine and Transmission Holder .

Scheme 198

1 - Cylinder block

1. Paired to - 12
2. Sealant applied on cylinder block (for guide frame) --> «Guide frame sealant application on cylinder block»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

2 - Seals

1. Replace

3 - Crankshaft seal, ribbed belt side

1. Replacing --> «Crankshaft Seal, Belt Pulley Side, Replacing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__crankshaft-seal-belt-pulley-side-replacing) .

4 - Alignment bushing

1. 3 pieces
2. Insert into guide frame
3. Installed location --> «Installation position of alignment bushings»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

5 - 9 Nm

6 - Guide tube for oil dipstick

7 - O-ring

1. Replace

8 - Bolts

1. For guide frame
2. Replace
3. Various bolt sizes
4. Tightening order --> «Installing guide frame»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

9 - Baffle plate

10 - 9 Nm

1. Tightening order --> «Baffle plate tightening plate»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

11 - Bolt

1. For sealing surfaces of cylinder block/guide frame
2. Different bolt lengths
3. Tightening specifications and tightening sequence --> «Installing guide frame»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

12 - Bearing bracket

1. Paired to - 1
2. Sealant applied on cylinder block (for guide frame) --> «Guide frame sealant application on cylinder block»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)
3. Tightening order --> «Installing guide frame»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

13 - 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/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__axial-clearance-measuring)

14 - 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: With new crankshafts --> «Main Bearing Shells, New Crankshafts, Allocating»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) , with used and reworked crankshafts --> «Main Bearing Shears, Used and Reworked Crankshafts, Allocating»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__main-bearing-shears-used-and-reworked)

15 - Crankshaft

1. Measuring axial play --> «Axial Clearance, Measuring»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__axial-clearance-measuring)
2. Radial clearance, measuring --> «Radial Clearance, Measuring»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__radial-clearance-measuring)
3. Do not turn crankshaft when measuring radial play
4. Crankshaft dimensions --> «Crankshaft Dimensions»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__crankshaft-dimensions)

16 - Thrust washer

1. Only at 4th crankshaft bearing
2. Lubricating grooves face outward
3. Measuring crankshaft axial clearance --> «Axial Clearance, Measuring»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__axial-clearance-measuring)

17 - 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: With new crankshafts --> «Main Bearing Shells, New Crankshafts, Allocating»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) , with used and reworked crankshafts --> «Main Bearing Shears, Used and Reworked Crankshafts, Allocating»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__main-bearing-shears-used-and-reworked)

18 - Seals

1. Replace

Scheme 199

1. Then tighten bolts in sequence - 1 to 21 -.

Scheme 200

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: 2.0 mm.

1. Install seals - 1 to 4 -.

Scheme 201

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

Scheme 202

1. Replace bolts - 1 to 24 -.
2. Tighten bolts for guide frame as follows
3. Tighten bolts - 1 to 12 - to 30 Nm using a torque wrench.
4. Tighten bolts - 13 to 24 - to 20 Nm using a torque wrench.

1. Tighten bolts - 1 to 12 - to 50 Nm using a torque wrench.
2. Tighten bolts - 13 to 24 - to 30 Nm using a torque wrench.
3. Tighten bolts - 1 to 12 - 90 ( 1 / 4 turn) using a rigid wrench.
4. Tighten bolts - 13 to 24 - 90 ( 1 / 4 turn) using a rigid wrench.

1. Tighten cylinder block/guide frame bolts - dark shaded - in a diagonal sequence to 9 Nm.

Scheme 203

1. Bearing shells with the correct thickness are allocated to the cylinder block in the 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 front left 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 204

1. Bearing shells with correct thickness are allocated to the 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.

Scheme 205

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.

Main Bearing Shears, Used and Reworked Crankshafts, Allocating

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 the matching bearing shells.
3. Basic dimension of main crankshaft journals = Diameter 65.00 mm.
4. Repair stage of main crankshaft journals = Diameter 64.75 mm.

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.

Crankshaft Dimensions

Axial Clearance, Measuring

Special tools, testers and auxiliary items required

Scheme 206

1. Dial gauge holder VW 387

Scheme 207

1. Dial gauge VAS 6079

Procedure

Scheme 208

1. Secure Dial Gauge VAS 6079 with Dial Gauge Holder VW 387 to cylinder block as shown in illustration.
2. Position dial gauge against crankshaft counterweight.
3. Press crankshaft by hand against gauge and set gauge to "0".
4. Press crankshaft off gauge and read value.

1. Axial clearance: 0.090 to 0.158 mm.

Radial Clearance, Measuring

Special tools, testers and auxiliary items required

1. Plastigage

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.

Radial clearance

1. New: 0.017 to 0.044 mm.
2. Wear limit: 0.08 mm.

Piston and Connecting Rod, Disassembling and Assembling

> Piston and Connecting Rod, Component Overview

> Piston and Cylinder Dimensions

> Connecting Rod, Measuring Radial Clearance

Piston and Connecting Rod, Component Overview

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

Scheme 209

1 - Connecting rod bolt - 50 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace
2. Lubricate threads and contact surface
3. Tighten to 50 Nm to measure radial play, do not turn further

2 - Connecting rod bearing cap

1. Do not interchange
2. Mark affiliation to cylinder with paint --> «Mark connecting rod»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)
3. Installation position of connecting rod pairs --> «Connecting rod, installed location»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

3 - Bearing shells

1. Check that retaining tabs are secured
2. Do not interchange used bearing shells (mark, but not on the running surface)
3. Radial clearance, measuring --> «Connecting Rod, Measuring Radial Clearance»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__connecting-rod-measuring-radial-clearance)
4. To measure radial play, tighten bolts - 1 - to 60 Nm but no further

1. Over-sized bearings are available for reworked crankshaft connecting rod journals

4 - Connecting rod

1. Only replace as set
2. Mark affiliation to cylinder with paint --> «Mark connecting rod»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)
3. Installation position of connecting rod pairs --> «Connecting rod, installed location»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)
4. Axial play for each new connecting rod pair: 0.20 to 0.38 mm

