Manual-Estudio (5 2L)

Service
Workshop Manual
Audi R8 2007 ➤
Audi R8 GT 2011 ➤
Audi R8 Spyder 2010 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-
valve)
BUJ CMP
Engine ID
CTY CTP CTP
A A A B
Edition 10.2019
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Audi AG, Ingolstadt D3E801AE1F3

Audi R8 2007 ➤ , Audi R8 GT 2011 ➤ , Audi R8 Spyder 2010 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve) - Edition 10.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 4
3.3 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Safety precautions when using testers and measuring instruments during a road test . . . . 5
3.5 Safety precautions when working on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Rules for cleanliness when working on fuel supply system and injection system . . . . . . . . 7
4.2 Checking for leaks on vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 General notes on self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.5 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.6 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.7 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.8 Nuts, bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.9 Identification plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.10 Use of impact wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.11 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.12 Fitting protective covers on bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.13 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Placing engine/gearbox assembly on scissor-type assembly platform . . . . . . . . . . . . . . . . 90
1.3 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.4 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.5 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.2 Removing and installing engine mountings with electro-hydraulic engine mounting solenoid
valves N144 / N145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.3 Exploded view - engine compartment cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.4 Removing and installing engine compartment cross member . . . . . . . . . . . . . . . . . . . . . . 118
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.1 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.1 Exploded view - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.4 Removing and installing bracket for alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.5 Removing and installing vibration damper with poly V-belt pulley . . . . . . . . . . . . . . . . . . . . 132
1.6 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.1 Exploded view - flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.2 Renewing ball bearing for crankshaft (gearbox end) - vehicles with manual gearbox/R tronic
gearbox 086 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Contents i
2.3 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

2.4 Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.1 Exploded view - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.2 Allocation of main bearing shells for new crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.3 Allocation of main bearing shells on used and machined crankshafts . . . . . . . . . . . . . . . . 147
3.4 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.5 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.6 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.7 Removing and installing intake module and retaining frame . . . . . . . . . . . . . . . . . . . . . . . . 149
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.3 Checking piston bores and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.4 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

1 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.1 Exploded view - timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.2 Removing and installing timing chain cover (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.3 Removing and installing timing chain cover (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.4 Removing and installing timing chain cover (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.5 Exploded view - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.6 Removing timing chains from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
1.7 Removing and installing camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.8 Exploded view - drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.9 Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.10 Exploded view - drive chain for auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.11 Removing and installing drive chain for auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.12 Exploded view - auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
1.13 Renewing oil seal for air conditioner compressor drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.14 Renewing oil seal for power steering pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.15 Removing and installing spur gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.1 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.2 Removing and installing cylinder head cover (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.3 Removing and installing cylinder head cover (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3.2 Measuring axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3.4 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3.5 Renewing valve stem oil seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . 227
3.6 Renewing valve stem oil seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . 230
3.7 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
3.8 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3.9 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3.10 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1 Oil pump and intake module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.1 Exploded view - oil pump, intake module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.2 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
ii Contents
2 Oil filter housing, engine oil cooler, oil retention valves, spray nozzle valve . . . . . . . . . . . . 243
2.1 Exploded view - oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.2 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
2.3 Exploded view - engine oil cooler (top), oil retention valves, spray nozzle valve . . . . . . . . 246
2.4 Removing and installing engine oil cooler (top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.5 Removing and installing mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2.6 Removing and installing oil retention valve “1” and spray nozzle valve . . . . . . . . . . . . . . . . 251
2.7 Removing and installing oil retention valve “2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
2.8 Exploded view - crankcase breather hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
2.9 Removing and installing crankcase breather hoses “1” and “2” . . . . . . . . . . . . . . . . . . . . 255
2.10 Removing and installing crankcase breather hose “3” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2.11 Removing and installing crankcase breather hose “4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2.12 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
2.13 Checking oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
2.14 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2.15 Removing and installing oil temperature sender 2 G664 . . . . . . . . . . . . . . . . . . . . . . . . . . 260
2.16 Exploded view - oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
2.17 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 264
2.18 Removing and installing oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
2.19 Exploded view - engine oil cooler (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
2.20 Removing and installing engine oil cooler (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
2.21 Removing and installing temperature regulator for engine oil cooler . . . . . . . . . . . . . . . . . . 271
2.22 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
2.23 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
2.24 First filling of engine with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
2 Coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
2.1 Exploded view - thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
2.2 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
2.3 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
2.4 Exploded view - coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
2.6 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 292
2.7 Exploded view - gearbox coolant pump V532 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
2.8 Removing and installing gearbox coolant pump V532 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
3.1 Exploded view - coolant pipes at front and in centre of vehicle . . . . . . . . . . . . . . . . . . . . . . 295
3.2 Exploded view - coolant pipes (rear) to body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3.3 Exploded view - coolant expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
3.4 Fitting coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
3.5 Removing and installing large coolant pipe (rear left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
3.6 Removing and installing small coolant pipe (rear left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3.7 Removing and installing coolant pipe (rear right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3.8 Removing and installing coolant pipe (rear right) to ATF cooler . . . . . . . . . . . . . . . . . . . . 303
3.9 Removing and installing coolant pipes located at centre of vehicle . . . . . . . . . . . . . . . . . . 305
3.10 Removing and installing coolant supply pipe (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
3.11 Removing and installing coolant supply pipe (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . 311
3.12 Removing and installing coolant return pipe (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3.13 Removing and installing coolant return pipe (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
4 Radiator and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Contents iii
4.1 Exploded view - side radiators and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

4.2 Removing and installing side radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
4.3 Removing and installing radiator cowl with radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . 320
4.4 Removing and installing radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.5 Exploded view - radiator (centre) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
4.6 Removing and installing radiator (centre) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
1.2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
2 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
2.1 Exploded view - air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
2.2 Removing and installing air filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
2.3 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
2.4 Removing and installing air mass meter G70 / air mass meter 2 G246 . . . . . . . . . . . . . . 348
3 Intake manifold, fuel rail and injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
3.1 Exploded view - intake manifold (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
3.2 Removing and installing throttle valve module J338 / throttle valve module 2 J544 . . . . . . 351
3.3 Removing and installing intake manifold (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3.4 Exploded view - intake manifold (bottom section), fuel rail and injectors . . . . . . . . . . . . . . 356
3.5 Removing and installing intake manifold (bottom section) with fuel rail . . . . . . . . . . . . . . . . 358
3.6 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
4 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
4.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
4.2 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
4.3 Removing and installing high-pressure pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
4.4 Removing and installing fuel pressure sender G247 / fuel pressure sender 2 G624 . . . . 372
5 Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
5.1 Overview - Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
5.2 Removing and installing Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
6 Engine control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
6.1 Exploded view - engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
6.2 Wiring and component check with test box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . . . . . . . 378
6.3 Removing and installing engine control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387

1 Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
1.2 Exploded view - heat shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
1.3 Removing and installing silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
1.4 Renewing exhaust pipe with exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
2 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
2.1 Exploded view - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
2.2 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
3 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
3.1 Exploded view - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
3.2 Removing and installing secondary air pump motor V101 / V189 . . . . . . . . . . . . . . . . . . . . 405
3.3 Checking combination valves for secondary air system for correct operation and leakage
........................................................................ 407
3.4 Removing and installing combination valve for secondary air system (left-side) . . . . . . . . 409
3.5 Removing and installing combination valve for secondary air system (right-side) . . . . . . . . 411
3.6 Removing and installing senders for secondary air pressure G609 / G610 . . . . . . . . . . . . 412
4 Exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
iv Contents
4.1 Checking vacuum unit for exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
1.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
1.2 Exploded view - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
1.3 Removing and installing ignition coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
1.4 Removing and installing knock sensors G61 / G66 / G198 / G199 . . . . . . . . . . . . . . . . . . 419
1.5 Removing and installing Hall senders G40 / G163 / G300 / G301 . . . . . . . . . . . . . . . . . . 420
1.6 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Contents v
vi Contents
00 – Technical data
1 Engine number
(ARL006557; Edition 10.2019)
♦ The engine number (engine code and serial number) is loca‐
ted on the top of the cylinder block at the front -arrow-.
♦ Engine codes starting with the letter “C” have four letters (pre‐
viously three letters).
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
are stamped onto the cylinder block together with the serial
number.
♦ The 4th character indicates the power output and torque of the
engine and is determined by the engine control unit.
Note
♦ The engine code is also included on the vehicle data sticker.

♦ The four-letter engine code is found on the type plate (certain
countries only), vehicle data sticker and engine control unit.
♦ Fitting locations of the type plate (certain countries only) and
the vehicle data sticker ⇒ Maintenance ; Booklet 420 .
1. Engine number 1
2 Engine data
Code letters BUJ CMPA CTPA
Capacity ltr. 5.204 5.204 5.204
Power out‐ kW at rpm 386/8000 412/8000 404/8000
put
Torque Nm at rpm 530/6500 540/6500 540/6500
Bore ∅ mm 84.5 84.5 84.5
Stroke mm 92.8 92.8 92.8
Compression ratio 12.5 12.5 12.5
RON at least 981) 981) 981)
Injection system/ignition system Bosch Motronic Bosch Motronic Bosch Motronic
Firing order 1-6-5-10-2-7-3-8-4-9 1-6-5-10-2-7-3-8-4-9 1-6-5-10-2-7-3-8-4-9
Turbocharging/supercharging no no no
Knock control 4 sensors 4 sensors 4 sensors
Lambda control 2 probes before cat‐ 2 probes before cat‐ 2 probes before cat‐
alytic converter alytic converter alytic converter
2 probes after cata‐ 2 probes after cata‐ 2 probes after cata‐
lytic converter lytic converter lytic converter
Variable valve timing Inlet Inlet Inlet
Exhaust Exhaust Exhaust
Intake manifold change-over Yes Yes Yes
Secondary air system Yes Yes Yes
Valves per cylinder 4 4 4
• 1) Unleaded premium RON 95 can also be used, but results in reduced power
Code letters CTPB CTYA

Capacity ltr. 5.204 5.204
Power out‐ kW at rpm 419/8000 386/8000
put
Torque Nm at rpm 540/6500 530/6500
Bore ∅ mm 84.5 84.5
Stroke mm 92.8 92.8
Compression ratio 12.5 12.5
RON at least 981) 981)
Injection system/ignition system Bosch Motronic Bosch Motronic
Firing order 1-6-5-10-2-7-3-8-4-9 1-6-5-10-2-7-3-8-4-9
Turbocharging/supercharging no no
Knock control 4 sensors 4 sensors
Lambda control 2 probes before cat‐ 2 probes before cat‐
alytic converter alytic converter
2 probes after cata‐ 2 probes after cata‐
lytic converter lytic converter
Variable valve timing Inlet Inlet
Exhaust Exhaust
Intake manifold change-over Yes Yes
Secondary air system Yes Yes
Valves per cylinder 4 4
• 1) Unleaded premium RON 95 can also be used, but results in reduced power
2 Rep. gr.00 - Technical data

2. Engine data 3
3 Safety precautions
⇒ “3.1 Safety precautions when working on the fuel supply sys‐
tem”, page 4
⇒ “3.2 Safety precautions when working on vehicles with start/
stop system”, page 4
⇒ “3.3 Safety precautions when working on the cooling system”,
page 4
⇒ “3.4 Safety precautions when using testers and measuring in‐
struments during a road test”, page 5
⇒ “3.5 Safety precautions when working on the ignition system”,
page 5
3.1 Safety precautions when working on the fuel supply system

Risk of injury - fuel system operates under high pressure
The fuel system is pressurised. There is a risk of injury as fuel
may spray out.
Before opening the fuel system:
– Put on safety goggles.
– Put on protective gloves.
– Release pressure (wrap a clean cloth around connection and
open connection carefully).
Risk of fire due to escaping fuel

If the battery is connected, the door contact switch activates the
fuel pump when the driver's door is opened. Escaping fuel may
ignite, causing a fire.
– Before opening the fuel system, disconnect power supply to
fuel pump.
3.2 Safety precautions when working on vehicles with start/stop system

Risk of injury - engine may start unexpectedly
The engine can start unexpectedly if the vehicle's start/stop sys‐
tem is activated. A message in the instrument cluster indicates
whether the start/stop system is activated.
– To deactivate the start/stop system, switch off the ignition.
3.3 Safety precautions when working on the cooling system

Risk of scalding as hot coolant can escape
The cooling system is under pressure when the engine is hot. Risk
of scalding due to hot steam and hot coolant.
– Put on protective gloves.
– Put on safety goggles.

– Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
3.4 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury if test equipment is not secured
If an accident occurs and the front passenger's airbag is triggered,
test equipment which is not secured adequately may be catapul‐
ted through the vehicle with potentially serious consequences.
– Set passenger seat to rearmost position.
– Use only vehicle diagnosis and service information system -
VAS 5052 A- or diagnosis system - VAS 5053- .
– The test equipment -1- must rest flat on the passenger's thighs
(as shown in illustration) and must be operated by the pas‐
senger.
3.5 Safety precautions when working on the ignition system

Risk of injury due to electric shock
When the engine is running, there are high voltage levels in the
ignition system. There is a risk of electric shock when touching
the ignition system!
– Never touch or disconnect ignition wiring when the engine is
running or being turned at cranking speed.
Risk of damage to components

Washing the engine or connecting/disconnecting electrical wiring
may result in components being damaged if the engine is running.
– Switch off ignition before connecting/disconnecting electrical
wiring.
– Switch off ignition before cleaning engine.
3. Safety precautions 5

4 General repair instructions

⇒ “4.1 Rules for cleanliness when working on fuel supply system
and injection system”, page 7
⇒ “4.2 Checking for leaks on vehicle”, page 7
⇒ “4.3 General notes on self-diagnosis”, page 8
⇒ “4.4 General notes on ignition system”, page 8
⇒ “4.5 Foreign particles in engine”, page 9
⇒ “4.6 Contact corrosion”, page 9
⇒ “4.7 Routing and attachment of pipes, hoses and wiring”, page
9
⇒ “4.8 Nuts, bolts”, page 9
⇒ “4.9 Identification plates”, page 10
⇒ “4.10 Use of impact wrenches”, page 10
⇒ “4.11 Installing radiators and condensers”, page 11
⇒ “4.12 Fitting protective covers on bodywork”, page 11
⇒ “4.13 Checking vacuum system”, page 11
4.1 Rules for cleanliness when working on

fuel supply system and injection system
Even small quantities of dirt can lead to defects. When working
on the fuel supply system and injection system, pay careful at‐
tention to the following basic rules:
♦ Clean connections and surrounding area thoroughly with en‐
gine cleaner or brake cleaner and dry cleaned area before
loosening.
♦ Immediately seal open lines and connections with clean plugs,
for example from engine bung set - VAS 6122- .
♦ After removal, place parts on a clean surface and cover them.
Only use lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use any
parts that have been unpacked previously and stored away
loosely (e.g. in a tool box).
♦ Do not work with compressed air when the system is open. If
possible, do not move vehicle.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
4.2 Checking for leaks on vehicle

With vehicle stationary:
– Interrogate entries in event memory ⇒ Vehicle diagnostic test‐
er, Guided Functions , Interrogate event memory . If
event memory has been erased, Generate readiness
code .
– Let engine idle with vehicle stationary until oil temperature

reaches 80°.
– Switch off ignition.
4. General repair instructions 7

– Check all pipe connections for leaks and check complete fuel
system for leaks.
Note
If leaks are found although the connections have been tightened

to the correct torque, the relevant component must be renewed.

code .
– Assemble vehicle completely in accordance with the proce‐

dures described in the corresponding sections of the Work‐
shop Manual.
Road test:
– Road-test vehicle over a distance of 30 km (19 miles) and ac‐
celerate with full throttle at least once.
– Check all pipe connections again for leaks and check com‐
plete fuel system for leaks (remove engine compartment trim
panels, noise insulation and/or wheel housing liners, depend‐
ing on repairs performed prior to road test).
code .
– Assemble vehicle completely.
4.3 General notes on self-diagnosis

♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding, the event memory must
be interrogated. The vacuum hoses and connections must al‐
so be checked (unmetered air).
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. O-type clips or screw-type clips must not be
used.
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and will
damage the Lambda probe.
♦ The vehicles are fitted with a crash fuel shut-off system. This
system is designed to reduce the risk of a vehicle fire after a
crash by deactivating the fuel pump via the fuel pump relay.
♦ At the same time, this system also improves the engine's start‐
ing performance. When the driver's door is opened, the fuel
pump is activated for 2 seconds in order to build up pressure
in the fuel system
⇒ “3.1 Safety precautions when working on the fuel supply
system”, page 4 .
♦ Use release tool - T40138- to unplug connectors that cannot
be accessed easily.
4.4 General notes on ignition system

♦ The engine control unit has a self-diagnosis capability.

