5.2L 10-CYL. 4V Engine Mechanical, Engine Code(s): Bsm: Maintenance Audi S8 D3 facelift

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 24

1 - Oil pan (lower section)

1. Removing and installing --> «Oil Pan Lower Section, Removing and Installing»(ref-289204-S35332422122008062700000)
2. With Oil Level Thermal Sensor G266
3. Oil Level Thermal Sensor G266 , removing and installing --> «Oil Level Thermal Sensor G266, Removing and Installing»(ref-289204-S10432607642008062700000)

2 - 9 Nm

1. Tighten diagonally in 2 stages --> Tighten bolts for lower part of oil pan in 2 stages as follows. under «Installing»(ref-289204-S27798828442009012300000)

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»(ref-289204-S17576375052008062700000)

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 25

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

Cooling System, Draining and Filling

Special tools, testers and auxiliary items required

Scheme 26

1. Adapter V.A.G 1274/8
2. Drip tray for workshop crane VAS 6208
3. Hose clamp pliers V.A.G 1921
4. Cooling system charge unit VAS 6096

1. Refractometer T10007

Draining

Note. Drained coolant must be stored in a clean container for disposal or reuse.

1. Remove cover above coolant reservoir - arrows -.

1. Open cap of coolant expansion tank.

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

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

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

Note. Ignore - 1 -.

Filling

1. Ignition switched off.

Note. The cooling system is filled all year round with a mixture of frost and corrosion protection additives and water. Use only coolant additive Plus G 012 A8F A1 (short: G12+) "according to TL VW 774 F". Other coolant additives may above all reduce the corrosion protection effect significantly. The damage resulting from this may lead to loss of coolant and consequently to severe engine damage. G12+ and coolant additives with the designation "according to TL VW 774 F" reduce frost and corrosion damage as well as lime deposits. They also raise the boiling point. For this reason the system must be filled all year round with frost and corrosion protection additives. Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates. Freeze protection must be guaranteed down to -25 C (in extremely cold countries to about -35 C). The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The coolant additive portion must be at least 40%. If for climatic reasons greater frost protection is required, the amount of G12+ can be increased, but only up to 60% (frost protection to about -40 C), otherwise frost protection and cooling effectiveness will be reduced. Only clean drinking water may be used for mixing coolant. If the radiator, heater core, cylinder head and cylinder head gasket or cylinder block is replaced, completely replace the engine coolant. Dirty coolant must not be re-used. For coolant G12+ , use refractometer T10007 to test frost protection in cooling system.

1. Reinstall drain plug - arrow - with new O-ring at coolant thermostat housing.

1. Reinstall drain plug - arrow - with new gasket at front coolant pipe.

1. Install lower coolant hose - 2 - on right auxiliary cooler - arrow -.

Scheme 27

1. Fill coolant reservoir of Cooling System Charge Unit VAS 6096 with at least 15 liters of pre-mixed coolant with correct mixture ratio

1. G12+ (60%) and water (40%) for freeze protection down to -25 C
2. G12+ (50%) and water (50%) for freeze protection up to -35 C
3. G12+ (60%) and water (40%) for freeze protection down to -40 C

1. Attach adapter V.A.G 1274/8 to coolant expansion tank.
2. Install Cooling System Charge Unit VAS 6096 on adapter V.A.G 1274/8.
3. Place air outlet hose - 1 - into a small container - 2 -. (A small amount of coolant is drawn off which should be reserved with the discharged air.)
4. Close both valves - A - and - B - by turning lever perpendicular to direction of flow.

1. Connect hose - 3 - to pressurized air.

1. Pressure: 6 to 10 bar pressure.

Scheme 28

1. Open valve - B - , turn lever in direction of flow to do this.

A vacuum is created in the cooling system by the suction jet pump.

1. Needle on the instrument display must travel into the green region.

1. Also briefly open valve - A - by turning lever in direction of flow so that Cooling System Charge Unit VAS 6096 coolant reservoir hose is filled with coolant.
2. Close valve - A - again.
3. Let valve - B - remain open another 2 minutes.

1. A further vacuum is created in the cooling system by the suction jet pump.
2. Needle on the instrument display must still remain in the green region.

1. Close valve - B -.

1. Needle in display must remain in green region, then vacuum in cooling system is sufficient for subsequent filling.

If needle stands below the green region, repeat procedure.

If the vacuum decreases, cooling system is leaking.

1. Disconnect pressurized air hose.
2. Open valve - A -.

The vacuum in the cooling system has the effect of extracting coolant from replacement reservoir; cooling system is filled.

1. Detach Cooling System Charge Unit VAS 6096 from adapter V.A.G 1274/8 on coolant expansion tank.

1. Remove rubber seal - 1 - and remove plenum chamber cover - 2 -.

Note. Ignore - 3 -.

Scheme 29

1. Open bleeder screws - arrows -.
2. Fill up coolant until it escapes from the bleeder holes in the coolant hoses.
3. Close bleeder screws.
4. Twist expansion tank cap closed.

1. Make sure that the auxiliary heater is switched off.
2. Start engine.
3. Set heating air conditioning system to "HI" on both sides.
4. Let engine run at 2000 RPM for 3 minutes.

1. Let engine run at idle long enough until both large coolant hoses on main cooler are warm.
2. Let engine run at 2000 RPM for 1 minute.
3. Turn off engine and allow it to cool off.

Scheme 30

1. Check coolant level.

1. With cold engine, coolant level must be at MAX marking.
2. Coolant level may be above MAX marking with engine at operating temperature.

Tightening Specifications

Scheme 31

1 - Seal

1. Replace

2 - Coolant pump housing

1. Removing and installing --> «Coolant Pump, Removing and Installing»(ref-289204-S27217030182008062700000)

3 - 8 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

4 - Front coolant line

1. Removing and installing --> «Front Coolant Line, Removing and Installing»(ref-289204-S04357474082008062700000)

5 - O-ring

1. Replace

6 - Seal

1. Replace

7 - Coolant pump

1. Removing and installing --> «Coolant Pump, Removing and Installing»(ref-289204-S27217030182008062700000)

8 - O-ring

1. Replace

9 - 9 Nm

10 - Drive shaft for coolant pump

11 - O-ring

1. Replace

12 - Thermostat housing

1. Removing and installing --> «Thermostat Housing, Removing and Installing»(ref-289204-S25991837152008062700000)
2. Coolant thermostat opening data --> «Thermostat Opening Data»(ref-289204-S31836316102008062700000)

13 - O-ring

1. Replace

14 - Drain plug - 4 Nm

15 - 9 Nm