1. Radial clearance, measuring --> «Connecting Rod, Measuring Radial Clearance»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__connecting-rod-measuring-radial-clearance)

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/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)
2. Piston and cylinder dimension, piston allocation to cylinder bore --> «Piston and Cylinder Dimensions»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__piston-and-cylinder-dimensions)
3. Checking --> «Checking piston»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)
4. Install with piston ring compressor

1. Measuring cylinder bore --> «Measuring cylinder bore»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

8 - Piston rings

1. Offset gaps by 120
2. Use piston ring pliers for removal and installation
3. "TOP" marking or inscribed side must point to piston head
4. Gap, measuring --> «Piston ring end gap, measuring»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

1. Measuring side clearance --> «Measuring piston ring side clearance»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

Scheme 210

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

Scheme 211

1. Clean ring groove of piston before checking.

Scheme 212

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

1. Maximum deviation from nominal dimension: 0.03 mm.

Nominal dimension --> Piston and Cylinder Dimensions .

Scheme 213

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 214

1. Identify allocation to cylinder with paint on piston crown.

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

Installation position

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

Scheme 215

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 216

1. Molded tabs - arrows - at the beveled surfaces of the connecting rod pairs 1 and 2, 3 and 4, 5 and 6, 7 and 8 as well as 9 and 10 must point toward each other.

Scheme 217

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

Piston and Cylinder Dimensions

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

Connecting Rod, Measuring Radial Clearance

Special tools, testers and auxiliary items required

1. Plastigage

Procedure

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 60 Nm. Do not turn crankshaft.

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

Radial clearance

1. New: 0.020 to 0.069 mm.
2. Wear limit: 0.120 mm.

1. Replace bolts for connecting rod bearings.

Cylinder Head, Removing and Installing

> Cylinder Head, Component Overview

> Left Cylinder Head Cover, Removing and Installing

> Right Cylinder Head Cover, Removing and Installing

> Cylinder Head, Removing and Installing

> Compression, Checking

Cylinder Head, Component Overview

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

Scheme 218

1 - Cylinder head gasket

1. Replacing --> «Cylinder Head, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
2. Installation position: Part Number, points to cylinder head
3. After replacing, change coolant and engine oil

2 - Cylinder Head

1. Removing and installing --> «Cylinder Head, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)
2. Check for distortion --> «Checking cylinder head for distortion»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)
3. Reworking dimension --> «Checking cylinder head for distortion»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)
4. After replacing, change coolant and engine oil

3 - Cylinder head cover gasket

1. Replace if damaged or leaking

4 - Cylinder head cover

1. Removing and installing: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-cylinder-head-cover-removing-and)

5 - Gasket

1. For cap
2. Replace if damaged or leaking

6 - Cap

7 - Ignition coil

1. Remove with Ignition Coil Puller T40039

8 - Special bolt - 9 Nm

1. Replace if seal is damaged
2. Note tightening sequence --> (Scheme 223)

9 - Camshaft Adjustment Valve 2 N208

10 - 2.4 Nm

11 - O-ring

1. Replace

12 - Seal

1. Replace

13 - Locking bolt - 35 Nm

14 - 2.4 Nm

15 - Camshaft Adjustment Valve 2 (exhaust) N319

16 - O-ring

1. Replace

17 - Cylinder head bolt

1. Replace
2. Observe sequence for loosening --> (Scheme 228)
3. Note tightening sequence --> (Scheme 230)

Scheme 219

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

1. Max. permissible distortion: 0.1 mm.

Scheme 220

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

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

Left Cylinder Head Cover, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 221

1. Ignition Coil Puller T40039

Removing

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

1. Disconnect electrical connector - 2 - for Mass Air Flow (MAF) Sensor 2 G246.
2. Disconnect air duct hose - 1 - from intake manifold.
3. Remove bolts - arrows - and remove left upper part of air filter housing.

1. Remove air duct - 1 -.
2. Remove bolts - arrows -.
3. Tilt lower part of air filter housing and remove air flap vacuum hose.
4. Remove lower part of left air filter housing.

Scheme 222

1. Remove crankcase ventilation hose from oil separator - 6 - and from cylinder head cover - 5 -.
2. Remove oil dipstick - 3 - from guide tube.
3. Disconnect electrical connectors - 1 - and - 7 -.
4. Remove bolts - 2 - and - 4 -.

1. Disconnect electrical connectors to ignition coils.
2. Free up electrical wiring harness by removing harness bracket.

1. Remove ignition coils using Ignition Coil Puller T40039.

Scheme 223

1. Loosen bolts in sequence - 16 to 1 - and remove them.
2. Remove left cylinder head cover.

Installing

Installation is in reverse order of removal, note the following

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

1. Clean sealing surfaces, they must be free of oil and grease.
2. Tighten cylinder head cover in sequence - 1 to 16 -.
3. Install left air filter housing --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .

Tightening Specifications

Right Cylinder Head Cover, Removing and Installing

Special tools, testers and auxiliary items required

1. Ignition Coil Puller T40039

Removing

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

1. Disconnect electrical connector - 1 - for mass air flow (MAF) sensor G70.
2. Disconnect vacuum hose - 2 - from air guide hose.
3. Loosen hose clamps and lay aside air guide hose - 4 -.

1. Remove bolts - arrows - and remove right upper part of air filter housing.
2. Remove front part of right front wheel housing liner --> «66 - EXTERIOR EQUIPMENT»(/audi/s8/d3-2007-2011/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Remove lower air guide hose - arrow - from right upper part of air filter housing.

1. Disconnect both vacuum hoses - 1 -.
2. Remove air duct - 2 -.
3. Remove bolts - arrows -.
4. Tilt lower part of air filter housing and disconnect electrical connector - 3 - on Intake Air Switch-Over valve N335.