♦ A voltage of at least 11.5 V is required for proper operation of

the electrical components.
♦ During some of the tests the control unit may detect a fault and
store it in the memory. The event memory should therefore be
interrogated and, if necessary, erased after completing all
tests and repair work.
♦ If the engine starts, runs for a short period and then cuts out
after completing fault finding, repairs or component tests, this
may be due to the immobiliser disabling the engine control
unit. The event memory must then be interrogated and, if nec‐
essary, the control unit must be adapted.
4.5 Foreign particles in engine

♦ When performing assembly work on the engine, all open pas‐
sages in the intake and exhaust systems must be sealed with
suitable plugs (e.g. from engine bung set - VAS 6122- ) to
prevent foreign particles from entering the engine.
♦ In the event of mechanical damage to one of the cylinder
banks, the intake and exhaust systems and combustion cham‐
bers of the opposite cylinder bank must always be examined
to prevent further damage occurring later.
♦ If large quantities of metal shavings or abrasion are found
when performing engine repairs, this may be an indication of
damage to the crankshaft or conrod bearings. To prevent fur‐
ther damage, the following steps are required after completion
of repair work: clean oil passages carefully and renew the oil
spray jets, engine oil cooler, oil pipes, oil hoses and oil filter.
4.6 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Please note:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend using Audi Genuine Accessories.
♦ Damage caused by contact corrosion is not covered by war‐
ranty.
4.7 Routing and attachment of pipes, hoses

and wiring
Mark hydraulic lines, vacuum lines and electrical wiring before
removal so they can be re-installed in the original positions and
correctly connected. Make sketches or take photographs if nec‐
essary.
4.8 Nuts, bolts

♦ Loosen bolts in reverse sequence to specified tightening se‐
quence.
♦ Bolts and nuts used to secure covers and housings must be
tightened in steps according to the specified tightening se‐
quence and method.

♦ Bolts and nuts which secure covers and housings should be

loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ Always renew self-locking bolts and nuts.
♦ Unless otherwise specified, use a wire brush to clean the
threads of bolts which are secured with locking fluid. Then in‐
stall bolts with locking fluid; for locking fluid refer to ⇒ Elec‐
tronic parts catalogue .
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned using a thread tap or similar.
Otherwise there is a danger of the bolts shearing off the next
time they are removed.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
4.9 Identification plates

When renewing vehicle components, the identification plates on
the old parts that have a replacement part number (see ⇒ Elec‐
tronic parts catalogue ) must be attached to the new parts due to
approval regulations.
4.10 Use of impact wrenches

In general, it is permitted to use an impact wrench to unscrew
bolts and nuts. An exception to this is when work is performed
inside an open high-voltage battery. For this work, it is not per‐
mitted to use an impact wrench.
An impact wrench may be used to screw in bolts and nuts when
performing repair work if the following requirements are observed.
In general, electric and compressed-air impact wrenches should
be used.
Requirements:
• Only screw in bolts with locking fluid or self-locking nuts at low
speed.
• Use a suitable impact wrench with variable speed and adjust‐
able torque range.
• Use suitable bits when working in the vicinity of sensitive sur‐
faces, e.g. plastic-coated bits for aluminium rims.
• When working in the vicinity of natural gas systems, observe
the information in the Workshop Manual “Natural gas engines
- General information”.
Use:
• Fit bolts/nuts by hand.
• Only use an impact wrench to screw in bolts/nuts until the head
of the bolt/nut makes contact and then continue tightening with
a torque wrench.
• Clean threaded pins before unscrewing the bolt/nut.

4.11 Installing radiators and condensers

Even when the radiator and condenser are correctly installed,
slight impressions may be visible on the fins of these components.
This does not mean that the components are damaged. If the fins
are only very slightly distorted, this does not justify renewal of the
radiator or the condenser.
4.12 Fitting protective covers on bodywork

Special tools and workshop equipment required
♦ Rear end protector (Audi R8) - VAS 6411-
♦ Side panel protector (Audi R8) - VAS 6412- or
♦ Side panel protector (Audi R8 Spyder) - VAS 6428-
Procedure
Note
Door protectors (Audi R8) - VAS 6413- are not necessary when
working on the engine compartment.
– Wash affected parts of body and dry with chamois leather.

R8 Coupé and R8 GT:
– Fit side panel protectors (Audi R8) - VAS 6412- on side panels
(rear left and right).
– Fit rear end protector (Audi R8) - VAS 6411- so that ends
overlap with side panel protectors.
R8 Spyder:
– Fit side panel protectors (Audi R8 Spyder) - VAS 6428- on side
panels (rear left and right).
– Fit rear end protector (Audi R8) - VAS 6411- so that ends
overlap with side panel protectors.
4.13 Checking vacuum system


♦ Hand vacuum pump - VAS 6213-
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ Porous or leaking lines
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If an entry is stored in the event memory, check the vacuum
lines leading to the corresponding component and also check
the remaining vacuum lines in the system.
– If it is not possible to build up a vacuum with the hand vacuum
pump - VAS 6213- or if the vacuum pressure drops again im‐
mediately, check the hand vacuum pump and connecting
hoses for leaks.
Vacuum units
– After renewing intake manifold (bottom section) with vacuum
unit, check vacuum system for leaks.
– If there are still leaks, remove intake manifold (bottom section)
and trace leaks.
– Also check that intake manifold flaps function correctly and are
not obstructed by guide plates in cylinder head.

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 13
⇒ “1.2 Placing engine/gearbox assembly on scissor-type assem‐
bly platform”, page 90
⇒ “1.3 Separating engine and gearbox”, page 94
⇒ “1.4 Securing engine to engine and gearbox support”,
page 103
⇒ “1.5 Installing engine”, page 107
1.1 Removing engine

⇒ “1.1.1 Removing engine - R8 Coupé with manual gearbox/
R tronic gearbox”, page 13
⇒ “1.1.2 Removing engine - R8 Coupé with dual clutch gearbox
0BZ”, page 32
⇒ “1.1.3 Removing engine - R8 Spyder with manual gearbox/R
tronic gearbox”, page 52
⇒ “1.1.4 Removing engine - R8 Spyder with dual clutch gearbox
0BZ”, page 71
1.1.1 Removing engine - R8 Coupé with manual gearbox/R tronic gearbox
1. Removing and installing engine 13

Special tools and workshop

equipment required
♦ Adapter - 10 - 222 A /7-

♦ Removal lever - 80 - 200-
♦ Lifting tackle - 2024 A-
♦ Lifting tackle - 3033-
♦ Hose clamps up to 25 mm - 3094-
♦ Counterhold tool - 3145-
14 Rep. gr.10 - Removing and installing engine

♦ Used oil collection and extraction unit - VAS 6622A- or used

oil collection and extraction unit - V.A.G 1782-
♦ Workshop hoist - VAS 6100-
♦ Lift arm extension/workshop hoist - VAS 6101-
♦ Engine bung set - VAS 6122-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Hose clip pliers - VAS 6362-
♦ Support - T40137-

♦ Bracket - T10059-
Procedure
Note
♦ The engine is removed upwards together with the gearbox.

♦ Fit all cable ties in the original positions when installing.
♦ All bolts on running gear components with bonded rubber
bushes must be tightened with suspension in unladen position
(vehicle unladen).
♦ Bonded rubber bushes can only be turned to a limited extent.
Therefore, before tightening the bolts, suspension compo‐
nents with bonded rubber bushes must be brought into a
position corresponding to the normal position while driving
(unladen position). Otherwise, the bush would be subject to
torsion loading and its service life shortened.
♦ Before starting work, use measuring tape or similar to meas‐
ure distance -a- from centre of wheel to lower edge of wheel
housing.
♦ This measurement must be taken with the suspension in the
unladen position (vehicle unladen).
♦ Make a note of the measured value. This will be needed when
tightening the bolts/nuts on the suspension.
– Remove engine compartment trim panels on both sides ⇒

Rep. gr. 53 .
– Fit protective covers on bodywork ⇒ page 11 .

– Remove engine cover panel ⇒ page 128 .
WARNING
Risk of accident.
♦ Knurled sleeves -arrows- must be tightened before work‐
ing on vehicle.
– Move rear lid to service position ⇒ Rep. gr. 55 .

– Remove side panel trim on left and right ⇒ Rep. gr. 53 .
– Discharge refrigerant system ⇒ Air conditioner with refrigerant
R134a .
– Extract hydraulic fluid for power steering from reservoir using
used oil collection and extraction unit - VAS 6622A- .
– Remove front passenger's seat ⇒ Rep. gr. 72 .
– Remove both rear wheels ⇒ Wheels and tyres; Rep. gr. 44 .
– Remove rear and front noise insulation ⇒ Rep. gr. 66 .
– Remove rear left and right wheel housing liners ⇒ Rep. gr.
66 .
– Remove rear impact bar ⇒ Rep. gr. 63 .
– Remove left and right tail lights ⇒ Electrical system; Rep. gr.
94 .
– Remove rear member ⇒ Rep. gr. 53 .
Caution
When disconnecting the battery there is a risk of irreparable

damage to electronic components.
♦ Observe notes on procedure for disconnecting the battery.
– With ignition switched off, disconnect earth cable arrow at bat‐

tery ⇒ Electrical system; Rep. gr. 27 .
WARNING
Risk of scalding due to hot steam and hot coolant.

♦ The cooling system is under pressure when the engine is
hot.
♦ To allow pressure to dissipate, cover filler cap on coolant
expansion tank with cloth and open carefully.
– Open filler cap on coolant expansion tank.

– Place drip tray for workshop hoist - VAS 6208- beneath en‐
gine.
– Unscrew drain plug -arrow- at intake module and drain off
coolant.
– Remove drain plug -arrow- at thermostat housing and drain off

coolant.
– Release hose clips -1, 2, 3- and disconnect coolant hoses.

– Move coolant hose -arrow- clear.
– Drain off engine oil ⇒ Maintenance ; Booklet 420 .
– Position used oil collection and extraction unit - VAS 6622A-

below connection point.
– Remove bolts -1- and -2- and disconnect pipe/hose assem‐
blies.
– Seal off open lines and connections with clean plugs from en‐
gine bung set - VAS 6122- .
– Remove propshaft ⇒ Rep. gr. 39 .

– Counterhold flange -1- of transmission shaft using counterhold

tool - 3145- and remove nut -2-. Then take off flange and, if
fitted, damper weight.
Note
If the flange of the transmission shaft cannot be removed by hand,

use a puller (normal commercially available type).
Caution
Risk of damage to refrigerant lines and hoses

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Unscrew nut -1- from retaining clamp or cut through cable tie
(depending on version).
– Remove bolt -2- and disconnect refrigerant line.
– Remove bolt -arrow-, detach refrigerant line from reservoir and

place it in the engine compartment.
– Remove bolts for engine mountings -arrows- (left and right).

– Remove bolts -2- and disconnect oil line from oil reservoir.
Caution
Take care to keep components clean.

♦ There will still be some oil in the oil line.
– Remove bolt -1- for earth wire.
– If engine is to be separated from gearbox after removing en‐

gine/gearbox assembly, remove bolt -9- and nuts -1, 7, 8-
securing engine to gearbox.

– Disconnect power steering hydraulic line at connection -1-.
– Remove bolt -2- from retaining clip.

below connection points.
– Remove bolt -arrow- and disconnect gearbox oil lines from
temperature regulator.

– Unbolt drive shafts -2- (left and right) from gearbox.
– Release hose clips -2- and -4-.

– Remove bolts -arrows- for air cleaner housing.
– Detach boots -1- and -6- from air cleaner housing.
– Unplug electrical connectors:
3 - On air mass meter 2 - G246-
5 - On air mass meter - G70-
– Remove air cleaner housing with air mass meters.
– Disconnect vacuum hose -1- for brake servo.

Note
Disregard -item 2-.

WARNING
The fuel system is pressurised.

Risk of injury as fuel may spray out.
♦ Put on safety goggles.
♦ Put on protective gloves.
♦ Release pressure (wrap clean cloth around connection
and open connection carefully).
– Disconnect fuel supply line -1- and move to one side.

Note
Disregard -item 2-.
– Remove nuts -1, 3- and bolt -4-.

– Move vacuum line -2- clear.
– Move electrical wiring harness clear -arrow-.
– Pull heat shield off threaded pin.
– Repeat procedure on opposite side of vehicle.
– Unplug electrical connector -1-.

– Remove nuts -arrows-.

– Press release tabs and disconnect secondary air hoses

-arrows-.
– Remove nut -1-, detach secondary air pump (right-side) and
move wiring harness clear.
– Loosen clamp -1- on exhaust pipe (left-side), move clamp and

spring element outwards -arrow- and detach clamp.
Note
If clamp is difficult to remove, use multi-purpose tools -VW 771/1-

and -VW 771/3- in conjunction with oil seal extractor lever - VW
681- to detach clamp.
Note
The assistance of a second person is required to remove the si‐

lencer.
– Remove nut -arrow- on heat shield.

– Disconnect vacuum hose -1- from vacuum unit for exhaust flap
and move hose clear.
– Remove bolts -2- and -4- and detach bush -3-.
– Detach silencer.
– Remove bolts -1- and -2- on both sides and take off anti-roll
bar.

– Detach vacuum hose -1- for vacuum unit for exhaust flap from
T-connector -2- and place on left side.
– Unplug electrical connector -arrow- at exhaust flap 1 valve -
N321- and move wiring clear.
– Disconnect vacuum hose -arrow-.
– Detach hoses -1- and -3- for crankcase breather from oil res‐
ervoir (press release tabs).
– Move crankcase breather hose clear at engine compartment
cross member -arrows-.
– Move crankcase breather hoses to front.
Note
Lay a cloth under the separating point to catch escaping hydraulic

fluid.
– Detach supply hose -1- for power steering hydraulic fluid.

– Remove bolts -2- and move power steering reservoir clear to
one side.

– If fitted, move breather hose clear -arrows-.
– Remove bolts -arrows- (left and right).
– Detach boots -1- (left and right) -arrow-.
– Remove bolt -3- on retaining clip for electrical wiring harness.

– Move wiring harness on engine compartment cross member
clear.
– Remove bolts -1-.
– Remove bolts -arrows- on both sides (hold spacer plates -2-
in position).
– Using felt-tip pen, mark position of spacer plates on both sides
for re-installation in the original position and detach.
– Lift cross member out of engine compartment.


– Remove bolts -4- and disconnect oil line -3-.
– Remove bolts -1- and -2- and take out oil reservoir.
Note
Bolt -2- can be accessed from the wheel housing (left-side).
– Detach air duct -1- from engine oil cooler towards rear
-arrows-.
Note
Lay a cloth under the separating point to catch escaping engine

oil.
– Remove bolt -arrow-, disconnect oil line -1- from engine oil
cooler (left-side) and remove.
Vehicles with manual gearbox:

– Press locking sleeve to front as far as stop -arrow 1-.
– Turn locking sleeve to right as far as stop -arrow 2- and allow
to engage.
– Detach cable end-piece -A- from corresponding gear selector
cable -B-.

– Detach securing clips -1- and -2-.

– Pull gear selector cables out of cable support bracket and
move clear on engine.
– Remove bolts -arrows- and detach cable support bracket.
Note
Lay a cloth under the separating point to catch escaping brake

fluid.
– Clamp off pipe/hose assembly using hose clamps up to 25 mm

- 3094- .
– Remove banjo bolt -arrow- and move pipe/hose assembly
clear to one side.
Caution
Risk of contamination by escaping brake fluid.

♦ Do not operate clutch pedal after detaching pipe/hose as‐
sembly from clutch slave cylinder.
Vehicles with R tronic:

– Remove bolt -arrow- and move retaining bracket with electrical
connector to one side.
All vehicles (continued):

– Press release tabs and disconnect secondary air hose -1-.
– Unplug electrical connector -2- at secondary air pump motor 2
- V189- .
Note
Disregard -arrows-.

– Remove bolt -arrow- and move wiring harness clear.
– Press release tabs and disconnect secondary air hose

-arrow- from combination valve for secondary air system
(right-side).
– Press release tab and disconnect vacuum hose -1- at activa‐

ted charcoal filter.
– Move hose clear -arrow-.
– Move wiring harness clear at longitudinal member (right-side).
– Unplug electrical connector -2- at coolant shortage indicator

switch - F66- .
– Detach coolant hoses -1- and -3-.
– Slide coolant expansion tank forwards slightly -arrow- and de‐
tach it from bracket.
– Detach coolant hose -4-.

– Unscrew bolts -arrows- and detach bracket for coolant expan‐

sion tank.
– Remove sill panel trim (right-side), A-pillar trim (bottom right),
rear shelf and side trim (right-side) ⇒ Rep. gr. 70 .
– Remove rear right mid-range and bass loudspeaker - R160-
⇒ Rep. gr. 91 .

– Unplug electrical connectors -1- and -2- at automatic gearbox
control unit - J217- .
– Remove bolts -arrows- at relay carrier and at fuse holder.
– Remove positive wire -4-.
– Unplug electrical connectors -3- at connector console.
– Move clear wiring harness.
Note
Use removal lever - 80 - 200- to lever out the wiring clips.
– Mark position of relay in relation to relay socket for re-instal‐

lation.
– Remove relay carrier and detach relays.
– Detach relay socket from relay carrier (release all retainers
-arrows A-).
– Detach fuse socket from relay carrier (release retainers
-arrows B-).

– Remove base retainer for fuse holder (rear right) from retainer.
– Release retaining clips -arrows- and press fuse holders -1-
and -2- to rear out of base retainer.
– Move engine wiring harness clear and guide carefully through
into engine compartment.
– Fold back floor covering in area of A-pillar (right-side).

– Turn catches -1- and -3- 90° in anti-clockwise direction and
open cover -2- above main fuse box.
– Remove nut -2- securing battery positive wire -1-.

– Move battery positive wire clear as far as engine compartment,
pull out towards rear and place on engine.
Note

– Remove bolt -1- for earth wires.

– Loosen nuts -arrows-, move retaining clips to the side and de‐
tach engine control unit 2 - J624- .
– Move electrical wiring clear and place engine control unit 2 -
J624- on engine (wiring remains connected).
Note
Secure the engine control units to prevent them falling.
– Remove nuts -1- for gearbox mounting on both sides (coun‐

terhold with open-end spanner -2-).
– Secure support - T40137- to gearbox and tighten to 20 Nm.
– Fit shackle - T10059- on lifting tackle - 2024A- , as shown in

illustration, and secure pin -1- with split pin.
– Engage lifting tackle - 2024 A- in front lifting eyes on engine.
WARNING
There is a risk of injury if lifting components are not secured.

