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

General Information

> Clean Working Conditions

> Contact Corrosion

> Lines, Routing and Securing

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 1

1 - Cylinder block

1. Paired to - 12
2. Sealant applied on cylinder block (for guide frame) --> «Guide frame sealant application on cylinder block»(ref-289204-S16576188912008062700000)

2 - Seals

1. Replace

3 - Crankshaft seal, ribbed belt side

1. Replacing --> «Crankshaft Seal, Belt Pulley Side, Replacing»(ref-289204-S21011939322008062700000) .

4 - Alignment bushing

1. 3 pieces
2. Insert into guide frame
3. Installed location --> «Installation position of alignment bushings»(ref-289204-S38017570762008062700000)

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»(ref-289204-S35059408402008062700000)

9 - Baffle plate

10 - 9 Nm

1. Tightening order --> «Baffle plate tightening plate»(ref-289204-S02456562552008062700000)

11 - Bolt

1. For sealing surfaces of cylinder block/guide frame
2. Different bolt lengths
3. Tightening specifications and tightening sequence --> «Installing guide frame»(ref-289204-S35059408402008062700000)

12 - Bearing bracket

1. Paired to - 1
2. Sealant applied on cylinder block (for guide frame) --> «Guide frame sealant application on cylinder block»(ref-289204-S16576188912008062700000)
3. Tightening order --> «Installing guide frame»(ref-289204-S35059408402008062700000)

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»(ref-289204-S00951356672008062700000)

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»(ref-289204-S21191248812008062700000) , with used and reworked crankshafts --> «Main Bearing Shears, Used and Reworked Crankshafts, Allocating»(ref-289204-S09766166962008062700000)

15 - Crankshaft

1. Measuring axial play --> «Axial Clearance, Measuring»(ref-289204-S00951356672008062700000)
2. Radial clearance, measuring --> «Radial Clearance, Measuring»(ref-289204-S18402904872008062700000)
3. Do not turn crankshaft when measuring radial play
4. Crankshaft dimensions --> «Crankshaft Dimensions»(ref-289204-S40789089622008062700000)

16 - Thrust washer

1. Only at 4th crankshaft bearing
2. Lubricating grooves face outward
3. Measuring crankshaft axial clearance --> «Axial Clearance, Measuring»(ref-289204-S00951356672008062700000)

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»(ref-289204-S21191248812008062700000) , with used and reworked crankshafts --> «Main Bearing Shears, Used and Reworked Crankshafts, Allocating»(ref-289204-S09766166962008062700000)

18 - Seals

1. Replace

Scheme 2

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

Scheme 3

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 4

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

Scheme 5

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 6

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 7

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 8

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.

Piston and Connecting Rod, Component Overview

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

Scheme 9

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»(ref-289204-S32800379042008062700000)
3. Installation position of connecting rod pairs --> «Connecting rod, installed location»(ref-289204-S31129679062008062700000)

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»(ref-289204-S05605644112008062700000)
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»(ref-289204-S32800379042008062700000)
3. Installation position of connecting rod pairs --> «Connecting rod, installed location»(ref-289204-S31129679062008062700000)
4. Axial play for each new connecting rod pair: 0.20 to 0.38 mm

1. Radial clearance, measuring --> «Connecting Rod, Measuring Radial Clearance»(ref-289204-S05605644112008062700000)

5 - Piston pin

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

6 - Circlip

7 - Piston

1. Installation position of pistons --> «Piston installation position»(ref-289204-S38919402702008062700000)
2. Piston and cylinder dimension, piston allocation to cylinder bore --> «Piston and Cylinder Dimensions»(ref-289204-S25590583062008062700000)
3. Checking --> «Checking piston»(ref-289204-S07136840022008062700000)
4. Install with piston ring compressor

1. Measuring cylinder bore --> «Measuring cylinder bore»(ref-289204-S21567437572008062700000)

8 - Piston rings

1. Offset gaps by 120
2. Use piston ring pliers for removal and installation
3. "TOP" marking or inscribed side must point to piston head
4. Gap, measuring --> «Piston ring end gap, measuring»(ref-289204-S31699272042008062700000)

1. Measuring side clearance --> «Measuring piston ring side clearance»(ref-289204-S15201294742008062700000)

Scheme 10

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 11

1. Clean ring groove of piston before checking.

Scheme 12

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 13

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 14

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 15

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 16

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 17

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

Cylinder Head, Component Overview

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

Scheme 18

1 - Cylinder head gasket

1. Replacing --> «Cylinder Head, Removing and Installing»(ref-289204-S28932534492008062700000) .
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»(ref-289204-S28932534492008062700000)
2. Check for distortion --> «Checking cylinder head for distortion»(ref-289204-S41652398412008062700000)
3. Reworking dimension --> «Checking cylinder head for distortion»(ref-289204-S41652398412008062700000)
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»(ref-289204-S38994496072008062700000) , right --> «Right Cylinder Head Cover, Removing and Installing»(ref-289204-S04034480112008062700000)

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 --> see scheme 302

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 --> see scheme 316
3. Note tightening sequence --> see scheme 320

Scheme 19

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

1. Max. permissible distortion: 0.1 mm.

Scheme 20

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

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

Valvetrain, Component Overview

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

Scheme 21

1 - Sealing plug

1. Insert with sealant

2 - Valve stem seal

1. Replacing, Cylinder Head Installed --> «Valve Stem Seals, Cylinder Head Installed, Replacing»(ref-289204-S33259049032008062700000)
2. Replacing, Cylinder Head Removed --> «Valve Stem Seals, Cylinder Head Removed, Replacing»(ref-289204-S12985736402008062700000)

3 - Valve spring

1. Installed location --> «Installed position of valve spring»(ref-289204-S25684737312008062700000)

4 - Hydraulic adjusting element

1. Clipped into roller rocker lever - 8
2. Checking --> «Hydraulic Adjusting Elements, Checking»(ref-289204-S39718252622008062700000)
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»(ref-289204-S31103121852008062700000)
2. Checking axial play --> «Camshafts, Checking Axial Clearance»(ref-289204-S31386626142008062700000)
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»(ref-289204-S31103121852008062700000)

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

1. Replace
2. Observe tightening sequence --> «Camshaft guide frame, tightening sequence»(ref-289204-S35440182012008062700000)

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»(ref-289204-S31103121852008062700000)
2. Checking axial play --> «Camshafts, Checking Axial Clearance»(ref-289204-S31386626142008062700000)
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»(ref-289204-S14088712482008062700000)

21 - Intake valve

1. Do not rework, only lapping is permitted
2. Mark installed position for re-installation
3. Valve dimensions --> «Valve Dimensions»(ref-289204-S04178181422008062700000)
4. Check valve guides --> «Valve Guides, Checking»(ref-289204-S14088712482008062700000)

22 - Exhaust valve

1. Do not rework, only lapping is permitted
2. Mark installed position for re-installation
3. Valve dimensions --> «Valve Dimensions»(ref-289204-S04178181422008062700000)
4. Check valve guides --> «Valve Guides, Checking»(ref-289204-S14088712482008062700000)

Scheme 22

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

Scheme 23

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.