1. Remove lower part of right air filter housing.

1. Disconnect crankcase ventilation hose - 2 -.
2. Disconnect electrical connectors - 1 - and - 5 -.
3. Remove bolts - 3 - and - 4 -.
4. Disconnect electrical connectors to ignition coils.

1. Free up electrical wiring harness by removing harness bracket.

1. Remove ignition coils using Ignition Coil Puller T40039.

1. Loosen bolts in - 16 to 1 - sequence and remove them.
2. Remove cylinder head cover.

Installing

Installation is in reverse order of removal, note the following

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

1. Clean sealing surfaces, they must be free of oil and grease.
2. Tighten cylinder head cover in sequence - 1 to 16 -.
3. Install right air filter housing --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .

Tightening Specifications

Special tools, testers and auxiliary items required

Scheme 224

1. Torque Wrench V.A.G 1331
2. SW 17 socket V.A.G 1331/6
3. SW 14 socket, open ring V.A.G 1331/8

Removing

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. The following removal and installation procedure is for the left cylinder head. The procedure for the other side is identical.

1. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
2. Leave engine with transmission installed on scissor lift platform VAS 6131 A.
3. Remove exhaust system tract: Left --> «Left Exhaust System Tract, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-exhaust-system-tract-removing-and) , right --> «Right Exhaust System Tract, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-exhaust-system-tract-removing-and) .

Scheme 225

1. Remove front secondary air injection connecting piece from cylinder head - arrows -.
2. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .

1. Remove camshaft timing chains from camshafts --> «Camshaft Timing Chain, Removing from Camshaft»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-from-camshaft) .
2. Remove bolts - 1 - and - 2 - and remove right chain tensioner.

Scheme 226

1. Disconnect electrical connectors - arrows - at fuel injectors.
2. Remove high pressure line - 2 - from connector on fuel rail.
3. Remove high pressure line - 1 - from connector on fuel rail. To do this, counterhold at hex head with and open-end wrench and loosen the union nut.

Note. Do not change bend shape of high pressure lines.

Scheme 227

1. Remove locking bolt - arrow -.

Scheme 228

1. Remove bolts - arrows -.
2. Loosen cylinder head bolts in sequence - 1 to 12 - and remove them.
3. Remove cylinder head and place it on a soft surface (foam).

Installing

Note. Replace cylinder head bolts. Replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as O-rings and gaskets. Carefully remove sealant residue 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. Only unpack new cylinder head gasket immediately prior to installation. Handle gasket carefully. Damage in silicon layer and recessed area lead to leakage. 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 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 free up valves until immediately before installing cylinder head. Secure all hose connections with hose clamps appropriate for the model . During installation, all cable ties must be re-installed at the same location. 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. When replacing the cylinder head or cylinder head seal, all of the coolant and engine oil must be replaced.

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

1. The camshaft clamp T40070 must be installed on both cylinder heads and tightened to 25 Nm - arrows -.

1. Crankshaft holder 3242 must be installed.

Scheme 229

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 230

1. Tighten cylinder head bolts in 4 stages in - 1 to 12 - sequence 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.

1. Insert bolts - arrows - with locking compound and tighten to 8 Nm .
2. Tighten bolts - arrows - 90 ( 1 / 4 additional turn) using a rigid wrench.

1. Tighten locking bolt - arrow -.

1. Check whether camshaft timing chain tensioner guide rail is secured with Locking Pin T40071.

Note. If the tensioning element is to be removed from the chain tensioner, observe the installed position: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail. Disregard - arrow -.

1. Clean chain tensioner oil screen - 2 - if necessary.
2. Place a new gasket - 3 - onto rear of chain tensioner - 1 -.

1. Set chain tensioner in place and install camshaft timing chain, as shown in the illustration.
2. Tighten bolts - 1 - and - 2 -.

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

1. Install camshaft timing chains --> Installing under «Camshaft Timing Chain, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-and-installing) .
2. Install left and right timing chain covers --> Installing under «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
3. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-cylinder-head-cover-removing-and) .

Scheme 231

1. To tighten SW 14 union nut at fuel rail, use Torque Wrench V.A.G 1331 with Socket Insert AF 14, open ring V.A.G 1331/8.

Scheme 232

1. To tighten SW 17 union nut at fuel rail, use torque wrench V.A.G 1331 with SW 17 socket V.A.G 1331/6.
2. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .
3. Install exhaust system tract: Left --> «Left Exhaust System Tract, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-exhaust-system-tract-removing-and) , right --> «Right Exhaust System Tract, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-exhaust-system-tract-removing-and) .
4. Install engine --> «Engine, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-installing) .

1. Change engine oil --> «01 - MAINTENANCE»(/audi/s8/d3-2007-2011/remont/procedures/#maintenance-procedures) .
2. Replace coolant --> «Cooling System, Draining and Filling»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__cooling-system-draining-and-filling) .

Tightening Specifications

Compression, Checking

Special tools, testers and auxiliary items required

Scheme 233

1. Spark plug removal tool 3122 B
2. Compression tester V.A.G 1763
3. Ignition Coil Puller T40039

Procedure

1. Engine oil temperature min. 30 C.
2. Battery voltage min. 12.5 V.

1. Switch off ignition.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and remove front noise insulation.

1. Disconnect electrical connector on Engine Speed (RPM) Sensor G28 - arrow - at bottom of transmission.

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

Scheme 234

1. Remove left air duct hose - arrows -.

Scheme 235

1. Remove oil dipstick - 2 - from guide tube.
2. Remove bolts - 1 - and - 3 -.
3. Disconnect electrical connectors to ignition coils and press wiring harness to side.
4. Disconnect vacuum hose - 2 - from air guide hose.

1. Loosen hose clamps - arrows - and lay aside air guide hose.

Scheme 236

1. Remove bolts - 1 - and - 2 -.
2. Disconnect electrical connectors to ignition coils and press wiring harness to side.

1. Remove all ignition coils using Ignition Coil Puller T40039.
2. Using spark plug removal tool 3122 B , remove spark plugs.
3. Check compression using compression tester V.A.G 1763.