♦ The support hooks and retaining pins on the lifting tackle
must be secured with locking pins -arrows-.

– Attach lifting tackle - 3033- with adapter - 10 - 222 A /7- to

engine and workshop hoist as shown in illustration.
Caution
Danger of damage to hose and wiring connections and to en‐

gine compartment.
♦ Check that all hoses and electrical connections between
engine/gearbox assembly and body have been detached.
♦ Carefully guide engine/gearbox assembly out of engine
compartment when lifting out.
– Use workshop hoist - VAS 6100- to lift engine/gearbox as‐

sembly and carefully guide out to rear.
Caution
Risk of damage to intake module.

♦ Do not place the engine/gearbox assembly on a work‐
bench or on the ground with it resting on the intake mod‐
ule.
– Position engine/gearbox assembly on scissor-type assembly

platform - VAS 6131 B- ⇒ page 90 .
1.1.2 Removing engine - R8 Coupé with dual clutch gearbox 0BZ


equipment required



♦ Shackle - 10-222A/12-

♦ Shackle - VAS 691 009-
♦ Retaining strap - T40155-
♦ Front-end hook - 3370-

Procedure
Note

(vehicle unladen).
housing.

Rep. gr. 53 .

WARNING
Risk of accident.
♦ Knurled sleeves -arrows- must be tightened before work‐
ing on vehicle.
– Move rear lid to service position ⇒ Rep. gr. 55 .

– Remove side panel trim on left and right ⇒ Rep. gr. 53 .
R134a .
66 .
– Remove tail lights (left and right) ⇒ Electrical system; Rep. gr.
94 .
Caution

– With ignition switched off, disconnect earth cable arrow at bat‐

tery ⇒ Electrical system; Rep. gr. 27 .
WARNING

hot.

gine.
coolant.
– Remove drain plug -arrow- on thermostat housing using front-

end hook - 3370- and drain off coolant.

– Move coolant hose -arrow- clear.

blies.


tool - 3145- and remove nut -2-. Then take off flange and
damper weight.
Note

Caution

– Unscrew nut -1- from retaining clamp or cut through cable tie
(depending on version).


– Remove bolts -2, 3- and pull pipe/hose assemblies -1, 4- out

of oil reservoir.
Caution

♦ There will still be some oil in the pipe/hose assembly.
– Remove bolt -arrow- for earth wire.

– Unplug electrical connector -2- and move clear.
Note
Place a cloth underneath to catch escaping coolant.
– Release hose clip -1- and detach coolant hose.


– Remove union nuts -arrows- and disconnect ATF lines.
Note
Disregard -item 1-.
– Release hose clip -3- and detach air hose.

– Move crankcase breather hose -2- clear at air cleaner housing.
– Unplug electrical connector -4- at air mass meter 2 - G246- .
– Detach boot -1- from air cleaner housing.
– Remove air cleaner housing.
– Press release tabs and disconnect crankcase breather hoses

-1, 4-.
Note
Disregard items -2 and 3-.

– Remove bolts -arrows-.

– Remove oil reservoir and unplug electrical connector -1- at oil
level and oil temperature sender - G266- .

Note
Disregard -item 2-.
WARNING


Note
Disregard -item 2-.



– Remove nuts accessible from above -arrows-.

-arrows-.
– Remove nut -1-, detach secondary air pump (right-side) and
move wiring harness clear.

Note


Note

lencer.

bar.
– Remove bolt -1-.
Note
– Detach vacuum hose -1- for vacuum unit for exhaust flap from
T-connector -2- and place on left side.

Vacuum reservoir, version 1:

– Detach vacuum hoses -1- and -2- from Y-connector and move
clear.
– Remove bolts -arrows- and detach vacuum reservoir.

clear.
Note

fluid.
– Detach supply hose -1- for power steering hydraulic fluid.

one side.


clear.
– Mark position of spacer plates -1- on both sides with felt-tip
pen for re-installation in the original position and detach.
-arrows-.
Note

oil.


– Unplug electrical connector -2- at secondary air pump motor 2
- V189- .
Note
Disregard -arrows-.
– Press release tabs and disconnect secondary air hose

-arrow- from combination valve for secondary air system
(right-side).
– Press release tab and disconnect vacuum hose -1- at activa‐

ted charcoal filter.
– Move hose clear -arrow-.


switch - F66- .

sion tank.
– Remove rear right mid-range and bass loudspeaker - R160-
⇒ Rep. gr. 91 .

control unit 2 - J1006- .
– Remove nut -4- for battery positive wire.
– Move clear wiring harness.
Note


lation.
– Remove relay carrier and detach relays.
– Detach relay socket from relay carrier (release all retainers
-arrows A-).
– Detach fuse socket from relay carrier (release retainers
-arrows B-).
– Move engine wiring harness clear and guide carefully through
into engine compartment.



Note
– Remove bolt -1- for earth wires.

– Loosen nuts -arrows-, move retaining clips to the side and de‐
tach engine control unit 2 - J624- .
– Move electrical wiring clear and place engine control unit 2 -
J624- on engine (wiring remains connected).
Note
Secure the engine control units to prevent them falling.
– Remove rear mounting for rear noise insulation ⇒ Rep. gr.

66 .
– Remove bolts -arrows- and detach bracket -2- for gearbox

mounting and impact element -1-.

– Fit intake manifold protector for Audi R8 - VAS 871 017-

-item 3-.
– Set up lifting tackle as shown in illustration:
1- Shackle - 10-222A/12-
2- Lifting tackle - 2024A-
3- Intake manifold protector - VAS 871 017-
4- Shackle - 10-222A/12-
WARNING

Note
For illustration purposes, the procedure is shown with the engine

removed.
– Secure shackle - VAS 691 009- -item 1- to lifting eye on gear‐

box and attach retaining strap - T40155- -item 2-, as shown in
illustration.
– Secure lifting tackle - 3033- -item 1- to workshop hoist - VAS

6100- -item 2-, as shown in illustration.
Caution
Danger of damage to hoses, pipes and wiring connections and

to engine compartment.
♦ Check that all hoses and other connections between en‐
gine/gearbox assembly and body have been detached.

Caution
Avoid damage to sump (bottom section).

bench or on the ground with it resting on the sump.


1.1.3 Removing engine - R8 Spyder with manual gearbox/R tronic gearbox

equipment required
♦ Adapter - 10 - 222 A /7-



♦ Support - T40137-

♦ Bracket - T10059-

Procedure
Note

(vehicle unladen).
housing.

Rep. gr. 53 .
– Remove convertible roof compartment lid ⇒ Rep. gr. 61 .
– Remove service flap ⇒ Rep. gr. 55 .
– Remove mounting plates for rear lid hinges on both sides ⇒
Rep. gr. 55 .
– On vehicles with bolted connecting piece (depending on ver‐
sion), remove connecting piece for hinge mounting ⇒ Rep. gr.
61 .
– On vehicles with welded connecting piece (depending on ver‐
sion), remove hinge mounting for convertible roof compart‐
ment lid ⇒ Rep. gr. 61 .
R134a .
66 .
– Remove left and right tail lights ⇒ Electrical system; Rep. gr.
94 .

Caution

– Disconnect earth wire at battery with ignition switched off ⇒

Rep. gr. 27 .
WARNING

hot.
gine.
coolant.

coolant.


– Move coolant hose clear -arrow-.

blies.

tool - 3145- and remove nut -2-. Then take off flange and, if
fitted, damper weight.
Note

Caution

– Remove nut -1- from retaining clip.



Caution

♦ There will still be some oil in the oil line.
– If engine is to be separated from gearbox after removing en‐

gine/gearbox assembly, remove bolt -9- and nuts -1, 7, 8-
securing engine to gearbox.



below connection points.
– Remove bolt -arrow- and disconnect gearbox oil lines from
temperature regulator.

Note
Disregard -item 2-.

– Unscrew bolt -2- and nut -7- and detach service pipe -1- for air
conditioner.
– Remove bolts -3- and move service pipe -6- for air conditioner
with bracket -4- to one side.
Note
Disregard -item 5-.
WARNING



– Press release tabs and detach secondary air hoses -1- and
-2-.
– Remove bolts -3-, detach secondary air pump (left-side) and
unplug electrical connector -arrow-.


Note

Note

lencer.

bar.
– Detach vacuum hose -2- for vacuum unit for exhaust flap (left-
side) from T-connector -1- and move clear on left side.

– Disconnect vacuum hose -arrow- from T-piece.
– Detach drain hose -1- and take off catch container -2-.
Note

fluid.
– Release hose clip -5- and detach hydraulic hose for power
steering.
– Remove bolt -1-, detach power steering reservoir -2- from
bracket -4- and move clear to one side.
– Remove bolts -3- and remove bracket.
– Detach hoses -1- and -3- for crankcase breather from oil res‐
ervoir (press release tabs).


clear.
in position).


– Remove bolts -4- and disconnect oil line -3-.
– Remove bolts -1- and -2- and take out oil reservoir.
Note
-arrows-.
Note

oil.
– Remove nut -1- and bolt -2- and detach oil line from temper‐
ature regulator for engine oil cooler.

– Remove bolts -arrows- and detach engine oil cooler (left-side)

-1-.

– Press locking sleeve to front as far as stop -arrow 1-.
– Turn locking sleeve to right as far as stop -arrow 2- and allow
to engage.
– Detach cable end-piece -A- from corresponding gear selector
cable -B-.
– Detach securing clips -1- and -2-.

– Pull gear selector cables out of cable support bracket and
move clear on engine.
– Remove bolts -arrows- and detach cable support bracket.

Note
Lay a cloth under the separating point to catch escaping brake

fluid.
– Use hose clamp -3094- to clamp off pipe/hose assembly.

– Remove banjo bolt -arrow- and move pipe/hose assembly
clear to one side.
Caution
Risk of contamination by escaping brake fluid.

♦ Do not operate clutch pedal after detaching pipe/hose as‐
sembly from clutch slave cylinder.

– Remove bolt -arrow- and move retaining bracket with electrical
connector to one side.


switch - F66- .


sion tank.
– Unscrew bolts -4, 6- and nut -1- and detach heat shield -2-.
– Remove bolts -3- and -5- on bracket for wiring harness.
– Press release tab and disconnect vacuum hose -arrow- from

activated charcoal filter.
– Move vacuum hose clear.
– Remove cover for control units (top) ⇒ Rep. gr. 69 .

control unit - J217- .


– Move wiring harness clear.

lation.
– Pull all relays out of relay and fuse carrier -3-.
– Detach fuse holders -1, 2, 4, 5, 6- from relay and fuse carrier.
– Pull fuse out of fuse holder -4- (⇒ illustration above) and re‐
lease connector contact in chamber “2” using release tool -
VAS 1978/8A- .
– Move engine wiring harness clear and guide carefully into en‐
gine compartment.
– Remove engine control unit - J623- and engine control unit 2
- J624- ⇒ page 381 .

– Unscrew bolt -arrow- for earth wire on both sides.

– Move electrical wiring clear and lay on top of engine.


Note

– Remove nuts -1- for gearbox mounting on both sides (coun‐

terhold with open-end spanner -2-).
– Secure support - T40137- to gearbox and tighten to 20 Nm.
– Fit shackle - T10059- on lifting tackle - 2024A- , as shown in

illustration, and secure pin -1- with split pin.
– Engage lifting tackle - 2024 A- in front lifting eyes on engine.
WARNING


– Attach lifting tackle - 3033- with adapter - 10 - 222 A /7- to

engine and workshop hoist as shown in illustration.
Caution
Danger of damage to hose and wiring connections and to en‐

gine compartment.
♦ Danger of damage to hose and wiring connections and to
engine compartment.
♦ Check that all hoses and electrical connections between
engine/gearbox assembly and body have been detached.

Caution
Risk of damage to intake module.

bench or on the ground with it resting on the intake mod‐
ule.

1.1.4 Removing engine - R8 Spyder with dual clutch gearbox 0BZ


equipment required



♦ Shackle - 10-222A/12-

♦ Shackle - VAS 691 009-
♦ Retaining strap - T40155-
♦ Front-end hook - 3370-

Procedure
Note

(vehicle unladen).
housing.

Rep. gr. 53 .
– Remove convertible roof compartment lid ⇒ Rep. gr. 61 .
– Remove mounting plates -1- for rear lid hinges on both sides
⇒ Rep. gr. 55 .
– On vehicles with bolted connecting piece (depending on ver‐
sion), remove connecting piece for hinge mounting ⇒ Rep. gr.
61 .
– On vehicles with welded connecting piece (depending on ver‐
sion), remove hinge mounting for convertible roof compart‐
ment lid ⇒ Rep. gr. 61 .
R134a .
66 .
– Remove left and right tail lights ⇒ Rep. gr. 94 .

Caution

– Disconnect earth wire at battery with ignition switched off ⇒

Rep. gr. 27 .
WARNING

hot.
gine.
coolant.
– Remove drain plug -arrow- on thermostat housing using front-

end hook - 3370- and drain off coolant.


– Move coolant hose clear -arrow-.

blies.

damper weight.
Note

Caution

– Remove nut -1- from retaining clip.




of oil reservoir.
Caution

– Remove bolt -arrow- for earth wire.


– Unplug electrical connector -2- and move clear.
Note

– Remove union nuts -arrows- and disconnect ATF lines.
Note
Disregard -item 1-.


-1, 4-.
Note

– Remove oil reservoir and unplug electrical connector -1- at oil
level and oil temperature sender - G266- .

Note
Disregard -item 2-.
– Unscrew bolt -2- and nut -7- and detach service pipe -1- for air
conditioner.
– Remove bolts -3- and move service pipe -6- for air conditioner
with bracket -4- to one side.
Note
Disregard -item 5-.

WARNING



-2-.

Note


Note

lencer.

bar.
Note
– Detach vacuum hose -2- for vacuum unit for exhaust flap (left-
side) from T-connector -1- and move clear on left side.

clear.
Note

fluid.
– Release hose clip -5- and detach hydraulic hose for power
steering.

clear.

-arrows-.
Note

oil.

-1-.



switch - F66- .

sion tank.

– Unscrew bolts -4, 6- and nut -1- and detach heat shield -2-.
– Remove bolts -3- and -5- on bracket for wiring harness.
– Press release tab and disconnect vacuum hose -arrow- from

activated charcoal filter.
– Move vacuum hose clear.
– Remove cover for control units (top) ⇒ Rep. gr. 69 .

control unit 2 - J1006- .

– Move wiring harness clear.


lation.
– Pull all relays out of relay and fuse carrier -3-.
– Detach fuse holders -1, 2, 4, 5, 6- from relay and fuse carrier.
– Pull fuse out of fuse holder -4- (⇒ illustration above) and re‐
lease connector contact in chamber “2” using release tool -
VAS 1978/8A- .
– Move engine wiring harness clear and guide carefully into en‐
gine compartment.
– Remove engine control unit - J623- and engine control unit 2
- J624- ⇒ page 381 .
– Unscrew bolt -arrow- for earth wire on both sides.

– Move electrical wiring clear and lay on top of engine.



Note
– Remove rear mounting for rear noise insulation ⇒ Rep. gr.

66 .
– Remove bolts -arrows- and detach bracket -2- for gearbox

mounting and impact element -1-.


-item 3-.
1- Shackle - 10-222A/12-
4- Shackle - 10-222A/12-
WARNING

Note
For illustration purposes, the procedure is shown with the engine

removed.

illustration.


Note
Version fitted in vehicle may differ from illustration.
Caution
Danger of damage to hoses, pipes and wiring connections and

to engine compartment.
♦ Check that all hoses and other connections between en‐
gine/gearbox assembly and body have been detached.

Caution
Avoid damage to sump (bottom section).

bench or on the ground with it resting on the sump.

1.2 Placing engine/gearbox assembly on

scissor-type assembly platform
⇒ “1.2.1 Placing engine/gearbox assembly on scissor-type as‐
sembly platform - vehicles with manual gearbox/R tronic gearbox
086”, page 90
⇒ “1.2.2 Placing engine/gearbox assembly on scissor-type as‐
sembly platform - vehicles with dual clutch gearbox 0BZ”,
page 92
1.2.1 Placing engine/gearbox assembly on

scissor-type assembly platform - vehi‐
cles with manual gearbox/R tronic gear‐
box 086

♦ Scissor-type assembly platform - VAS 6131 B-
♦ Support set for Audi - VAS 6131/10- , supplementary set -VAS

6131/11- and -VAS 6131/12-
Setting up scissor-type assembly platform:

– Set up scissor-type assembly platform - VAS 6131 B- with
support set for Audi - VAS 6131/10- , support set -VAS
6131/11- and supplementary set -VAS 6131/12- as follows:
Platform Parts of support set for Audi - VAS 6131/10- , sup‐
coordinates port set -VAS 6131/11- and supplementary set -
VAS 6131/12-
C2 /10-1 /10-3 /10-5 /10-11
F2 /10-1 /10-3 /10-5 /10-11
B13 /10-1 /12-2 /10-5 /11-1
G13 /10-1 /12-2 /10-5 /11-1
– Initially hand-tighten the support elements on the scissor-type
assembly platform.
– Position scissor-type assembly platform - VAS 6131 B- hori‐
zontally.
• Take note of spirit level (bubble gauge).
– Use workshop hoist - VAS 6100- to place engine/gearbox as‐
sembly on scissor-type assembly platform - VAS 6131 B- .

– Position front of engine/gearbox assembly on support ele‐

ments from -VAS 6131/10- as shown in illustration.
– Position engine/gearbox assembly with gearbox supports (left

and right) on support elements from -VAS 6131/11- and -VAS
6131/12- as shown in illustration.
– Turn spindles of support elements upwards until engine/gear‐
box assembly rests horizontally on scissor-type assembly plat‐
form - VAS 6131 B- .
– Tighten base plates for support elements to 20 Nm on scissor-
type assembly platform - VAS 6131 B- .
1.2.2 Placing engine/gearbox assembly on

scissor-type assembly platform - vehi‐
cles with dual clutch gearbox 0BZ
♦ Scissor-type assembly platform - VAS 6131 B-

6131/12- and gearbox support - VAS 6131/14-


support set for Audi - VAS 6131/10- , supplementary set -VAS
6131/12- and gearbox support - VAS 6131/14- as follows:
coordinates plementary set -VAS 6131/12- and gearbox sup‐
port - VAS 6131/14-
C3 /10-1 /10-2 /10-5 /12-1
F3 /10-1 /10-2 /10-5 /12-1
C13 /10-1 /12-2 /10-5 /14
F13 /10-1 /12-2 /10-5
– Initially hand-tighten the support elements on the scissor-type
assembly platform.
– Position scissor-type assembly platform - VAS 6131 B- hori‐
zontally.
• Take note of spirit level (bubble gauge).
– Use workshop hoist - VAS 6100- to place engine/gearbox as‐
sembly on scissor-type assembly platform - VAS 6131 B- .
– Position rear of engine/gearbox assembly onto support ele‐

ments from -VAS 6131/10- and gearbox support - VAS
6131/14- as shown in illustration.
– Position front of engine/gearbox assembly onto support ele‐

ments from -VAS 6131/10- and -VAS 6131/12- as shown in
illustration.
– Turn spindles of support elements upwards until engine/gear‐
box assembly rests horizontally on scissor-type assembly plat‐
form - VAS 6131 B- .

1.3 Separating engine and gearbox

⇒ “1.3.1 Separating engine and gearbox - vehicles with manual
gearbox/R tronic gearbox 086”, page 94
⇒ “1.3.2 Separating engine and gearbox - vehicles with dual
clutch gearbox 0BZ”, page 99
1.3.1 Separating engine and gearbox - vehi‐

cles with manual gearbox/R tronic gear‐
box 086
6131/12- and -VAS 6131/13-
♦ Assembly tool - T10118-
Procedure
• Engine/gearbox assembly removed and secured to scissor-
type assembly platform - VAS 6131 B-
Note
Fit all cable ties in the original positions when installing.

– Remove banjo bolt -2- from power steering pump and detach
hydraulic line.
Note
-Item 1- and -arrows- can be disregarded.
– Unplug electrical connector -2- for engine speed sender -

G28- .
Note
Disregard -item 1-.
– Release electrical connector -4- at starter solenoid switch and

unplug connector ⇒ Electrical system; Rep. gr. 27 .
– Detach protective cap for battery positive wire.
– Remove nut -2-, detach battery positive wire from starter sol‐
enoid switch and move wire clear.
Note

– Unplug electrical connector -arrow- for reversing light switch -
F4- and move electrical wire clear.


– Unfasten bolts -1- and remove heat shield -arrow-.
Caution
Make sure not to interchange electrical connectors.

♦ The electrical connectors at gear selection valves and
gearbox hydraulic pressure sender - G270- are colour co‐
ded to prevent them from being interchanged. If the colour
coding is no longer visible, mark the connectors before
unplugging them to prevent them from being inter‐
changed.
– Unplug electrical connectors -1 ... 6- and move clear.
Note
Disregard -arrow-.
– Remove earth connection -arrow- at top of bracket for hy‐

draulic unit.
– Unplug electrical connectors -1 ... 4- and move clear.

– Move clear wiring harness on gearbox and lay harness on en‐
gine.

– Remove bolts -arrows- and detach heat shield.

– Remove bolts -1- and -2- and take off bracket for exhaust
manifold with catalytic converter (right-side).
– Remove bolt -arrow- on bracket for exhaust manifold with cat‐

alytic converter.

support set for Audi - VAS 6131/10- , support set -VAS
6131/12- and supplementary set -VAS 6131/13- as follows:
coordinates port set -VAS 6131/12- and supplementary set -
VAS 6131/13-
C2 1) /10-1 /10-3 /10-5 /10-11
F2 1) /10-1 /10-3 /10-5 /10-11
C7 /10-1 /10-2 /10-5 /12-1
F7 /10-1 /10-2 /10-5 /12-1
E10 /10-1 /10-2 Spindle /13-2
from /13-6
B13 1) /10-1 /12-2 /10-5 /11-1
G13 1) /10-1 /12-2 /10-5 /11-1
• 1) Support elements remain unchanged.

– Position the support elements from -VAS 6131/10- and -VAS

6131/12- at left of engine, as shown in the illustration.
– Position the support elements from -VAS 6131/10- and -VAS

6131/12- at right of engine, as shown in illustration.
– Turn spindles for support elements upwards until all locating
lugs make contact with mounting points.
– Position support elements from -VAS 6131/10- and -

VAS 6131/13- at front of gearbox, as shown in illustration.
– Turn spindle for the support element upwards until the support
plate makes contact with the mounting point.
– Move hydraulic line clear -arrow- and push to side.

– Unscrew remaining nuts -2 ... 6- securing engine to gearbox.
– Loosen clamping bolts -1- on sides of scissor-type assembly

platform - VAS 6131 B- and pull rear section of platform to‐
gether with gearbox towards rear -arrow-.
1.3.2 Separating engine and gearbox - vehi‐

cles with dual clutch gearbox 0BZ
♦ Assembly tool - T10118-
Procedure
type assembly platform - VAS 6131 B-
Note

– Unscrew banjo bolt -2- from power steering pump and detach
pressure line for hydraulic fluid.
Note
-Item 1- and -arrows- can be disregarded.
– Remove bolts -arrows- and detach heat shield -1-.
– Turn retainer catch anti-clockwise -arrow- and unplug electri‐

cal connector -1- at gearbox.
– Move electrical wiring harness clear at gearbox.
Caution
Risk of irreparable damage to mechatronic unit for dual clutch

gearbox - J743- due to electrostatic discharge.
♦ Before unplugging or plugging in electrical connector, me‐
chanic must discharge static electricity.
♦ Do NOT touch connector contacts in electrical connector
for mechatronic unit for dual clutch gearbox - J743- with
your hands.
– Touch vehicle earth with bare hands to eliminate any static

charge.
cal connector for mechatronic unit for dual clutch gearbox -
J743- together with heat insulation sleeve.
– Move electrical wiring harness clear at gearbox.

– Unplug electrical connector -1- for engine speed sender - G28-

-item 3-.
Note
Disregard -item 2-.
– Touch vehicle earth with bare hands to eliminate any static

charge.
cal connector -1- at gearbox.

– Push back cover -2- for positive battery terminal and unscrew
positive wire from starter solenoid switch.
– Move electrical wiring at gearbox clear and tie up.
– Remove bolts -1, 2- at brackets for catalytic converters.

– Disconnect breather hose -arrow- for gearbox.

support set for Audi - VAS 6131/10- , supplementary set -VAS
6131/11- , -VAS 6131/13- and gearbox support - VAS
6131/14- as follows:
coordinates plementary set -VAS 6131/11- , -VAS 6131/13- and
gearbox support - VAS 6131/14-
C3 1) /10-1 /10-2 /10-5 /12-1
F3 1) /10-1 /10-2 /10-5 /12-1
C8 /10-1 /10-4 /10-5 /10-6
F8 /10-1 /10-4 /10-5 /10-6
C10 /10-1 /10-3 /10-5 /11-3
F10 /10-1 /10-3 /10-5 /10-13
C13 1) /10-1 /10-2 /10-5 /14
F13 1) /10-1 /10-2 /10-5
• 1) Support elements remain unchanged.
– Position the support elements from -VAS 6131/10- at left and

right of engine, as shown in illustration.

– Position support elements from -VAS 6131/10- and -VAS

6131/11- at left and right of gearbox as shown in illustration.
– Turn spindles for support elements upwards until all locating
lugs make contact with mounting points.
– Remove bolts -1 ... 9- securing gearbox to engine.

– Move electrical wiring clear at gearbox.
Note
Disregard -item A-.
– Loosen clamping bolts -1- on sides of scissor-type assembly

platform - VAS 6131 B- and pull rear section of platform to‐
gether with gearbox towards rear -arrow-.
1.4 Securing engine to engine and gearbox support


equipment required

♦ Engine and gearbox support - VAS 6095- with bracket for V10
5.2 ltr. engine, Audi R8 - VAS 6095/1-10-
♦ Hooks - 10 - 222 A /2-

♦ Tensioning strap - T10038-
Procedure
type assembly platform - VAS 6131 B- (with engine detached
from gearbox) ⇒ page 94 .
– Detach electrical connectors from bracket (left-side) and un‐
plug:
1- For Lambda probe 2 after catalytic converter - G131-
2- For Lambda probe 2 - G108-
– Detach electrical connectors from bracket (right-side) and un‐

plug:
1- For Lambda probe after catalytic converter - G130-
2- For Lambda probe - G39-
– Move clear electrical wiring leading to all Lambda probes.
– Unfasten nuts -6 … 1- and remove exhaust manifold (left-side)

with catalytic converter.

– Unfasten nuts -6 … 1- and remove exhaust manifold (right-

side) with catalytic converter.
– Remove bolts -arrows- and detach heat shield (left-side).

– Unplug electrical connector -2- on solenoid valve (left-side) for

electro-hydraulic engine mounting - N144- .
– Remove bolt -1- and remove engine mounting (left-side).
– Remove bolt -1- on bracket for oil pump and bolts -arrows-.
Then take off engine support (left-side).

– Remove bolt -1- for retaining clip and bolts -arrows-. Then take
off engine support (right-side).
– Attach lifting tackle - 3033- with tensioning strap - T10038- and

hook - 10 - 222 A /2- to engine lifting eyes and to workshop
hoist - VAS 6100- with lift arm extension - VAS 6101- , as
shown in illustration.
– Lift engine off support elements on scissor-type assembly
platform -VAS 6131 B- .
– Secure engine with bracket for V10 5.2 ltr. engine, Audi R8 -
VAS 6095/1-10- to engine and gearbox support - VAS 6095-
as shown and tighten to 42 Nm.
1.5 Installing engine

Tightening torques
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricants such as engine or gear oil may be used,
but do not use lubricants containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for tightening torques: ± 15 %

Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
Assembly mountings ⇒ page 114
Engine to manual gearbox/R tronic gearbox 086
Item Nut/bolt Nm
1, 2, 7, 8 M10 45
3…6 M10 65
9 M10x175 45
A Dowel sleeves for centralising
– Check whether dowel sleeves -A- for centring engine and
gearbox are fitted in cylinder block; install missing dowel
sleeves.
Securing engine to dual-clutch gearbox 0BZ

Item Bolt Nm
1, 2, 7, 8 M10x60 1) 15 + 90°
3…6 M12x75 1) 30 + 90°
92) M10x100 1) 15 + 90°
A Dowel sleeves for centralising
• 1)Aluminium bolts must not be used more often than twice
⇒ page 109 .
• 2) With locating element.
– Check whether dowel sleeves -A- for centring engine and

gearbox are fitted in cylinder block; install missing dowel
sleeves.

♦ Aluminium bolts must not be used more than twice. After first
use, bolts must therefore be identified with an “X” made by two
chisel marks -arrow-.
♦ To avoid damaging the bolts when making this mark, do not
clamp them directly in a vice. Clamp a 14 mm socket with 1/
2" drive in a vice and insert the bolt as shown.
♦ Bolts already marked with an “X” must not be used again.
Procedure
Installation is carried out in reverse order; note the following:
Note
♦ Renew bolts tightened with specified tightening angle.

♦ Renew self-locking nuts and bolts as well as seals, gaskets
and O-rings.
♦ Hose connections and air pipes/hoses must be free of oil and
grease prior to fitting.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ The screw sections of used screw-type clips must be sprayed
with rust remover prior to fitting so that the air hoses can be
attached securely to the hose connections.
♦ Check that crankcase breather hoses are undamaged and
securely fitted and renew damaged hoses.
– Install engine supports with engine mountings (left and right).

– Secure gearbox to engine.
– Install exhaust manifold with catalytic converter ⇒ page 396 .
– Install starter ⇒ Electrical system; Rep. gr. 27 .
– Electrical connections and routing on gearbox ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
– Install heat shield for R tronic shift unit ⇒ Rep. gr. 34 .
Vehicles with manual gearbox/R tronic gearbox 086:

– Support engine/gearbox assembly as shown in illustration.
Vehicles with dual clutch gearbox 0BZ:


-item 3-.
1- Shackle - 10-222A/12-
4- Shackle - 10-222A/12-
WARNING


illustration.


Note
When lowering the engine/gearbox assembly, guide it carefully

into the engine compartment to avoid damage.
– Use workshop hoist - VAS 6100- to lower engine/gearbox as‐

sembly and carefully guide into engine compartment.
– Tighten bolts for left and right engine mountings
⇒ page 114 .
– Tighten bolts for left and right gearbox mountings ⇒ Rep. gr.
34 .
R8 Spyder:
– Install cover for control units (top) ⇒ Rep. gr. 69 .
– Install engine control units ⇒ page 381 .
– Electrical connections and routing on engine ⇒ Current flow
– Connect electrical wiring harness in passenger compartment
⇒ Electrical system; Rep. gr. 97 .
– Install rear right mid-range and bass loudspeaker - R160- ⇒
Rep. gr. 91 .
– Install side trim (right-side), rear shelf, A-pillar trim (bottom
right) and sill panel trim (right-side) ⇒ Rep. gr. 70 .
– Install secondary air pumps ⇒ page 405 .
– Install and adjust gear selector cables ⇒ Rep. gr. 34 .
– Install hose/pipe assembly for clutch slave cylinder ⇒ Rep. gr.
30 .
– Install oil reservoir ⇒ page 265 .
– Install oil lines on engine, engine oil cooler and oil reservoir
⇒ page 238 , ⇒ page 261 and ⇒ page 268 .
– Install engine compartment cross member ⇒ page 118 .
– Install bracket and power steering reservoir ⇒ Rep. gr. 48 .
– Install anti-roll bar with suspension in unladen position ⇒ Rep.
gr. 42 .
– Install silencer ⇒ page 390 .
– Install fuel supply line ⇒ page 367 .
– Install gear oil pipes on gear oil thermostat ⇒ Rep. gr. 34 .
– Install hoses/pipes for power steering hydraulic fluid ⇒ Rep.
gr. 48 .
– Install drive shafts ⇒ Rep. gr. 42 .
– Install refrigerant lines ⇒ Rep. gr. 87 .

– Before assembly, the threaded holes in the flange for the

transmission shaft must be cleaned with a thread tap to re‐
move remaining locking fluid.
– Install transmission shaft and propshaft ⇒ Rep. gr. 39 .
– Install rear member ⇒ Rep. gr. 53 .
– Install tail lights ⇒ Electrical system; Rep. gr. 94 .
– Install rear impact bar ⇒ Rep. gr. 63 .
– Install rear wheel housing liners ⇒ Rep. gr. 66 .
– Fit wheels ⇒ Wheels and tyres; Rep. gr. 44 .
– Before starting engine, top up hydraulic fluid in power steering
reservoir ⇒ Rep. gr. 48 .
Note
The power steering pump must not be run when dry.
– Install air cleaner housing ⇒ page 345 .

– Fill up with engine oil and check oil level ⇒ Maintenance ;
Booklet 420 .
– Observe notes on procedure for connecting the battery ⇒
Electrical system; Rep. gr. 27 .
Caution
Risk of irreparable damage to control units because of exces‐

sive voltage.
♦ Never use battery charging equipment for boost starting.
– Install front passenger's seat ⇒ Rep. gr. 72 .

R8 Spyder:
– Install hinge mounting for convertible roof compartment lid or
connecting piece for hinge mounting ⇒ Rep. gr. 61 .
– Install mounting plates for rear lid hinges on both sides ⇒ Rep.
gr. 55 .
– Install service flap ⇒ Rep. gr. 55 .
– Install convertible roof compartment lid ⇒ Rep. gr. 61 .
– Install engine compartment side trim panels ⇒ Rep. gr. 53 .
– Fit coolant hoses and hose clips ⇒ page 299 .
Note
Do not reuse coolant.
– Fill up with coolant ⇒ page 279 .

– Evacuate and refill refrigerant system ⇒ Air conditioner with
refrigerant R134a .
– Install side panel trim panels and engine compartment trim
panels ⇒ Rep. gr. 53 .

– Install noise insulation panels ⇒ Rep. gr. 66 .

– After renewing engine, misfire adaptions must be reset. To do
so, select 01 - Reset adaptions misfires in Guided
Functions mode of ⇒ Vehicle diagnostic tester.