Note. Using 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.

Assembly is in reverse order of removal, note the following

1. Install spark plugs --> «28 - IGNITION/GLOW PLUG SYSTEM»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .
2. As a final step, check Engine Control Module (ECM) DTC memory and erase it, since malfunctions were stored by disconnecting electrical connectors

Tightening specifications

Valvetrain, Servicing

> Valvetrain, Component Overview

> Camshafts, Checking Axial Clearance

> Camshafts, Removing and Installing

> Valve Stem Seals, Cylinder Head Installed, Replacing

> Valve Stem Seals, Cylinder Head Removed, Replacing

> Hydraulic Adjusting Elements, Checking

> Valve Dimensions

> Valve Guides, Checking

> Valves, Checking

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 approximately 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on 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.

Valvetrain, Component Overview

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

Scheme 237

1 - Sealing plug

1. Insert with sealant

2 - Valve stem seal

1. Replacing, Cylinder Head Installed --> «Valve Stem Seals, Cylinder Head Installed, Replacing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__valve-stem-seals-cylinder-head-installed)
2. Replacing, Cylinder Head Removed --> «Valve Stem Seals, Cylinder Head Removed, Replacing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__valve-stem-seals-cylinder-head-removed)

3 - Valve spring

1. Installed location --> «Installed position of valve spring»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

4 - Hydraulic adjusting element

1. Clipped into roller rocker lever - 8
2. Checking --> «Hydraulic Adjusting Elements, Checking»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__hydraulic-adjusting-elements-checking)
3. Do not interchange
4. Lubricate contact surface

5 - Valve spring plate

6 - Valve keys

7 - Securing clip

1. Not available individually
2. Check for secure seat

8 - Roller rocker lever

1. Do not interchange
2. Check roller for easy movement
3. Lubricate contact surface
4. To assemble, clip onto hydraulic adjusting element - 4 - using a circlip - 7

9 - Intake camshaft

1. Removing and installing --> «Camshafts, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshafts-removing-and-installing)
2. Checking axial play --> «Camshafts, Checking Axial Clearance»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshafts-checking-axial-clearance)
3. Check radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance at bearing-diameter 24 mm: 0.024 to 0.066 mm

1. Radial clearance at bearing-diameter 36 mm: 0.100 to 0.325 mm
2. Run-out: max. 0.04 mm

10 - Gasket

1. Replace

11 - Bearing bracket

1. With integrated camshaft bearings
2. Removing and installing --> «Camshafts, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshafts-removing-and-installing)

12 - 8 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace
2. Observe tightening sequence --> «Camshaft guide frame, tightening sequence»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

13 - 9 Nm

14 - Camshaft position (CMP) sensor 2 G163

15 - O-ring

1. Replace

16 - O-ring

1. Replace

17 - Camshaft position (CMP) sensor 4 G301

18 - 9 Nm

19 - Exhaust camshaft

1. Removing and installing --> «Camshafts, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshafts-removing-and-installing)
2. Checking axial play --> «Camshafts, Checking Axial Clearance»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshafts-checking-axial-clearance)
3. Check radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance at bearing-diameter 24 mm: 0.024 to 0.066 mm

1. Radial clearance at bearing-diameter 36 mm: 0.100 to 0.325 mm
2. Run-out: max. 0.04 mm

20 - Cylinder Head

1. Check valve guides --> «Valve Guides, Checking»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__valve-guides-checking)

21 - Intake valve

1. Do not rework, only lapping is permitted
2. Mark installed position for re-installation
3. Valve dimensions --> «Valve Dimensions»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)
4. Check valve guides --> «Valve Guides, Checking»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__valve-guides-checking)

22 - Exhaust valve

1. Do not rework, only lapping is permitted
2. Mark installed position for re-installation
3. Valve dimensions --> «Valve Dimensions»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)
4. Check valve guides --> «Valve Guides, Checking»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__valve-guides-checking)

Scheme 238

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

Scheme 239

Note. The Illustration Shows The Guide Frame For The Left Cylinder Head.

1. Tighten Bolts In 3 Stages In Sequence - 1 To 28
2. Tighten Bolts By Hand.

1. The Guide Frame Must Be In Contact With The Entire Contact Surface Of The Cylinder Head.

1. Tighten Bolts To 8 Nm.
2. Tighten Bolts An Additional 90.

Camshafts, Checking Axial Clearance

Special tools, testers and auxiliary items required

1. Dial gauge holder VW 387

1. Dial gauge VAS 6079

Scheme 240

Test Sequence

1. Perform measurement with guide frame removed.
2. Secure dial gauge holder VW 387 to dial gauge VAS 6079 on cylinder head.
3. Determine axial clearance.

1. Axial clearance: 0.100 to 0.191 mm.

Camshafts, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 241

1. Locking pin 3242

Scheme 242

1. Camshaft Clamp T40070 , qty. 2

Scheme 243

1. Impact puller T10133/3 from tool set T10133

Scheme 244

1. Securing pins 1 set = qty. 2 T40116
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Sealant

Note. Here, removal and installation at left cylinder head is depicted in the following description.

Scheme 245

Removing

1. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
2. Leave engine with transmission installed on scissor lift platform VAS 6131 A.
3. Remove camshaft timing chains from camshafts --> «Camshaft Timing Chain, Removing from Camshaft»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-from-camshaft) .
4. Remove Ground (GND) wire - 1 - from guide frame.

1. Disconnect electrical connectors - 2 - and - 3 -.
2. Remove high-pressure pump --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .

1. Loosen guide frame bolts in sequence - 28 to 1 -.

Note. Proceed in the same way with right guide frame.

1. Carefully remove guide frame and lay it on a soft surface on the workbench.

1. Remove Camshaft Clamp T40070 at left cylinder head.

Scheme 246

1. Mark camshafts and remove.

Installing

Note. Always replace gaskets and seals.

1. Secure crankshaft - 1 - using crankshaft holder 3242.

1. Remove sealant residue on cylinder head and guide frame, e.g. with rotating plastic brush.
2. Clean sealing surfaces, they must be free of oil and grease.
3. Oil journal surfaces of camshafts.

Scheme 247

1. Set camshafts into guide frame.

1. The placement of the camshafts must be exactly within the axial bearings - arrows - of the guide frame.

1. Rotate guide frame with camshafts installed while holding camshafts inside the frame.

1. Rotate camshafts until threaded holes - arrows - point upward.
2. Check whether camshafts still lie exactly in axial bearings of guide frame.

1. Install camshaft clamp T40070 at intake and exhaust camshafts as shown in the illustration and tighten the bolts to 25 Nm.

1. Cut off nozzle on tube of sealant at front mark (diameter of nozzle approximately 2 mm).

Scheme 248

1. Turn around guide frame again.
2. Lay a new seal - 2 - in guide frame groove.

Note. Sealant beads must not be thicker than specified, otherwise extra sealant can enter camshaft bearing.

1. Apply sealant beads - 1, 3, 4 - on clean guide frame sealing surfaces as shown in illustration.

1. Thickness of sealant beads: 2.5 mm.

Note. Because the sealant begins hardening immediately, guide frame must be promptly positioned and tightened.

1. Place guide frame on cylinder head.

Scheme 249

1. Insert locating pins T40116 in guide frame and cylinder head.

Note. After installing guide frame, sealant must dry for approximately 30 minutes.

1. Tighten guide frame bolts evenly by hand in sequence - 1 to 28 -.
2. Fasten guide frame bolts in sequence - 28 to 1 - until they stop.
3. Clean sealing plug hole in cylinder head. It must be free of oil and grease.

Scheme 250

1. Coat outer circumference of sealing plugs - arrows - with sealant .
2. Install sealing plugs so they are flush.

Scheme 251

1. Remove locating pins T40116 with impact puller T10133/3.

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

1. Install high pressure pump --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .
2. Position camshaft timing chains on camshafts --> Installing under «Camshaft Timing Chain, Removing from Camshaft»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
3. Install left and right timing chain covers --> Installing under «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
4. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-cylinder-head-cover-removing-and) .

1. Install engine --> «Engine, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-installing) .

Note. After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on 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.

Tightening specifications

Valve Stem Seals, Cylinder Head Installed, Replacing

Special tools, testers and auxiliary items required

Scheme 252

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

1. Adapter T40012

Removing

1. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
2. Leave engine with transmission installed on scissor lift platform VAS 6131 A.
3. Remove camshaft timing chains from camshafts --> «Camshaft Timing Chain, Removing from Camshaft»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshaft-timing-chain-removing-from-camshaft) .
4. Remove camshafts --> «Camshafts, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshafts-removing-and-installing) .

1. Using spark plug removal tool 3122 B , remove spark plugs.

Scheme 253

1. Place drift VAS 5161/3 on valve spring plate and loosen stuck valve keepers using a plastic hammer.

Scheme 254

1. Place guide plate VAS 5161/19 A from valve cotter disassembly and assembly device VAS 5161 on cylinder head.
2. Secure guide plate with knurled screws VAS 5161/12.
3. Install adapter T40012 with gasket by hand into respective spark plug thread and apply constant pressure.

1. Minimum pressure: 6 bar positive pressure.

Scheme 255

1. Install engaging device VAS 5161/6 with installation fork VAS 5161/5 into guide plate.
2. Push installation cartridge VAS 5161/8 into guide plate.
3. Hook in pressure fork VAS 5161/2 at engaging device and press down installation cartridge.
4. At the same time, turn knurled bolt of installation cartridge to the right, until points engage in the valve keepers.

1. Lightly move knurled bolt back and forth, causing the valve keepers to be pressed apart and be captured in the installation cartridge.
2. Release pressure fork.
3. Take out installation cartridge.
4. Unfasten guide plate and turn it aside.

1. Pressurized air hose remains connected.

1. Remove valve spring with valve spring plate.

Scheme 256

1. Pull off valve stem oil seals using Valve Seal Removal Tool 3364.

Scheme 257

Note. A plastic sleeve - A - is supplied with the new valve shaft seals.

1. Place plastic sleeve - A - on valve stem to prevent damage to new valve stem seals - B -.
2. Lightly coat sealing lips of valve stem seal with oil.
3. Push valve stem seal onto plastic sleeve.
4. Carefully press valve stem oil seal onto valve guide using Valve Stem Seal Driver 3365.

1. Remove plastic sleeve again.

Scheme 258

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

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

1. Install valve spring and valve spring plate.

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

1. Install guide plate onto cylinder head again.
2. Insert installation cartridge into guide plate.
3. Press pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve keepers.
4. Release pressure fork with knurled bolt still pulled.

1. Make sure all roller rocker levers seat properly on the valve stem ends and are clipped onto the respective hydraulic adjusting elements.
2. Install camshafts --> «Camshafts, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshafts-removing-and-installing) .
3. Position camshaft timing chains on camshafts --> Installing under «Camshaft Timing Chain, Removing from Camshaft»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
4. Install left and right timing chain covers --> Installing under «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .

1. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-cylinder-head-cover-removing-and) .
2. Install engine --> «Engine, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-installing) .

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

Valve Stem Seals, Cylinder Head Removed, Replacing

Special tools, testers and auxiliary items required

Scheme 259

1. Valve seal removal tool 3364

Scheme 260

1. Valve stem seal driver 3365

Scheme 261

1. Valve cotter disassembly and assembly device VAS 5161

Scheme 262

1. Engine and transmission holder VAS 6095
2. Tensioning element VAS 6419

Procedure

1. Remove camshafts --> «Camshafts, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshafts-removing-and-installing) .

Scheme 263

1. Insert tensioning element VAS 6419 in engine and transmission holder VAS 6095.
2. Tension cylinder head on tensioning element VAS 6419 as shown in the illustration.
3. Connect tensioning element VAS 6419 to compressed air.
4. Slide air cushion with lever - arrow - under cylinder onto valve stem seal that will be removed.