2 Assembly mountings
⇒ “2.1 Exploded view - assembly mountings”, page 114
⇒ “2.2 Removing and installing engine mountings with electro-
hydraulic engine mounting solenoid valves N144 / N145 ”,
page 115
⇒ “2.3 Exploded view - engine compartment cross member”, page
116
⇒ “2.4 Removing and installing engine compartment cross mem‐
ber”, page 118
2.1 Exploded view - assembly mountings
1 - Bolt
❑ 20 Nm
2 - Washer
3 - Engine mounting (right-
side)
❑ With right electrohy‐
draulic engine mounting
solenoid valve - N145-
❑ Removing and installing
⇒ page 115
4 - Clamp
5 - Bolt
❑ 10 Nm
6 - Engine support (right-side)
7 - Bolt
❑ 40 Nm
8 - Heat shield
9 - Bolt
❑ 10 Nm
10 - Bolt
❑ 42 Nm
11 - Heat shield
12 - Bolt
❑ 10 Nm
13 - Bolt
❑ 40 Nm
14 - Bolt
❑ 40 Nm
15 - Engine support (left-side)
16 - Engine mounting (left-side)
❑ With left electrohydraulic engine mounting solenoid valve - N144-
❑ Removing and installing ⇒ page 115
17 - Washer
18 - Bolt
❑ 20 Nm

19 - Bolt
❑ 22 Nm
20 - Bolt
❑ Tightening torque ⇒ Item 22 (page 239)
21 - Bracket for oil pump
2.2 Removing and installing engine mount‐

ings with electro-hydraulic engine
mounting solenoid valves -N144- / -
N145-
Removing
type assembly platform - VAS 6131 B- ⇒ page 90 .
Note
♦ The following description is for removing and installing the left-

side engine mounting.
– Remove exhaust manifold (left-side) with catalytic converter

⇒ page 396 .
– Unplug electrical connector -2- on solenoid valve (left-side) for

electro-hydraulic engine mounting - N144- .
– Remove bolt -1- and remove engine mounting (left-side).
Installing
• Tightening torques
⇒ “2.1 Exploded view - assembly mountings”, page 114
– Install exhaust manifold (left-side) with catalytic converter
⇒ page 396 .
2. Assembly mountings 115

2.3 Exploded view - engine compartment

cross member
⇒ “2.3.1 Exploded view - engine compartment cross member, ve‐
hicles with manual gearbox/R tronic gearbox”, page 116
⇒ “2.3.2 Exploded view - engine compartment cross member, ve‐
hicles with dual clutch gearbox 0BZ”, page 117
2.3.1 Exploded view - engine compartment cross member, vehicles with manual
gearbox/R tronic gearbox
1 - Bolt
❑ 8 Nm
2 - Bracket for engine cover
panel
3 - Bolt
❑ 8 Nm
4 - Bolt
❑ Renew
❑ 10 Nm + 45°
5 - Retaining clamp
6 - Bolt
❑ 20 Nm
7 - Not fitted
8 - Not fitted
9 - Bracket for engine compart‐
ment trim panel
❑ Only for Coupé
10 - Bolt
❑ Only for Coupé
❑ 8 Nm
11 - Bolt
❑ Renew
❑ 10 Nm + 45°
12 - Bolt
❑ Tightening torque
⇒ page 336
13 - Air cleaner housing
⇒ page 345
14 - Bolt
❑ Only for Coupé
❑ 8 Nm
15 - Bolt
16 - Oil reservoir
17 - Bracket for engine compartment trim panel
❑ Only for Coupé

18 - Spacer plate
❑ Mark number and installation position for re-installation
19 - Bolt
❑ 20 Nm
20 - Engine compartment cross member
❑ Removing and installing: R8 Coupé ⇒ page 118 , R8 Spyder ⇒ page 123 .
21 - Bolt
❑ Renew
❑ 10 Nm + 45°
2.3.2 Exploded view - engine compartment cross member, vehicles with dual
clutch gearbox 0BZ
1 - Bolt
❑ 8 Nm
2 - Bolt
❑ Renew
❑ 10 Nm + 45°
3 - Retaining clamp
4 - Bolt
❑ 20 Nm
5 - Bolt
❑ 8 Nm
6 - Bracket for vacuum reser‐
voir
7 - Bracket for engine compart‐
ment trim panel
❑ Only for Coupé
8 - Bolt
❑ Only for Coupé
❑ 8 Nm
9 - Bolt
⇒ page 339
10 - Air cleaner housing (right-
side)
⇒ page 347
11 - Bolt
❑ Renew
❑ 10 Nm + 45°
12 - Bolt
❑ Only for Coupé
❑ 8 Nm
13 - Bracket for engine compartment trim panel
❑ Only for Coupé

14 - Bolt
❑ 8 Nm
15 - Oil reservoir
16 - Spacer plate
❑ Mark number and installation position for re-installation
17 - Bolt
❑ 20 Nm
18 - Engine compartment cross member
19 - Bolt
❑ Renew
❑ 10 Nm + 45°
2.4 Removing and installing engine com‐

partment cross member
⇒ “2.4.1 Removing and installing engine compartment cross
member - R8 Coupé with manual gearbox/R tronic gearbox 086”,
page 118
member - R8 Coupé with dual-clutch gearbox 0BZ”, page 120
member - R8 Spyder with manual gearbox/R tronic gearbox 086”,
page 123
member - R8 Spyder with dual-clutch gearbox 0BZ”, page 125
2.4.1 Removing and installing engine com‐

partment cross member - R8 Coupé with
manual gearbox/R tronic gearbox 086
Removing
Rep. gr. 53 .
– Remove air cleaner housing ⇒ page 346 .
– Press release tabs and detach crankcase breather hoses -1-
and -3- from oil reservoir.
– Remove bolt -2- on retaining clip.


one side.
Note
Disregard -item 1-.
– Remove both rear wheels ⇒ Rep. gr. 44 .



clear.
in position).
Installing
⇒ “2.3.1 Exploded view - engine compartment cross member,
vehicles with manual gearbox/R tronic gearbox”, page 116
Note
Check that crankcase breather hoses are undamaged and se‐

curely fitted and renew damaged hoses.
– Note marking on spacer plates -2- if the same cross member

is re-installed.
– Bring cross member into installation position and tighten bolts
hand-tight if the cross member is renewed.
– Fit as many spacer plates as can be inserted by hand (same
number on each side).
– Secure cross member.
– Fit rear wheels ⇒ Rep. gr. 44 .
– Install power steering reservoir with bracket ⇒ Rep. gr. 48 .
– Install crankcase breather hose 2 ⇒ page 252 .
– Install engine compartment trim panels ⇒ Rep. gr. 53 .

partment cross member - R8 Coupé with
dual-clutch gearbox 0BZ
Removing
– Remove oil reservoir ⇒ page 267 .

– Press release tabs and detach crankcase breather hose -3-.

– Press crankcase breather hose -1- to side.
Note

one side.
Note
Disregard -item 1-.

clear.

clear.



clear.
– Remove bolts -arrows- on both sides (hold spacer plates in
position).
Installing
vehicles with dual clutch gearbox 0BZ”, page 117
Note


is re-installed.
– Fit rear wheels ⇒ Wheels and tyres; Rep. gr. 44 .


partment cross member - R8 Spyder
with manual gearbox/R tronic gearbox
086
Removing
Rep. gr. 55 .
Rep. gr. 53 .
– Press release tabs and detach crankcase breather hoses -1-
and -3- from oil reservoir.
– Remove bolt -2- on retaining clip.
– Detach drain hose -1- and take off catch container -2-.

Note

– Remove both rear wheels ⇒ Rep. gr. 44 .



clear.
in position).
Installing
vehicles with manual gearbox/R tronic gearbox”, page 116
Note


is re-installed.
– Fit rear wheels ⇒ Rep. gr. 44 .
– Install crankcase breather hose 2 ⇒ page 252 .
– Install mounting plates for rear lid hinges ⇒ Rep. gr. 55 .

partment cross member - R8 Spyder
with dual-clutch gearbox 0BZ
Removing
Rep. gr. 55 .


– Press crankcase breather hose -1- to side.
Note
– Remove bolts -arrows- and move vacuum reservoir to side

with vacuum hoses -1- and -2- attached.

Note



clear.
in position).
Installing
vehicles with dual clutch gearbox 0BZ”, page 117
Note


is re-installed.
– Fit rear wheels ⇒ Wheels and tyres; Rep. gr. 44 .
– Install mounting plates for rear lid hinges ⇒ Rep. gr. 55 .

3 Engine cover panel

⇒ “3.1 Removing and installing engine cover panel”, page 128
3.1 Removing and installing engine cover

panel
⇒ “3.1.1 Removing and installing engine cover panel - R8 Coupé
with manual gearbox/R tronic gearbox 086”, page 128
⇒ “3.1.2 Removing and installing engine cover panel - R8 Coupé
with dual-clutch gearbox 0BZ”, page 128
3.1.1 Removing and installing engine cover

panel - R8 Coupé with manual gearbox/
R tronic gearbox 086
Removing
– Carefully detach engine cover panel -arrows-. Do not jerk the
cover panel away, and do not try to pull on one side only.
Installing
– Press engine cover panel carefully into its mountings.
3.1.2 Removing and installing engine cover

panel - R8 Coupé with dual-clutch gear‐
box 0BZ
Removing
– Carefully detach engine cover panel -arrows-. Do not jerk the
cover panel away, and do not try to pull on one side only.
Installing
– Press engine cover panel carefully into its mountings.

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - poly V-belt drive”, page 129
⇒ “1.2 Removing and installing poly V-belt”, page 130
⇒ “1.3 Removing and installing tensioner for poly V-belt”,
page 131
⇒ “1.4 Removing and installing bracket for alternator”,
page 132
⇒ “1.5 Removing and installing vibration damper with poly V-belt
pulley”, page 132
⇒ “1.6 Renewing crankshaft oil seal (pulley end)”, page 133
1.1 Exploded view - poly V-belt drive
1 - Bolt
❑ 55 Nm
2 - Bolt
❑ 28 Nm
3 - Poly V-belt tensioner
⇒ page 131
4 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen
⇒ page 130
❑ Do not kink
❑ When installing, make
sure it is properly seated
on pulleys
5 - Cover for idler roller
6 - Bolt
❑ 22 Nm
7 - Bolt
❑ Tightening torque ⇒
Electrical system; Rep.
gr. 27
8 - Alternator
⇒ Electrical system;
Rep. gr. 27
9 - Bolt
❑ 42 Nm
10 - Bracket for alternator
1. Cylinder block (pulley end) 129

11 - Dowel sleeve
❑ For bracket for alternator
❑ 2x
12 - Idler roller for poly V-belt
13 - Vibration damper with poly V-belt pulley
❑ Must always be renewed if bolts are loosened
14 - Bolt
❑ Renew
❑ Apply locking fluid when installing non-self-locking bolts; refer to ⇒ Electronic parts catalogue for locking
fluid
❑ Threaded holes for bolts must be cleaned using a thread tap or similar
❑ Tightening torque and sequence ⇒ page 130
Vibration damper - tightening torque and sequence
Note
♦ Always renew the vibration damper if the bolts have been

loosened.
♦ Replace bolts which are tightened to a specified angle with
new bolts of the correct type (same as original equipment) ⇒
Electronic parts catalogue .
♦ The threaded holes for the bolts must be cleaned using a
thread tap or similar.
♦ Apply locking fluid when installing non-self-locking bolts; for
locking fluid, refer to ⇒ Electronic parts catalogue .
– Tighten bolts in 3 stages as follows:

Stage Bolts Tightening torque/angle specification
1. -arrow- 15 Nm in diagonal sequence
2. -arrow- 22 Nm in diagonal sequence
3. -arrow- Turn 90° further in diagonal sequence
1.2 Removing and installing poly V-belt

♦ Socket Torx T60 - T40087-
130 Rep. gr.13 - Crankshaft group

Removing
– Remove front noise insulation -2- ⇒ Rep. gr. 66 .
Caution
Running a used poly V-belt in the opposite direction could

cause irreparable damage.
♦ Before removing the poly V-belt, mark the direction of ro‐
tation with chalk or a felt-tip pen for re-installation.
– Slacken poly V-belt by turning tensioner anti-clockwise

-arrow- using socket Torx T 60 - T40087- .
– Remove poly V-belt and release tensioner.
Note
♦ On vehicles with damper weight -1-, the asymmetrically fitted

weight -2- on the vibration damper prevents the poly V-belt
from being pulled out between the vibration damper and the
damper weight in certain positions of the crankshaft.
♦ In this case, turn the crankshaft as far as is necessary for you
to be able to remove the poly V-belt between the vibration
damper with the belt pulley and the damper weight.
Installing
– Fit poly V-belt -2- onto pulleys in the following sequence:
1 - Alternator
3 - Idler roller
4 - Vibration damper
5 - Tensioner
Note
When installing poly V-belt, make sure it is properly seated on

pulleys.
– Start engine and check that poly V-belt runs properly.

– Install noise insulation ⇒ Rep. gr. 66 .
1.3 Removing and installing tensioner for

poly V-belt
Removing
– Remove poly V-belt ⇒ page 130 .
Vehicles with damper weight:


damper weight.
Note


– Remove bolts -arrows- and take off tensioner -1-.
Installing
– Install poly V-belt ⇒ page 130 .
1.4 Removing and installing bracket for al‐

ternator
Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 .
– On vehicles with manual gearbox: move gear selector cables
clear at bracket for alternator.
– Remove bolt -1- for poly V-belt tensioner.
– Remove bolts -arrows- and detach bracket for alternator.
Installing
– Install alternator ⇒ Electrical system; Rep. gr. 27 .
1.5 Removing and installing vibration damp‐

er with poly V-belt pulley
Removing
– Remove front noise insulation ⇒ Rep. gr. 66 .

– Slacken off bolts -arrow- on vibration damper several turns

(counterhold with ring spanner on nut for poly V-belt pulley for
alternator).
– Remove poly V-belt ⇒ page 130 .
– Completely remove bolts and detach vibration damper with
poly V-belt pulley.
Installing
Note
♦ Always renew the vibration damper if the bolts have been

loosened.
♦ Replace vibration damper bolts with new bolts of the correct
type (same as original equipment) ⇒ Electronic parts cata‐
logue .
♦ The threaded holes for the bolts must be cleaned using a
thread tap or similar.
♦ Apply locking fluid when installing non-self-locking bolts; for
locking fluid, refer to ⇒ Electronic parts catalogue .
• The vibration damper can only be fitted in one position.

– Install poly V-belt ⇒ page 130 .
– Tighten bolts for vibration damper ⇒ page 130 .
– Install noise insulation ⇒ Rep. gr. 66 .
1.6 Renewing crankshaft oil seal (pulley

end)
♦ Oil seal extractor - T40019-

♦ Assembly tool - T40048 A-
♦ Bolts M8x55 mm (2x)

Procedure
– Remove vibration damper with poly V-belt pulley
⇒ page 132 .
– Adjust inner part of oil seal extractor -T40019- so that it is level
with the outer part and lock in position with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and screw it into oil seal as far as possible (applying firm
pressure).
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Clamp flats of oil seal extractor in vice and use pliers to remove
oil seal.
– Clean contact surface and sealing surface.
– Fit assembly aid -T40048/1- onto assembly sleeve -T40048/2-

and slide oil seal -1- onto assembly sleeve.
– Detach assembly aid.
– Fit assembly sleeve -T40048/2- on crankshaft and slide oil

seal -1- into sealing surface in cylinder block.
• Leave assembly sleeve in position on crankshaft for pressing
in seal.

– Apply press sleeve -T40048/3- to crankshaft using two

M8×55 mm bolts -arrows-.
– Initially screw in bolts by hand until they make contact.
– Tighten bolts alternately, 180° at a time, to press in oil seal
onto stop.
– Install vibration damper with poly V-belt pulley ⇒ page 132 .

2 Cylinder block (gearbox end)

⇒ “2.1 Exploded view - flywheel”, page 136
⇒ “2.2 Renewing ball bearing for crankshaft (gearbox end) - ve‐
hicles with manual gearbox/R tronic gearbox 086”, page 137
⇒ “2.3 Removing and installing flywheel”, page 138
⇒ “2.4 Renewing crankshaft oil seal (gearbox end)”, page 141
2.1 Exploded view - flywheel

⇒ “2.1.1 Exploded view - flywheel, vehicles with manual gearbox/
R tronic gearbox 086”, page 136
⇒ “2.1.2 Exploded view - flywheel, vehicles with dual clutch gear‐
box 0BZ”, page 137
2.1.1 Exploded view - flywheel, vehicles with manual gearbox/R tronic gearbox
086
1 - Bolt
❑ Renew
❑ 60 Nm + 90°
2 - Starter ring gear
❑ With sender wheel for
engine speed sender -
G28-
❑ After renewing, misfire
adaptions must be re‐
set. To do so, select 01
- Reset adaptions
misfires in Guided
Functions mode of
⇒ Vehicle diagnostic
tester
3 - Bolt
❑ 12 Nm
4 - Flywheel
⇒ page 138
5 - Crankshaft oil seal (gearbox
end)
❑ Renewing ⇒ page 141
6 - Crankshaft
7 - Ball bearing
8 - Circlip
⇒ “2.2 Renewing ball
bearing for crankshaft
(gearbox end) - vehicles
with manual gearbox/R
tronic gearbox 086”, page 137

2.1.2 Exploded view - flywheel, vehicles with dual clutch gearbox 0BZ
1 - Bolt
❑ Renew
❑ 60 Nm + 90°
2 - Flywheel
❑ With sender wheel for
engine speed sender -
G28-
⇒ page 138
end)
4 - Crankshaft
2.2 Renewing ball bearing for crankshaft

(gearbox end) - vehicles with manual
gearbox/R tronic gearbox 086
♦ Tube - VW 418 A-
♦ Internal puller - VAS 251 605-
2. Cylinder block (gearbox end) 137

♦ Counter-support - VAS 251 621-

♦ Circlip pliers (commercially available)
Procedure
• Gearbox removed ⇒ Rep. gr. 34 .
– Remove pressure plate with clutch plates ⇒ Rep. gr. 30 .
– Remove circlip -2- using circlip pliers -1-.
– Remove ball bearing using internal puller - VAS 251 605-

(Kukko 21/2) and counter-support - VAS 251 621- (Kuk‐
ko 22/1).
– Drive in new ball bearing using tube - VW 418 A- .

– Install pressure plate with clutch plates ⇒ Rep. gr. 30 .
2.3 Removing and installing flywheel


♦ Used oil collection and extraction unit - VAS 6622A-
♦ Locking pin - 3242- , or alternatively locking pin - T40237-
♦ Adapter - T40058-
Removing
below engine.
– Unscrew plug -arrow- for “TDC” marking from intake module.

– Insert guide pin of adapter -T40058- as follows:

• The smaller-diameter section -arrow 1- faces the engine.
• The larger-diameter section -arrow 2- faces the adapter.
– Turn crankshaft with adapter - T40058- in normal direction of

rotation -arrow- to “TDC position”.
– Screw locking pin - 3242- into groove -1- and tighten to 20 Nm.
If necessary, turn crankshaft backwards and forwards slightly
to fully centralise locking pin.
– Vehicles with manual gearbox/R tronic gearbox 086: Remove
pressure plate with clutch plates ⇒ Rep. gr. 30 .

– Remove bolts -arrow- and remove flywheel.

Installing
• Tightening torque
⇒ “2.1 Exploded view - flywheel”, page 136
Note
Renew bolts for flywheel.
• Flywheel can only be fitted in one position.

– Vehicles with manual gearbox/R tronic gearbox 086: Install
pressure plate with clutch plates ⇒ Rep. gr. 30 .
– Remove locking pin - 3242- , install plug for “TDC” marking
with new seal and tighten plug ⇒ Item 16 (page 144) .
– Check oil level ⇒ Maintenance ; Booklet 420 .
– After renewing flywheel with sender wheel, misfire adaptions
must be reset. To do so, select 01 - Reset adaptions mis-
fires in Guided Functions mode of ⇒ Vehicle diagnostic
tester.
2.4 Renewing crankshaft oil seal (gearbox

end)
♦ Fitting tool - T10122 A-
♦ Extractor hook - T20143/2-

Procedure
– Remove flywheel ⇒ page 138 .
– Pry out oil seal using extractor hook -T20143/2- .
– Fit assembly aid -T10122/1- onto assembly sleeve -T10122/2-

and slide oil seal -A- onto assembly sleeve.
– Detach assembly aid.
– Fit assembly sleeve -T10122/2- with oil seal -1- onto crank‐
shaft.
– Press in oil seal uniformly until flush all round using thrust
piece -T10122/5- .
– Install flywheel ⇒ page 138 .

3 Crankshaft
⇒ “3.1 Exploded view - crankshaft”, page 143
⇒ “3.2 Allocation of main bearing shells for new crankshaft”, page
146
⇒ “3.3 Allocation of main bearing shells on used and machined
crankshafts”, page 147
⇒ “3.4 Crankshaft dimensions”, page 148
⇒ “3.5 Measuring axial clearance of crankshaft”, page 148
⇒ “3.6 Measuring radial clearance of crankshaft”, page 148
⇒ “3.7 Removing and installing intake module and retaining
frame”, page 149
3.1 Exploded view - crankshaft
Note
When carrying out repairs, secure engine with bracket for 10-cyl. FSI -VAS 6095/1-10- to engine and gearbox
support - VAS 6095- ⇒ page 103 .
1 - Cylinder block
❑ Matched to -item 6-
2 - Seal
❑ Renew
3 - Dowel sleeves
❑ 3x
❑ Fit in retaining frame -
cylinder block side
4 - Oil seal for crankshaft (pul‐
ley end)
5 - Crankshaft
❑ Measuring axial clear‐
ance ⇒ page 148
❑ Measuring radial clear‐
ance ⇒ page 148
❑ Crankshaft dimensions
⇒ page 148
6 - Retaining frame
❑ Matched to -item 1-
⇒ page 149
❑ Tightening sequence
⇒ page 145
7 - Seal
❑ Renew
8 - O-ring
❑ Renew
❑ Lubricate lightly with en‐
gine oil
3. Crankshaft 143
9 - Dowel sleeve
❑ Fit in retaining frame - intake module side
10 - Bolt
❑ 9 Nm
11 - Flange for protective tube
❑ Apply sealant when installing; refer to ⇒ Electronic parts catalogue
❑ Applying sealant ⇒ page 153
12 - Intake module
13 - Bolt
❑ For sealing surfaces between intake module and retaining frame
14 - Bolts
❑ Renew
❑ Use old bolts when measuring radial clearance
❑ Different lengths
15 - Seal
❑ Renew
16 - Plug
❑ For “TDC” marking
❑ 45 Nm
17 - Dowel sleeve
❑ Fit in retaining frame - intake module side
18 - O-ring
❑ Renew
❑ Lubricate lightly with engine oil
19 - Bolt
❑ For sealing surfaces: retaining frame to cylinder block
❑ Different bolt lengths
20 - Thrust washer
❑ Only fitted on 5th crankshaft bearing
❑ Oil groove faces outwards
❑ Make sure it engages in retaining frame
21 - Bearing shell
❑ For retaining frame (without oil groove)
❑ Renew used bearing shells
❑ Fit new bearing shells for retaining frame with the correct colour coding: new crankshaft ⇒ page 146 ,
used and machined crankshaft ⇒ page 147
22 - Circlip
⇒ “2.2 Renewing ball bearing for crankshaft (gearbox end) - vehicles with manual gearbox/R tronic gear‐
box 086”, page 137
23 - Ball bearing

24 - Thrust washer
❑ Only fitted on 5th crankshaft bearing
❑ Oil groove faces outwards
25 - Bearing shell
❑ For cylinder block (with oil groove)
❑ Renew used bearing shells
❑ Fit new bearing shells for cylinder block with the correct colour coding: for new crankshafts
⇒ page 146 , for used and machined crankshafts ⇒ page 147
26 - Plug
❑ Apply locking fluid when installing; refer to ⇒ Electronic parts catalogue
❑ 9 Nm
27 - Seal
❑ Renew
Retaining frame and intake module - tightening torque and se‐

quence
Note

♦ Use old bolts when measuring radial clearance.
– Tighten bolts in 6 stages in the sequence shown:

1. -1 … 12- 30 Nm
2. -13 … 24- 20 Nm
3. -1 … 12- 50 Nm
4. -13 … 24- 40 Nm
5. -1 … 12- Turn 180° further
6. -13 … 24- Turn 135° further
– Tighten bolts for sealing surfaces between cylinder block and
retaining frame -shaded white- to 9 Nm in diagonal sequence.
3. Crankshaft 145
3.2 Allocation of main bearing shells for new

crankshaft
Matching crankshaft bearing shells to bearings in cylinder block
♦ Bearing shells of the correct thickness are matched to the
bearings in the cylinder block at the factory. Coloured dots on
the side of the bearing shells are used to identify the bearing
shell thickness.
♦ The allocation of the bearing shells to the cylinder block is in‐
dicated by letters on the front left of the cylinder block (legible
from outside), as shown in illustration.
♦ The coding of the bearings applies to the original bearings in‐
stalled at the factory: “R” = red, “G” = yellow, “B” = blue.
♦ When the bearing shells are replaced in the workshop, select
a bearing shell which is one grade thinner; for example black
instead of red, as shown in the following table.
Letter on cylinder block Colour coding of bearing
R = Black
G= Red
B= Yellow
Note
♦ This procedure has been specified in order to compensate for

the settling of the cylinder block.
♦ Even if the retaining frame has only been loosened, you should
also follow the above procedure for installing replacement
bearing shells.
Matching crankshaft bearing shells to bearings in retaining frame

♦ Bearing shells of the correct thickness are matched to the
bearings in the retaining frame at the factory. Coloured dots
on the side of the bearing shells are used to identify the bear‐
ing shell thickness.
♦ The allocation of the bearing shells to the retaining frame is
indicated by letters on the front crankshaft web, as shown in
illustration. The row of letters begins after the -x- on the right
side with bearing -1- and ends with bearing -6- on the left side.
Note
♦ Other identification markings can be disregarded.

♦ For the bearing shells in the retaining frame the colour coding
of the original bearings and replacement bearings is the same.
Letter on crankshaft Colour coding of bearing

R = Red
G= Yellow
B= Blue

3.3 Allocation of main bearing shells on

used and machined crankshafts
Matching crankshaft bearing shells to bearings in cylinder block
♦ Bearing shells are allocated to the cylinder block according to
the colour codes stamped on the cylinder block.
♦ On used and machined crankshafts, the main bearing journals
must be measured in order to allocate the correct bearing
shells.
♦ Crankshaft dimensions ⇒ page 148 .
♦ There are oversized (thicker) bearing shells available for ma‐
chined crankshafts. However, these bearing shells have the
same colour coding as the original-size bearing shells.
♦ The coding of the bearings applies to the original bearings in‐
stalled at the factory: “R” = red, “G” = yellow, “B” = blue.
♦ When the bearing shells are replaced in the workshop, select
a bearing shell which is one grade thinner; for example black
instead of red, as shown in the following table.
Letter on cylinder block Colour coding of bearing
R = Black
G= Red
B= Yellow
Note
♦ This procedure has been specified in order to compensate for

the settling of the cylinder block.
♦ Even if the retaining frame has only been loosened, you should
also follow the above procedure for installing replacement
bearing shells.
Matching crankshaft bearing shells to bearings in retaining frame

♦ On used and machined crankshafts, the main bearing journals
must be measured in order to allocate the correct bearing
shells.
♦ Any markings still visible on a machined crankshaft are invalid.
♦ Allocate the bearing shells according to the measured diam‐
eter of the crankshaft main bearing journals as follows:
Main bearing journal ∅ Colour code of bearing shells for retaining frame
Dimensions in mm Red Yellow Blue
Basic dimension 66.978 … 66.972 66.971 … 66.965 66.964 … 66.958
67.000
Repair undersize 66.728 … 66.722 66.721 … 66.715 66.714 … 66.708
66.750 1)
• 1)The colour codes for the oversized (thicker) bearing shells required for a machined crankshaft are the
same as those on bearing shells for a new crankshaft, in spite of the greater bearing thickness.
3. Crankshaft 147
3.4 Crankshaft dimensions

Honing dimension Crankshaft Crankshaft
bearing journal ∅ conrod journal ∅
mm mm
Basic dimension 67.000 - 0.022 54.000 - 0.024
- 0.042 - 0.040
Repair oversize 66.750 - 0.022 53.750 - 0.024
- 0.042 - 0.040
3.5 Measuring axial clearance of crankshaft

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-
Procedure
– Secure dial gauge - VAS 6079- with universal dial gauge
bracket - VW 387- to cylinder block as shown in illustration.
– Apply dial gauge to crank web.
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off value.
• Axial clearance: 0.090 ... 0.231 mm
3.6 Measuring radial clearance of crank‐

shaft
♦ Plastigauge

Procedure
– Remove retaining frame and clean bearing journals.
– Place a length of Plastigauge corresponding to the width of the
bearing on the bearing journal or bearing shell.
• The Plastigauge must be positioned in the centre of the bear‐
ing shell.
– Fit retaining frame and secure with old bolts ⇒ page 145 with‐
out rotating crankshaft.
– Remove retaining frame again.
– Compare width of Plastigauge with measurement scale.
Radial clearance:
• New: 0.018 ... 0.046 mm.
• Wear limit: 0.08 mm.
– When carrying out final assembly, renew bolts.
3.7 Removing and installing intake module

and retaining frame
♦ Electric drill with plastic brush attachment
♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Removing
• Engine removed, engine separated from gearbox ⇒ page 94 .
• Engine secured to engine and gearbox support ⇒ page 103
Removing intake module
– Remove oil pump ⇒ page 240 .
– Remove bracket for alternator ⇒ page 132 .
– Remove transmission shaft ⇒ Rep. gr. 39 .
– Release flange -1- with protective tube -3- and input shaft -2-
from bonded joint and detach.
3. Crankshaft 149

– Slacken and remove bolts in the sequence: -24 ... 1-.
– Release intake module from bonded joint.
Removing retaining frame

– Remove vibration damper ⇒ page 132 .
– Remove spur gear drive ⇒ page 197 .
– Release retaining frame from bonded joint.
– Remove crankshaft oil seal (pulley end).
Installing
– Remove old sealant from sealing surfaces on timing chain
cover.
Caution
Protect lubrication system and bearings against contamina‐

tion.
♦ Cover exposed parts of the engine.
WARNING
Risk of eye injury.


– Remove sealant residue from sealing surfaces using rotating

plastic brush or similar.
– Clean sealing surfaces -1- on retaining frame, intake module
and sealing flange for protective tube; they must be free of oil
and grease.
– Check that dowel sleeves -arrows- are fitted in retaining frame

(cylinder block side), as shown in illustration.
– Check that dowel sleeves -arrows- are fitted in retaining frame

(intake module side), as shown in illustration.
3. Crankshaft 151
Note
Note the use-by date of the sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx.

1.5 mm).
Applying sealant onto cylinder block - retaining frame side

– Fit seals -1- and -2-.
Caution
Make sure lubrication system is not clogged by excess sealant.

♦ The sealant bead must not be thicker than specified.
– Apply sealant beads -arrows- onto clean sealing surfaces of

cylinder block as shown in illustration.
• Width of sealant beads: 2.0 mm.
Note
The retaining frame must be installed within 5 minutes after ap‐

plying the sealant.
– Carefully fit retaining frame on cylinder block, paying attention

to thrust washers and dowel pins.
Applying sealant to timing chain cover (bottom) if only the intake

module is removed
Caution

– Apply sealant bead -1- onto clean sealing surface of timing

chain cover (bottom) as shown in illustration.
• Width of sealant bead: 2.0 mm.
Note
The intake module must be installed within 5 minutes of applying

the sealant.
– Fit intake module, guiding it at an angle towards sealing sur‐

face on timing chain cover and retaining frame.
– Secure intake module ⇒ page 145 .

Applying sealant onto retaining frame - intake module side

– Fit seals -1, 2, 3-.
Caution

♦ The sealant beads must not be thicker than specified.
– Apply sealant beads -arrows- onto clean sealing surfaces of

retaining frame as shown in illustration.
Note
The intake module must be installed within 5 minutes of applying

the sealant.
– Secure retaining frame and intake module ⇒ page 145 .
Applying sealant to flange for protective tube

– Clean sealing surfaces; they must be free of oil and grease.
Caution

– Apply sealant bead -arrow- onto clean sealing surface of

flange as shown in illustration.
Note
The flange must be installed within 5 minutes after applying the

sealant.
3. Crankshaft 153
– Move flange -1- into installation position and tighten bolts

-arrows-.
Remaining installation steps are carried out in reverse sequence;
note the following:
Note
Renew O-rings.
– Install spur gear drive ⇒ page 197 .

– Install timing chain cover (bottom) ⇒ page 168 .
– Install transmission shaft ⇒ Rep. gr. 39 .
– Install oil pump ⇒ page 240 .
– Install crankshaft oil seal (pulley end) ⇒ page 133 .
– Install bracket for alternator ⇒ page 132 .
– Install vibration damper ⇒ page 132 .

4 Pistons and conrods

⇒ “4.1 Exploded view - pistons and conrods”, page 155
⇒ “4.2 Removing and installing pistons”, page 157
⇒ “4.3 Checking piston bores and cylinder bores”, page 158
⇒ “4.4 Measuring radial clearance of conrods”, page 159
4.1 Exploded view - pistons and conrods
Note
Oil spray jet for piston cooling ⇒ page 157 .
1 - Bolts
❑ Renew
❑ Use old bolts when
measuring radial clear‐
ance
❑ Lubricate threads and
contact surface
❑ 40 Nm +120°
2 - Conrod bearing cap
❑ Mark installation posi‐
tion for re-installation
❑ Mark conrod and cylin‐
der allocation in colour
⇒ page 156
❑ Installation position of
conrod pairs
⇒ page 157
3 - Dowel pin
❑ 2x
❑ Ensure secure fit in con‐
rod bearing cap
4 - Bearing shells
❑ Ensure that retaining
lugs are securely seat‐
ed.
❑ Renew used bearing
shells
❑ There are oversized
bearings available for
machined crankshaft
conrod journals ⇒ Elec‐
tronic parts catalogue
5 - Conrod
❑ Only renew as a complete set
❑ Mark conrod bearing cap and cylinder allocation in colour ⇒ page 156
❑ Installation position of conrod pairs ⇒ page 157
❑ Axial clearance for each conrod pair (when new): 0.20 … 0.38 mm
❑ Measuring radial clearance ⇒ page 159
4. Pistons and conrods 155

6 - Circlip
❑ Renew
7 - Piston pin
❑ Removing and installing ⇒ “4.2 Removing and installing pistons”, page 157
8 - Piston
❑ Mark installation position and cylinder number ⇒ page 156
❑ Checking pistons and cylinder bores ⇒ page 158
9 - Piston rings
❑ Measuring ring gap ⇒ page 159
❑ Measuring ring-to-groove clearance ⇒ page 159
❑ Use piston ring pliers to remove and install
❑ Marking “TOP” or side with identification mark must face piston crown
❑ Offset gaps by 120°
Installation position of pistons
Caution
Do not damage the coating of the piston crown.

♦ If you intend to re-install used pistons, mark the cylinder
number on the piston crown using paint. Do not attempt to
mark the piston crown with a centre punch or by making
a notch or similar.
Installation position:
• Arrows on piston crowns point to pulley end.
• Large valve recesses -1- point to centre of engine.
Marking conrods
Note
Only renew conrods as a complete set.
– Use a coloured pen to mark matching conrods and conrod

bearing caps with cylinder numbers -arrow- for re-installation.

Installation position of conrods

• The cast lugs -arrows- on the ground surfaces of the conrod
pairs “1 and 2”, “3 and 4”, “5 and 6”, “7 and 8” and “9 and 10”
must face each other.
Oil spray jet for piston cooling

1- Oil spray jet
2- Apply locking fluid to bolt when installing; for locking fluid
refer to ⇒ Electronic parts catalogue . Tighten to 9 Nm.
Note
♦ Do not bend oil spray jets.