1. Let enough compressed air flow into air cushion until it contacts the valve plate.

1. Place drift VAS 5161/3 on valve spring plate and loosen stuck valve keepers using a plastic hammer.

Scheme 264

1. Place guide plate VAS 5161/19 A from valve cotter disassembly and assembly device VAS 5161 on cylinder head.
2. Secure guide plate with knurled screws VAS 5161/12.

Scheme 265

1. Install engaging device VAS 5161/6 with installation fork VAS 5161/5 into guide plate.
2. Push installation cartridge VAS 5161/8 into guide plate.
3. Hook in pressure fork VAS 5161/2 at engaging device and press down installation cartridge.
4. At the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve keepers.

1. Lightly move knurled bolt back and forth, causing the valve keepers to be pressed apart and be captured in the installation cartridge.
2. Release pressure fork.
3. Take out installation cartridge.
4. Remove guide plate and turn it aside.

1. Remove valve spring with valve spring plate.

1. Pull off valve stem oil seals using Valve Seal Removal Tool 3364.

Note. A plastic sleeve - A - is supplied with the new valve shaft seals.

1. Place plastic sleeve - A - on valve stem to prevent damage to new valve stem seals - B -.
2. Lightly coat sealing lips of valve stem seal with oil.
3. Push valve stem seal onto plastic sleeve.
4. Carefully press valve stem oil seal onto valve guide using Valve Stem Seal Driver 3365.

1. Remove plastic sleeve again.

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

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

1. Install valve spring and valve spring plate.

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

1. Install guide plate onto cylinder head again.
2. Insert installation cartridge into guide plate.
3. Press pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve keepers.
4. Release pressure fork with knurled bolt still pulled.

1. Make sure all the roller rocker levers seat properly on the valve stem ends and are clipped onto the respective hydraulic adjusting elements.
2. Install camshafts --> «Camshafts, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshafts-removing-and-installing) .

Hydraulic Adjusting Elements, Checking

Special tools, testers and auxiliary items required

1. Adapter T40058
2. Feeler gauge

Note. The hydraulic adjusting elements cannot be repaired. Irregular valve noises are normal while starting the engine.

Procedure

1. Start the engine and let it run until the radiator fan has switched on once.
2. Increase engine speed for about 2 minutes to approximately 2500 RPM, perform road test if necessary.

Note. If irregular valve noises disappear but reappear during short drives, replace the oil check valve --> Oil Check Valve and Spray Nozzle Valve, Removing and Installing .

If the hydraulic adjusting elements are still loud, determine which element is faulty

1. Remove cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-cylinder-head-cover-removing-and) .
2. Remove fan shroud --> «Fan Shroud, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__fan-shroud-removing-and-installing) .

1. Insert Socket T40058 adapter so that small diameter - arrow 2 - points to engine. Large diameter - arrow 1 - points to socket.

1. Rotate crankshaft in direction of engine rotation - arrow - using adapter T40058 until camshafts on the hydraulic adjuster that needs to be checked face upward.

Scheme 266

1. Determine play between camshaft and roller rocker lever by pressing lever down using a screwdriver - arrow -.

If a 0.20 mm feeler gauge can be inserted between camshaft and roller rocker lever

1. Replace hydraulic adjusting element --> «Camshafts, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__camshafts-removing-and-installing) .

Final procedures

1. Install fan shroud --> «Fan Shroud, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__fan-shroud-removing-and-installing) .
2. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__right-cylinder-head-cover-removing-and) .

Scheme 267

Note. Intake and exhaust valves must not be refaced by grinding. Only lapping is permitted.

Valve Guides, Checking

Special tools, testers and auxiliary items required

1. Dial gauge holder VW 387

1. Dial gauge VAS 6079

Scheme 268

Test Sequence

1. Insert valve into valve guide. Due to the slight difference in stem dimensions, ensure that only an intake valve is used in the intake guide and an exhaust valve in the exhaust guide.

1. Valve stem tip must seal with valve guide.

1. Determine tilt clearance.

1. Wear limit: 0.8 mm.

Note. If the valve is to be replaced as part of a repair, use a new valve for the calculation. If wear limit is exceeded, re-measure using new valves. If wear limit is still exceeded, replace cylinder head.

Valves, Checking

1. Perform a visual check for signs of wear at stem and at seating surface.

If significant wear is discovered

1. Replace the respective valve.

Lubrication System Components, Removing and Installing

> Oil Pump and Oil Pan Lower Section, Component Overview

> Oil Pan Lower Section, Removing and Installing

> Oil Pump, Removing and Installing

> Oil Pan Upper Section, Component Overview

> Oil Pan Upper Section, Removing and Installing

> Oil Check Valve and Spray Nozzle Valve, Component Overview

> Oil Check Valve and Spray Nozzle Valve, Removing and Installing

> Crankcase Ventilation Hose, Removing and Installing

> Oil Filter Housing, Component Overview

> Oil Filter Housing, Removing and Installing

> Oil Cooler, Removing and Installing

> Oil Pressure Switch, Removing and Installing

> Oil Pressure and Oil Pressure Switch, Checking

> Oil Level, Checking

Note. If large quantities of metal shavings or abraded material are found in the engine oil while servicing the engine, the oil passages, lines and hoses must be carefully cleaned to prevent resulting damage and the oil cooler must be replaced. The oil level must not exceed the max. marking or the catalytic converter could be damaged. Oil quantities, oil specifications and viscosity classes --> Maintenance tables.