♦ Always renew bent oil spray jets.
4.2 Removing and installing pistons

♦ Pin - VW 222 A-
♦ Piston ring clamp, commercially available

Removing
• Engine secured to engine and gearbox support - VAS 6095-
⇒ page 103
– Remove cylinder head ⇒ page 208 .
– Remove intake module ⇒ page 238 .
– Mark installation position and matching of conrod bearing caps
to cylinder and to conrods for re-installation ⇒ page 156 .
– Unbolt conrod bearing caps.
– Pull out pistons upwards with conrods.

Note
If piston pin is difficult to remove, heat piston to approx. 60 °C.
– Take circlip out of piston pin boss.

– Use drift - VW 222 A- to drive out piston pin.
Installing
Tightening torques:
• ⇒ “4.1 Exploded view - pistons and conrods”, page 155
• ⇒ “1.1 Exploded view - oil pump, intake module”, page 238
Note
Renew bolts tightened with specified tightening angle.
– Oil running surfaces of bearing shells.

– Install pistons using piston ring clamp.
Installation position:
• Pistons ⇒ page 156
• Conrods ⇒ page 157
– Install conrod bearing caps according to markings.
– Install intake module ⇒ page 238 .
– Install cylinder head ⇒ page 208 .
4.3 Checking piston bores and cylinder

bores
Checking piston
– Using a micrometer (75 ... 100 mm), measure approx. 15 mm
from the lower edge, at 90° to the piston pin axis.
• Maximum deviation from nominal dimension: 0.03 mm.
There are different piston sizes specifically matched to the varying
bore dimensions for the cylinder block.
Nominal dimension for piston ∅ mm
Nominal piston dimension 1 84.4901)
Nominal piston dimension 2 84.5901)
• 1)Dimensions including coating (thickness 0.01 mm). The
coating will wear down in service.
Note
Renew piston if cracking is visible on piston skirt.

Measuring piston ring gap

– Insert ring at right angle to cylinder wall from above and push
down into lower cylinder opening approx. 15 mm from bottom
of cylinder.
– To do so, use a piston without rings.
Piston ring new Wear limit
mm mm
1st compression ring 0.20 … 0.35 0.80
2nd compression ring 0.20 … 0.40 0.80
Oil scraper ring 0.20 … 0.40 0.80
Measuring ring-to-groove clearance

– Clean groove in piston before checking clearance.
Piston ring new Wear limit
mm mm
1st compression ring 0.02 … 0.07 0.20
2nd compression ring 0.005 … 0.045 0.200
Oil scraper ring 0.02 … 0.06 0.15
Measuring cylinder bore

– Use a cylinder gauge - VAS 6078- to take measurements at 3
points in transverse direction -A- and in longitudinal direction
-B-.
• Maximum deviation from nominal dimension: 0.08 mm.
There are different piston sizes specifically matched to the varying
bore dimensions for the cylinder block ⇒ page 158 .
Nominal dimension for cylinder bore ∅ mm
Bore dimension 1 84.510 ± 0.005
Bore dimension 2 84.610 ± 0.005
4.4 Measuring radial clearance of conrods

♦ Plastigauge
Procedure
– Remove conrod bearing cap.
– Clean bearing cap and bearing journal.
bearing on the bearing journal or bearing shell.
– Fit conrod bearing cap and tighten with old bolts
⇒ Item 1 (page 155) . Do not rotate crankshaft.

– Remove conrod bearing cap again.

Radial clearance:
• New: 0.030 ... 0.062 mm.

15 – Cylinder head, valve gear

1 Chain drive
⇒ “1.1 Exploded view - timing chain covers”, page 161
⇒ “1.2 Removing and installing timing chain cover (left-side)”,
page 163
⇒ “1.3 Removing and installing timing chain cover (right-side)”,
page 166
⇒ “1.4 Removing and installing timing chain cover (bottom)”, page
168
⇒ “1.5 Exploded view - camshaft timing chains”, page 173
⇒ “1.6 Removing timing chains from camshafts”, page 176
⇒ “1.7 Removing and installing camshaft timing chains”,
page 183
⇒ “1.8 Exploded view - drive chain for valve gear”, page 186
⇒ “1.9 Removing and installing drive chain for valve gear”,
page 188
⇒ “1.10 Exploded view - drive chain for auxiliary drives”,
page 189
⇒ “1.11 Removing and installing drive chain for auxiliary drives”,
page 190
⇒ “1.12 Exploded view - auxiliary drives”, page 193
⇒ “1.13 Renewing oil seal for air conditioner compressor drive”,
page 194
⇒ “1.14 Renewing oil seal for power steering pump drive”,
page 196
⇒ “1.15 Removing and installing spur gear drive”, page 197
1.1 Exploded view - timing chain covers
1. Chain drive 161

1 - Bolt
❑ Renew M6 bolts
❑ Tightening torque and
sequence ⇒ page 163
end)
3 - Dowel sleeve
❑ 2x
4 - Timing chain cover (bottom)
⇒ page 168
5 - Cylinder head gasket (left-
side)
6 - Timing chain cover (left-
side)
⇒ page 163
7 - Bolt
8 - Bracket for wiring harness
9 - Bolt
10 - Bracket for electrical con‐
nectors
11 - Bolt
12 - Bracket for electrical connector
13 - Bolt
14 - Bracket for wiring harness
15 - Timing chain cover (right-side)
16 - Cylinder head gasket (right-side)
17 - Dowel sleeve
❑ 2x
18 - Seal
❑ Renew
19 - Oil drain plug
❑ 12 Nm
162 Rep. gr.15 - Cylinder head, valve gear

Timing chain cover (left-side) - tightening torque and sequence

– Tighten bolts in the sequence -1 ... 8- in 2 stages as follows:
1. Initially tighten to 5 Nm.
2. Tighten to 9 Nm.
Timing chain cover (right-side) - tightening torque and sequence

– Tighten bolts in the sequence -1 ... 8- in 2 stages as follows:
2. Tighten to 9 Nm.
Timing chain cover (bottom) - tightening torque and sequence
Note

1. -Arrows- 5 Nm
2. -1 … 11- 8 Nm in diagonal sequence
3. -Arrows- 11 Nm
4. -6, 7- 22 Nm
5. -1 … 5- and Turn 90° further
-8 … 11-
6. -Arrows- Turn 90° further
1.2 Removing and installing timing chain

cover (left-side)
♦ Safety goggles
1. Chain drive 163

Removing
Note
– Remove engine compartment cross member ⇒ page 118 .

– Detach electrical connectors from bracket and unplug.
– Move clear electrical wiring leading to Lambda probes.
Note
Disregard -item 1-.

– Move clear breather hose -arrow- for gearbox.

– Release hose clip, disconnect vacuum line -2- and swivel vac‐
uum line to one side.

– Disconnect vacuum hose -2-.

– Remove bolts -1- and move combination valve (left-side) for
secondary air system to one side.
– Remove bolts -1 ... 8-.
Note
♦ Due to restricted access, bolt -1- must be removed using pli‐

ers.
♦ When installing, use bolt - N 100 050 10- ⇒ Electronic parts
catalogue .
– Detach brackets -arrow A- and -arrow B-.

– Release timing chain cover (left-side) from bonded joint.
Installing
Caution
Protect lubrication system against contamination.

WARNING
Risk of eye injury.

– Remove remaining sealant on timing chain cover -1- and cyl‐

inder head using rotating plastic brush or similar.
Note

2 mm).
1. Chain drive 165

Caution

– Apply sealant bead -arrow- onto clean sealing surface of tim‐

ing chain cover (left-side) as illustrated.
Note
The timing chain cover must be installed within 5 minutes after

applying the sealant.
– Fit timing chain cover (left-side) and brackets -arrow A- and

-arrow B-.
– Replace bolt -6- with hexagon flange bolt ⇒ Electronic parts
catalogue .
– Tighten bolts ⇒ page 163 .
note the following:
– Install combination valve for secondary air (left-side)
⇒ page 409 .

cover (right-side)
♦ Safety goggles
Removing
Note



– Remove bolts -1- and move combination valve for secondary
air system (right-side) to one side with hose -4- and electrical
connector -3- attached.
– Move electrical wiring clear.

– Detach bracket -arrow A- and move bracket -arrow B- clear to
one side.
– Release timing chain cover (right-side) from bonded joint.
Installing
Caution

WARNING
Risk of eye injury.

– Remove remaining sealant on timing chain cover -1- and cyl‐

inder head using rotating plastic brush or similar.
1. Chain drive 167

Note

2 mm).
Caution

– Apply sealant bead -arrow- onto clean sealing surface of tim‐

ing chain cover (right-side) as illustrated.
Note

– Fit timing chain cover (right-side), brackets -arrow A- and

-arrow B- and tighten bolts ⇒ page 163 .
note the following:
– Install combination valve for secondary air (right-side)
⇒ page 411 .

cover (bottom)
♦ Stud extractor, commercially available
♦ Safety goggles
Removing
– Remove flywheel ⇒ page 138 .


– Remove power steering pump ⇒ Rep. gr. 48 .
– Remove studs -arrows- using commercially available stud ex‐
tractor.
– Remove transmission shaft ⇒ Rep. gr. 39 .
– Remove intake manifold (top section) ⇒ page 352 .
– Remove oil filter housing ⇒ page 245 .
– Remove timing chain covers: left-side ⇒ page 163 , right-side
⇒ page 166 .

– Remove bolts -1 ... 11- and release timing chain cover (bot‐
tom) from bonded joint.
– Press crankshaft oil seal (gearbox end) out of timing chain
cover (bottom).
Installing
– Pull dowel sleeve at top right out of cylinder block.
– Bevel the dowel sleeve with a file, as illustrated.
• Dimension -x- = 6.5 mm
• Dimension -y- = 8 mm
– Fit dowel sleeve on cylinder block in such a way that the bev‐
elled side points upwards.
Note
Bevelling the dowel sleeve makes it easier to fit the timing chain
cover (bottom) with the cylinder head installed.
1. Chain drive 169

Caution

WARNING
Risk of eye injury.

– Remove remaining sealant on timing chain cover -1-, cylinder

block and cylinder head using rotating plastic brush or similar.
– Clean old sealant from holes -arrow- in cylinder head gaskets.
Note
With the cylinder head installed the holes in the cylinder head
gasket are only half visible.
Caution
Avoid damage to cylinder head gasket.

♦ Only bend the ends of the cylinder head gaskets slightly
and do not kink.
Note
If the cylinder head gasket has been bent and kinked it must be
renewed.
– Carefully bend the ends of the cylinder head gaskets down

very slightly -arrows-, just far enough to be able to clean the
upper sealing surface on the cylinder head gasket and cylinder
head.
– Clean cylinder head gaskets (top and bottom); they must be
free of oil and grease.

Note

2 mm).
– Apply a small amount of sealant to sealing surfaces of cylinder

head gaskets (top and bottom). To do so, you again have to
bend cylinder head gaskets down very slightly -arrows-.
– Use a flat object (e.g. a feeler gauge) to apply sealant to the
area between cylinder head and gasket.
– Clean holes -arrow- in cylinder head gaskets and fill them with
sealant.
1. Chain drive 171

Caution

To avoid any risk of leakage, the sealant bead must be applied
exactly as specified.
♦ The sealant bead must be applied with a kink at the point
indicated by the -arrow-.
♦ The sealant bead must NOT run straight at this point.
– Apply sealant beads -1 ... 10- onto the clean sealing surfaces
of the timing chain cover (bottom) as illustrated.
Note

– Fit timing chain cover (bottom), guiding it towards the sealing

surface on cylinder block and cylinder head at an angle and
from below.
– Take care not to damage the cylinder head gaskets when fit‐
ting the cover.
– Tighten bolts for timing chain cover (bottom) ⇒ page 163 .

note the following:
– Install crankshaft oil seal (gearbox end) ⇒ page 141 .
– Install timing chain covers: left-side ⇒ page 163 , right-side
⇒ page 166 .

– Vehicles with manual gearbox/R tronic gearbox 086: Use stud

extractor (commercially available) to screw in studs until di‐
mension -a- is attained.
• Dimension -a- = 35 ± 1 mm.
– Install oil filter housing ⇒ page 245 .
– Install intake manifold (top section) ⇒ page 352 .
– Install transmission shaft ⇒ Rep. gr. 39 .
– Install power steering pump ⇒ Rep. gr. 48 .
– Install flywheel ⇒ page 138 .
Note

Booklet 420 .
1.5 Exploded view - camshaft timing chains

Camshaft timing chain (left-side)
1 - Camshaft adjuster for ex‐

haust camshaft
❑ Identification “Exhaust”
⇒ “1.6 Removing timing
chains from camshafts”,
page 176
2 - Bolt
❑ Renew
❑ Pre-tightening torque:
60 Nm
❑ Final tightening torque:
80 Nm + 90°
3 - Bolt
❑ Renew
60 Nm
80 Nm + 90°
4 - Camshaft adjuster for inlet
camshaft
❑ Identification “Intake”
page 176
5 - Camshaft timing chain (left-
side)
running direction with
paint
⇒ page 183
1. Chain drive 173

6 - Bolt
❑ Renew
❑ 5 Nm +90°
7 - Slide
8 - Chain tensioner for camshaft timing chain (left-side)
❑ Removing and installing ⇒ “1.6 Removing timing chains from camshafts”, page 176
9 - Oil strainer
❑ Inserted in chain tensioner
❑ Installation position: locating lug on outer circumference must engage in groove on chain tensioner
10 - Gasket
❑ Renew
❑ Clipped onto chain tensioner
11 - Bearing bracket for drive sprocket
12 - Bolt
❑ Renew
❑ 5 Nm +90°
13 - Drive sprocket for camshaft timing chain (left-side)
14 - Thrust washer for drive sprocket
15 - Bolt
❑ 22 Nm
Camshaft timing chain (right-side)

1 - Bearing mounting for drive

sprocket
❑ For camshaft timing
chain (right-side)
❑ Asymmetric version
❑ Installation position
⇒ page 176
2 - Bolt
❑ 42 Nm
3 - Camshaft adjuster for ex‐
haust camshaft
❑ Identification “Exhaust”
page 176
4 - Bolt for camshaft
❑ Renew
60 Nm
80 Nm + 90°
5 - Bolt for camshaft
❑ Renew
60 Nm
80 Nm + 90°
6 - Camshaft adjuster for inlet
camshaft
❑ Identification “Intake”
⇒ “1.6 Removing timing chains from camshafts”, page 176
7 - Camshaft timing chain (right-side)
❑ Before removing, mark running direction with paint
8 - Chain tensioner for camshaft timing chain (right-side)
❑ Removing and installing ⇒ “1.6 Removing timing chains from camshafts”, page 176
9 - Slide
10 - Oil strainer
❑ Inserted in chain tensioner
❑ Installation position: locating lug on outer circumference must engage in groove on chain tensioner
11 - Gasket
❑ Renew
❑ Clipped onto chain tensioner
12 - Bolt
❑ Renew
❑ 5 Nm +90°
14 - Drive sprocket for camshaft timing chain (right-side)
1. Chain drive 175

Installation position: bearing mounting for drive sprocket for cam‐

shaft timing chain (right-side)
• Dowel pins in bearing mounting -3- for drive sprocket for cam‐
shaft timing chain (right-side) must engage in drillings in thrust
washer -1- and in cylinder block drillings.
4 - Bolt
1.6 Removing timing chains from camshafts

equipment required
♦ Locking pin - 3242- , or alternatively locking pin - T40237-

♦ Torque wrench - V.A.G 1332-
♦ Tool insert - V.A.G 1332/9-
♦ Camshaft clamp - T40070- (2x)

♦ Locking pin - T40071- (2x)
♦ Key - T40079-
Removing
Note
In the following procedure the camshaft timing chains remain on

the engine.
– Remove cylinder head covers: left-side ⇒ page 204 ; right-

side ⇒ page 207 .
– Remove timing chain covers: left-side ⇒ page 163 , right-side
⇒ page 166 .
1. Chain drive 177


• The threaded holes -arrows- in the camshafts must face up‐

wards.
– Fit camshaft clamps - T40070- onto both cylinder heads and

tighten bolts -arrows- to 25 Nm.
• The camshaft clamp - T40070- is positioned correctly if the
holes for the cylinder head bolts remain free.

below engine.

– Press guide rail of chain tensioner for camshaft timing chain

(left-side) inwards as far as the stop using a screwdriver -1-.
Then lock chain tensioner by inserting locking pin - T40071- .
Note
The chain tensioner is oil-damped and can therefore only be

compressed slowly by applying constant pressure.

(right-side) inwards as far as the stop using a screwdriver
-1-. Then lock chain tensioner by inserting locking pin -
T40071- .
Note
The chain tensioner is oil-damped and can therefore only be

compressed slowly by applying constant pressure.
– Use paint to mark allocation of camshaft adjuster to corre‐

sponding cylinder head and camshaft for re-installation.
Caution
Risk of irreparable damage to engine.

♦ Block off the opening in the valve timing housing with a
clean cloth to prevent small items from dropping into the
engine.
– Unscrew bolts -1- and -2- on cylinder head (left-side) and re‐
move both camshaft adjusters.
1. Chain drive 179

– Use paint to mark allocation of camshaft adjuster to corre‐

sponding cylinder head and camshaft for re-installation.
– Unscrew bolts -1- and -2- on cylinder head (right-side) and
remove both camshaft adjusters.
Installing
Note
Caution
Risk of damage to valves and piston crowns.

♦ The crankshaft must not be at “TDC” at any cylinder when
the camshafts are turned.
• Drive chain for valve gear installed ⇒ page 188

• Crankshaft locked in position with locking pin - 3242- .
• Camshaft clamps - T40070- installed on both cylinder heads
and tightened to 25 Nm -arrows-.