Scheme 269

1 - Oil pan (lower section)

1. Removing and installing --> «Oil Pan Lower Section, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-pan-lower-section-removing-and)
2. With Oil Level Thermal Sensor G266
3. Oil Level Thermal Sensor G266 , removing and installing --> «Oil Level Thermal Sensor G266, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

2 - 9 Nm

1. Tighten diagonally in 2 stages --> Tighten bolts for lower part of oil pan in 2 stages as follows. under «Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm)

3 - 9 Nm

4 - 9 Nm

5 - Oil pipe

6 - Gasket

1. Replace

7 - O-ring

1. Replace

8 - O-ring

1. Replace

9 - 9 Nm

10 - Housing

1. For oil cooler by-pass valve

11 - Oil cooler by-pass valve

12 - Gasket

1. Replace

13 - Oil check valve

14 - O-ring

1. Replace

15 - 9 Nm

16 - 9 Nm

17 - Oil pipe

18 - O-ring

1. Replace

19 - Alignment bushing

1. 2 pieces

20 - Drive shaft for coolant pump

21 - Gasket

1. Replace

22 - Oil pump

1. Do not disassemble
2. With relief valve approximately 5.5 bar
3. Removing and installing --> «Oil Pump, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-pump-removing-and-installing)

23 - Drive shaft for oil pump

24 - 8 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

25 - Gasket

1. Replace

26 - 9 Nm

27 - Intake tube

1. For oil pump

28 - Oil strainer

1. Clean

29 - Oil baffle

30 - 5 Nm plus an additional 45 ( 1 / 8 turn)

1. Replace

31 - Rubber buffer

32 - 9 Nm

33 - Seal

1. Replace

34 - Oil drain plug - 25 Nm

Scheme 270

1. Nut - 9 Nm
2. Sealing ring; replace
3. Electrical harness connector
4. Oil Level Thermal Sensor G266

Oil Pan Lower Section, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 271

1. Engine support bridge 10 - 222 A
2. Adapter 10 - 222 A/21
3. Old oil collecting and extracting device V.A.G 1782
4. Hand drill with plastic brush attachment

1. Protective glasses
2. Sealant

Removing

1. Remove cover above coolant reservoir - arrows -.

1. Remove rubber seal - 1 - and remove plenum chamber covers - 2 - and - 3 -.

Scheme 272

1. Remove refrigerant line bracket at left from strut tower - arrow -.

Scheme 273

1. Remove clip - 1 - at right.
2. Unclip fuel line and vacuum pump from bracket - 2 - on strut tower.

Scheme 274

1. Remove suspension strut cross member rear bolts - 3 -.
2. Secure Engine Support Bridge 10 - 222 A to strut towers with Adapter 10 - 222 A/21.

1. The adapters are marked for the left and right side of the vehicle.
2. The center contact point - 2 - on the adapter is placed on the suspension strut cross member front bolts.
3. The adapters are tightened with the rear bolts - 3 - for suspension strut cross member.
4. The knurled thumb screw - 1 - must be turned downward far enough so that the contact plate rests on the strut tower.

Scheme 275

1. Secure spindles of Engine Support Bridge 10 - 222 A at the rear engine lifting eyes.
2. Tension engine with spindles of the engine support bridge.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.

Scheme 276

1. Evenly remove left and right bolts - 2 - on stabilizer bar retaining clamps and rotate stabilizer bar - 1 - downward.

Scheme 277

1. Remove left and right bolts - 1. 2, 3 - and remove engine carrier.

Scheme 278

1. Remove nut - 1 - and bolt - 6 - on lower left coolant pipe.

Note. Ignore items - 2 to 5 -.

Scheme 279

1. Disconnect electrical connector - 2 - at Oil Level Thermal Sensor G266.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove oil pan (lower part) - 1 - and pry out carefully.

Note. There is still a residual amount of oil in lower section of oil pan.

Scheme 280

Note. Replace seals.

1. Remove sealant residue lower part and upper part of oil pan, e.g. with rotating plastic brush.
2. Clean sealing surfaces, they must be free of oil and grease.

1. Cut off nozzle on tube of sealant at front mark (diameter of nozzle approximately 2 mm).

Scheme 281

1. Apply sealant bead - arrow - on clean sealing surface of lower part of oil pan as shown in illustration.

1. Thickness of sealant bead: 2.5 mm.

Note. Sealant bead must not be thicker than specified, otherwise excess sealant may get into lower section of oil pan and clog strainer in intake tube. The oil pan (lower part) must be installed within 5 minutes after application of sealant.

1. Position lower part of oil pan and hand tighten all bolts.
2. Tighten bolts for lower part of oil pan in 2 stages as follows.
3. Pre-tighten all bolts in a diagonal sequence to 5 Nm.
4. Tighten all bolts in a diagonal sequence to 9 Nm.

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

1. Install engine carrier --> «40 - FRONT SUSPENSION»(/audi/s8/d3-2007-2011/remont/axle-shafts/#suspension-wheels-and-steering) .
2. Install stabilizer bar --> «40 - FRONT SUSPENSION»(/audi/s8/d3-2007-2011/remont/axle-shafts/#suspension-wheels-and-steering) .
3. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-level-checking) .

Tightening Specifications

Oil Pump, Removing and Installing

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782
2. Water pump pliers (standard)

Removing

1. Remove coolant pump --> «Coolant Pump, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__coolant-pump-removing-and-installing) .

Scheme 282

1. Remove drive shaft - arrow - for coolant pump from oil pump.
2. Remove lower section of oil pan --> «Oil Pan Lower Section, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-pan-lower-section-removing-and) .

Scheme 283

1. Place old oil collecting and extracting device V.A.G 1782 under engine.
2. Remove bolts - arrows - and remove oil pipe.

Note. Oil escapes when removing oil lines.

Scheme 284

1. Remove bolts - arrows - and remove intake tube with oil baffle.

Scheme 285

1. Remove bolts - arrows - and remove oil line together with oil cooler by-pass valve housing.

Note. Oil escapes when removing oil lines.

Scheme 286

1. Remove bolts - arrows - and hold oil pump securely with hand.

Scheme 287

1. Pull oil pump input shaft - 1 - back against spring force with water pump pliers and remove oil pump.

Installing

Note. Always replace bolts that are tightened to torque as well as sealing rings and O-rings.

1. Check whether 2 alignment bushings are present in cylinder block, install if necessary.
2. Press oil pump input shaft - 1 - back with water pump pliers and place oil pump on cylinder block.
3. Open water pump pliers and let input shaft - 1 - glide into oil pump.

1. Tighten oil pump - arrows -.

Scheme 288

1. Check whether drive shaft is friction locked to oil pump. To do so, reach into intake opening - arrow - of oil pump and try to rotate oil pump gears.

1. Toothed gears must not be able to be rotated.

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

1. Install lower section of oil pan --> Installing under «Oil Pan Lower Section, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
2. Install coolant pump --> «Coolant Pump, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__coolant-pump-removing-and-installing) .
3. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-level-checking) .
4. Fill with coolant --> Filling under «Cooling System, Draining and Filling»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__cooling-system-draining-and-filling) .

Tightening Specifications

Scheme 289

1 - Oil pan (upper section)

1. Removing and installing --> «Oil Pan Upper Section, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-pan-upper-section-removing-and)

2 - Seals

1. Replace

3 - O-ring

1. Replace

4 - 14 Nm

5 - Seal

1. Replace

6 - Locking bolt - 35 Nm

Oil Pan Upper Section, Removing and Installing

Special tools, testers and auxiliary items required

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

Removing

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove engine --> «Engine, Removing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-removing) .
4. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-and-transmission-separating) .

1. Secure engine on engine and transmission holder --> «Engine, Securing to Engine and Transmission Holder»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-securing-to-engine-and-transmission) .
2. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .
3. Remove left and right timing chain covers --> «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__left-and-right-timing-chain-covers) .
4. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .

1. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
2. Remove lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__lower-timing-chain-cover-removing-and) .
3. Remove generator --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/s8/d3-2007-2011/remont/cruise-control-systems/#electrical-equipment) .
4. Remove front coolant pipe --> «Front Coolant Line, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__front-coolant-line-removing-and-installing) .

1. Remove coolant pump --> «Coolant Pump, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__coolant-pump-removing-and-installing) .

1. Disconnect electrical connector - 2 - at Oil Level Thermal Sensor G266.
2. Remove oil pan (lower part) - 1 - and pry out carefully.

Scheme 290

1. Remove oil pump --> «Oil Pump, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-pump-removing-and-installing) .
2. Remove bolts - 1 to 7 - for upper section of oil pan.
3. Press upper part of oil pan from alignment pins of cylinder block.

Installing

Note. Replace seals and O-rings.

Scheme 291

1. Using rotating plastic brush, remove any remaining sealant from oil pan (upper section) and at cylinder block.
2. Clean sealing surfaces, they must be free of oil and grease.

1. Cut off nozzle on tube of sealant at front mark (diameter of nozzle approximately 2 mm).

Scheme 292

1. Insert new seals - 1, 2, 3 - into grooves on cylinder block.

Scheme 293

1. Apply sealant bead - arrow - on clean sealing surface of upper section of oil pan as shown in illustration.

1. Thickness of sealant beads: 2.5 mm.

Note. Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the strainer on intake tube. The oil pan (upper section) must be installed within 5 minutes after application of sealant.

1. Position upper section of oil pan and hand tighten all bolts.
2. Tighten bolts - 1 to 7 - in 2 stages as follows.
3. Pre-tighten all the bolts in a diagonal sequence to 5 Nm.
4. Tighten bolts in a diagonal sequence to 14 Nm.

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

1. Install oil pump --> «Oil Pump, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-pump-removing-and-installing) .
2. Install lower section of oil pan --> Installing under «Oil Pan Lower Section, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
3. Install coolant pump --> «Coolant Pump, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__coolant-pump-removing-and-installing) .
4. Install front coolant pipe --> «Front Coolant Line, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__front-coolant-line-removing-and-installing) .

1. Install generator --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/s8/d3-2007-2011/remont/cruise-control-systems/#electrical-equipment) .
2. Install lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__lower-timing-chain-cover-removing-and) .
3. Install crankshaft seal, timing chain side --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__crankshaft-seal-timing-chain-side-replacing) .
4. Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .

1. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .
2. Install left and right timing chain covers --> Installing under «Left and Right Timing Chain Covers, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm) .
3. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__drive-plate-removing-and-installing) .
4. Install engine --> «Engine, Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__engine-installing) .

1. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-level-checking) .

Tightening specifications

Scheme 294

1 - O-ring

1. Replace

2 - Spray nozzle valve

1. Removing and installing --> «Oil Check Valve and Spray Nozzle Valve, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-check-valve-and-spray-nozzle)

3 - Gasket

1. Replace

4 - Cover

5 - O-ring

1. Replace

6 - Hose

1. For crankcase ventilation

7 - 9 Nm

8 - 9 Nm

9 - Oil check valve

1. Removing and installing --> «Oil Check Valve and Spray Nozzle Valve, Removing and Installing»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bsm__oil-check-valve-and-spray-nozzle)

10 - O-ring

1. Replace

Oil Check Valve and Spray Nozzle Valve, Removing and Installing

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

Removing

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .

Scheme 295

1. Remove bolts - 2 - and - 3 -.
2. Remove high pressure line - 1 - from fuel rail.
3. Remove high pressure line from connections - 4 - and - 5 - on fuel rail. To do this, counterhold at hex head with and open-end wrench and loosen union nut.
4. Remove high pressure lines.

Scheme 296

1. Remove bolts - arrows -.
2. Remove cover - 2 - with crankcase ventilation hose - 1 -.

Scheme 297

1. Remove oil check valve - 1 - and spray nozzle valve - 2 -.

Installing

Installation is in reverse order of removal, note the following

Note. Replace gaskets and O-rings.

1. Install high pressure lines --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) as described under "Fuel injectors, removing and installing".
2. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .

Tightening specifications

Crankcase Ventilation Hose, Removing and Installing

Removing

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s8/d3-2007-2011/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bsm) .

Scheme 298