– Re-install camshaft adjuster on cylinder head (left-side) in the

same position as before (pay attention to marks applied when
removing).
– Fit timing chain (left-side) onto drive chain sprocket and cam‐
shaft adjusters and fit bolts -1- and -2- without tightening.
• It should just be possible to turn both camshaft adjusters on
the camshaft without axial movement.
– Remove locking pin - T40071- .
– Re-install camshaft adjuster on cylinder head (right-side) in

the same position as before (pay attention to marks applied
when removing).
– Fit timing chain (right-side) onto drive chain sprocket and cam‐
shaft adjusters and fit bolts -1- and -2- without tightening.
• It should just be possible to turn both camshaft adjusters on
the camshaft without axial movement.
Note
A second mechanic is required for the following work steps.
– Fit key - T40079- onto camshaft adjuster of inlet camshaft on

cylinder head (left-side).
– Apply torque wrench - V.A.G 1332- with open ring spanner
insert - V.A.G 1332/9- to key - T40079- .
– Have a 2nd mechanic apply a torque of 40 Nm to camshaft
adjuster in clockwise direction -arrow-.
– Tighten bolts as follows while keeping camshaft adjuster un‐
der tension:
1. Pre-tighten bolt -1- on exhaust camshaft to 60 Nm.
2. Pre-tighten bolt -2- on inlet camshaft to 60 Nm.
– Fit key - T40079- onto camshaft adjuster of exhaust camshaft

on cylinder head (right-side).
– Apply torque wrench - V.A.G 1332- with open ring spanner
insert - V.A.G 1332/9- to key - T40079- .
– Have a 2nd mechanic apply a torque of 40 Nm to camshaft
adjuster in clockwise direction -arrow-.
– Tighten bolts as follows while keeping camshaft adjuster un‐
der tension:
1. Pre-tighten bolt -1- on inlet camshaft to 60 Nm.
2. Pre-tighten bolt -2- on exhaust camshaft to 60 Nm.

– Remove key - T40079- .
1. Chain drive 181

– Remove camshaft clamps - T40070- from both cylinder heads

-arrows-.
– Tighten camshaft adjuster bolts on cylinder head (left-side) as

follows:
1. Tighten bolt -1- on exhaust camshaft to final tightening tor‐
que.
2. Tighten bolt -2- on inlet camshaft to final tightening torque.
– Tighten camshaft adjuster bolts on cylinder head (right-side)

as follows:
1. Tighten bolt -1- on inlet camshaft to final tightening torque.
2. Tighten bolt -2- on exhaust camshaft to final tightening tor‐

que.
– Remove locking pin - 3242- .

– Using adapter - T40058- , turn crankshaft 2 revolutions in nor‐

mal direction of rotation -arrow- until crankshaft is at “TDC”
again.
Note
If you turn the crankshaft beyond “TDC” by mistake, turn it back

approx. 30° and set to “TDC” again.
• The threaded holes -arrows- in the camshafts must face up‐

wards.

• The camshaft clamp - T40070- is positioned correctly if the
holes for the cylinder head bolts remain free.
• The locking pin - 3242- must engage in the groove in the
crankshaft. If it does not, reset valve timing.
– Remove camshaft clamps from both cylinder heads.
– Remove locking pin.
note the following:
– Install plug for “TDC” marking with new seal and tighten plug
⇒ Item 16 (page 144) .
– Install timing chain covers: left-side ⇒ page 163 , right-side
⇒ page 166 .
– Install cylinder head covers: left-side ⇒ page 204 ; right-side
⇒ page 207 .
1.7 Removing and installing camshaft tim‐

ing chains
1. Chain drive 183

♦ Locking pin - T40071-
Removing
• Engine in position on scissor-type assembly platform -
VAS 6131 B- or secured to engine and gearbox support
⇒ page 103 .
– Remove timing chain cover (bottom) ⇒ page 168 .
– Remove timing chains from camshafts ⇒ page 176 .
Caution
If a used timing chain rotates in the opposite direction when it

is refitted, this can cause breakage.
♦ Mark running direction of timing chain with coloured ar‐
rows for re-installation. Do not attempt to mark the timing
chain with a centre punch or by making a notch or similar.
Camshaft timing chain (left-side):

– Remove bolts -1- and -2- and take off chain tensioner (left-
side) and camshaft timing chain (left-side).

Camshaft timing chain (right-side):

– Press guide rail for chain tensioner in direction of -arrow- and
lock chain tensioner by inserting locking pin - T40071- .
– Slacken bolt -1- securing drive sprocket for camshaft timing
chain approx. 11/2 turns only; do not remove bolt completely.
– Remove bolts -1- and -2- and take off chain tensioner (right-
side) and timing chain (right-side).
Installing
Note
♦ Note the correct installation position if the tensioning element

has been removed from the chain tensioner: drilling in base of
housing faces chain tensioner and piston faces tensioner rail.
♦ Renew gaskets for chain tensioner.
Caution
Risk of damage to valves and piston crowns.

♦ The crankshaft must not be at “TDC” at any cylinder when
the camshafts are turned.

(left and right) inwards -arrow- as far as the stop. Then lock
chain tensioner by inserting locking pin - T40071- .
1. Chain drive 185

– If necessary, clean oil strainer -2- in both chain tensioners.
Note
Pay attention to groove in chain tensioner when fitting oil strainer.
– Fit gasket -3- on rear of chain tensioner -1- and clip in.
Camshaft timing chain (left-side):

– Position timing chain (left-side) as shown in the illustration
(according to marks applied during removal).
– Tighten bolts -1- and -2-.
Camshaft timing chain (right-side):

– Fit chain tensioner on cylinder head (right-side) and position
timing chain as shown in the illustration (according to marks
applied when removing).
– Tighten bolt -1- securing drive sprocket for camshaft timing

chain.
Both sides (continued):
note the following:
– Fit timing chains on camshafts ⇒ page 180 .
1.8 Exploded view - drive chain for valve gear

1 - Guide rail
2 - Bolt
❑ Renew
❑ 17 Nm +90°
3 - Bolt
⇒ Item 15 (page 174)
4 - Thrust washer for drive
sprocket
5 - Drive sprocket for camshaft
timing chain (left-side)
6 - Bolt
❑ Renew
❑ 17 Nm +90°
7 - Drive chain for valve gear
paint
⇒ page 188
8 - Guide rail
9 - Bolt
❑ Renew
❑ 17 Nm +90°
10 - Bolt
11 - Bearing bracket for drive
sprocket
❑ For camshaft timing
chain (right-side)
❑ Asymmetric version
❑ Installation position ⇒ page 176
14 - Bearing mounting for drive sprocket
15 - Bolt
16 - O-ring
❑ Version fitted in vehicle may differ from illustration
❑ Renew
17 - Chain tensioner
18 - Bolt
❑ Renew
❑ 5 Nm +90°
1. Chain drive 187

19 - Crankshaft
20 - Bolt
❑ Renew
❑ 17 Nm +90°
1.9 Removing and installing drive chain for

valve gear
Removing
⇒ page 103 .
– Remove timing chains ⇒ page 183 .
– Remove drive chain for auxiliary drives ⇒ page 190 .

– Press guide rail of chain tensioner for drive chain in direction

of -arrow- and lock chain tensioner by inserting locking pin -
T40071- .
Caution
If a used drive chain rotates in the opposite direction when it is

refitted, this can cause breakage.
♦ Mark running direction of drive chain with paint for re-in‐
stallation. Do not attempt to mark the drive chain with a
centre punch or by making a notch or similar.
– Unscrew bolts -1- and remove guide rail.

– Remove bolts -2- and take off chain tensioner.
– Detach drive chain for valve gear.
Installing
⇒ “1.8 Exploded view - drive chain for valve gear”, page 186
Note
– Position drive chain for valve gear onto drive chain sprockets
(according to marks applied during removal).
– Install guide rail and tighten bolts -1-.

– Install chain tensioner and tighten bolts -2-.
– Press guide rail of chain tensioner for drive chain in direction
of -arrow- and remove locking pin - T40071- .
– Install drive chain for auxiliary drives ⇒ page 190 .
– Install camshaft timing chains ⇒ page 183 .
1.10 Exploded view - drive chain for auxiliary drives
1. Chain drive 189

1 - Bolt
❑ Renew
❑ 5 Nm +90°
2 - Guide rail
3 - Seal
❑ Renew
4 - Bolt
❑ 64 Nm
5 - Drive chain sprocket for
auxiliary drives
6 - Bolt
❑ 42 Nm
7 - Bearing mounting for idler
sprocket
8 - Idler sprocket
9 - Bearing bracket for idler
sprocket
10 - Bolt
❑ Renew
❑ 5 Nm +90°
11 - Drive chain for auxiliary
drives
paint
⇒ page 190
12 - Crankshaft
1.11 Removing and installing drive chain for

auxiliary drives

Removing
⇒ page 103 .

1. Chain drive 191


below engine.
Caution
If a used drive chain rotates in the opposite direction when it is

refitted, this can cause breakage.
♦ Mark running direction of drive chain with paint for re-in‐
stallation. Do not attempt to mark the drive chain with a
centre punch or by making a notch or similar.
– Press tensioning rail in direction of -arrow- and lock chain ten‐

sioner in place using locking pin - T40071- .
– Unscrew bolt -1- and remove drive chain sprocket for auxiliary
drives.
– Remove bolts -2, 3, 4- and take off chain tensioner.
– Detach drive chain for auxiliary drives.
Installing
⇒ “1.10 Exploded view - drive chain for auxiliary drives”, page
189
Note
Renew seal.

– Fit drive chain for auxiliary drives according to marks applied

when removing.
– Install chain tensioner and tighten bolts -2, 3, 4-.
– Fit drive chain onto drive chain sprocket for auxiliary drives and
tighten bolt -1-.
note the following:
– Install plug for “TDC” marking with new seal and tighten plug
⇒ Item 16 (page 144) .
1.12 Exploded view - auxiliary drives
1 - Power steering pump

⇒ Rep. gr. 48
2 - Compression spring
3 - Oil seal for power steering
pump drive
4 - Flat-section O-ring
⇒ page 194
❑ Renew if damaged
5 - Bolt
6 - Oil seal for air conditioner
compressor drive
7 - Dust cap for air conditioner
compressor drive
8 - Clamp
❑ Renew
❑ Use correct type (as
original equipment) ⇒
Electronic parts cata‐
logue
9 - Drive shaft for air condition‐
er compressor
Rep. gr. 87
10 - Spur gear drive
❑ Do not dismantle
1. Chain drive 193

11 - O-ring
❑ Renew
12 - Oil pump drive shaft
13 - Drive spur gear for auxiliary drives
❑ Cannot be renewed separately
14 - Drive chain sprocket for auxiliary drives
15 - Bolt
Spur gear drive - tightening torque and sequence

– Tighten bolts -1 ... 6- in diagonal sequence and in stages to
22 Nm.
Installation position of flat-section O-ring

♦ In power steering pump drive -arrow-.
1.13 Renewing oil seal for air conditioner

compressor drive
♦ Thrust piece - T40192-

♦ Oil seal extractor -T40195-
Procedure
• Engine removed and in position on scissor-type assembly
platform - VAS 6131 B- with gearbox attached ⇒ page 90 .
⇒ page 396 .
– Remove air conditioner compressor ⇒ Rep. gr. 87 .
– Detach hose clip on dust cap -arrow- for air conditioner com‐
pressor drive.
– Pull off dust cap together with drive shaft for air conditioner
compressor from stub shaft of spur gear for air conditioner
compressor drive.
– Screw spindle of oil seal extractor -T40195- all the way out.
pressure).
– Turn inner part of oil seal extractor against spur gear drive until
the oil seal is pulled out.
Note
If the sections of the oil seal come apart, apply oil seal extractor
again and pull out remaining part of oil seal.
– Clamp hexagon flats of oil seal extractor in vice and use pliers
to remove oil seal.
1. Chain drive 195

– Drive in oil seal for air conditioner compressor drive as far as

stop using thrust piece - T40192- .
Note
Secure with correct type of hose clip (same as original equipment)

⇒ Electronic parts catalogue .
– Press dust cap -arrow- with hose clip fitted onto stub shaft of
spur gear for air conditioner compressor drive and secure.
– Install air conditioner compressor ⇒ Rep. gr. 87 .
⇒ page 396 .
1.14 Renewing oil seal for power steering

pump drive
♦ Thrust piece - T40194-
♦ Oil seal extractor -T40195-

Procedure
– Screw spindle of oil seal extractor -T40195- all the way out.
pressure).
– Turn inner part of oil seal extractor against spur gear drive until
the oil seal is pulled out.
Note
If the sections of the oil seal come apart, apply oil seal extractor
again and pull out remaining part of oil seal.
– Clamp hexagon flats of oil seal extractor in vice and use pliers
to remove oil seal.
– Drive in oil seal for power steering pump drive as far as stop
using thrust piece - T40194- .
1.15 Removing and installing spur gear drive

Removing
• Engine is on scissor-type assembly platform - VAS 6131 B-
and separated from gearbox ⇒ page 94 , or secured to engine
and gearbox support ⇒ page 103 .
⇒ page 396 .
– Detach hose clip on dust cap -arrow- for air conditioner com‐
pressor drive.
– Remove drive chain for auxiliary drives ⇒ page 190 .
1. Chain drive 197

– Take off spur gear drive -1- and detach drive shaft -2- from oil
pump.
Installing
Note
Fit new O-ring.
– Renew oil seal ⇒ Item 3 (page 193) and flat-section O-ring

⇒ Item 4 (page 193) in power steering pump drive if damaged.
– Remove sealant residues from spur gear drive and cylinder
block.
Note

1.5 mm).

Caution

– Apply bead of sealant -arrow- onto clean sealing surface of

spur gear drive as shown in illustration.
– Apply O-ring -1- and secure in position with a small amount of
grease.
Note
The spur gear drive must be installed within 5 minutes after ap‐
plying the sealant.
Note
Secure with correct type of hose clip (same as original equipment)

⇒ Electronic parts catalogue .
– The new hose clip -1- must be guided through the hole in the
retaining frame and over the dust cap -3- onto the air condi‐
tioner compressor drive shaft -2- while the spur gear drive is
still removed.
– Insert drive shaft -2- in oil pump.

– Position spur gear drive -1- on drive shaft.
– Fit spur gear drive while turning gear wheels back and forth.
– Tighten bolts ⇒ page 194 .
1. Chain drive 199

– Press dust cap -arrow- with hose clip fitted onto stub shaft of
spur gear for air conditioner compressor drive and secure.
note the following:
– Install drive chain for auxiliary drives ⇒ page 190 .
⇒ page 396 .

2 Cylinder head
⇒ “2.1 Exploded view - cylinder head”, page 201
⇒ “2.2 Removing and installing cylinder head cover (left-side)”,
page 204
⇒ “2.3 Removing and installing cylinder head cover (right-side)”,
page 207
⇒ “2.4 Removing and installing cylinder head”, page 208
⇒ “2.5 Checking compression”, page 215
2.1 Exploded view - cylinder head
Note
The diagram shows the cylinder head on cylinder bank 2 (left-side).
1 - Cylinder head gasket

❑ Renewing
⇒ “2.4 Removing and in‐
stalling cylinder head”,
page 208
❑ Installation position:
part number must face
cylinder head
❑ If renewed, change en‐
gine oil and coolant
2 - Cylinder head
⇒ page 208
❑ Checking for distortion
⇒ page 203
❑ Machining limit
⇒ page 204
❑ If renewed, change en‐
gine oil and coolant
3 - Engine lifting eye
4 - Bolt
❑ 22 Nm
5 - Seal
❑ Renew
6 - Plug
❑ 45 Nm
7 - Seals
❑ Renew
8 - Gasket for cylinder head
cover
❑ Renew if damaged or
leaking
9 - Cylinder head cover
❑ Removing and installing: left-side ⇒ page 204 , right-side ⇒ page 207
2. Cylinder head 201

10 - Bolt
❑ Renew if gasket is damaged
❑ Tightening torque and tightening sequence for cylinder head cover (left-side) ⇒ page 203
❑ Tightening torque and tightening sequence for cylinder head cover (right-side) ⇒ page 203
11 - Banjo bolts
❑ Renew
❑ 8 Nm +90°
12 - Ignition coil
13 - Coolant lines and fuel lines
14 - Seals
❑ Renew
15 - Bolt
❑ Renew
❑ 7 Nm +90°
16 - Bolt
❑ 2.4 Nm
17 - Camshaft control valve
❑ Cylinder bank 1 (right-side) - camshaft control valve 1 - N205- ,
❑ Cylinder bank 2 (left-side): camshaft control valve 2 - N208-
18 - O-ring
❑ Renew
19 - Bolt
❑ Renew
❑ Note correct sequence when loosening ⇒ page 212
20 - Bolt
❑ 2.4 Nm
21 - Exhaust camshaft control valve
❑ Cylinder bank 1 (right-side): exhaust camshaft control valve 1 - N318- ,
❑ Cylinder bank 2 (left-side): exhaust camshaft control valve 2 - N319-
22 - O-ring
❑ Renew
23 - Engine lifting eye
24 - Bolt
❑ 22 Nm

Cylinder head cover (left-side) - tightening torque and sequence

– Tighten bolts in the sequence -1 ... 16- to 9 Nm.
Cylinder head cover (right-side) - tightening torque and sequence

– Tighten bolts in the sequence -1 ... 16- to 9 Nm.
Cylinder head - tightening torque and sequence
Note

1. -1 … 12- Screw in by hand until bolts make con‐
tact with cylinder head
2. -1 … 12- 30 Nm
3. -1 … 12- 60 Nm
4. -1 … 12- Turn 90° further
5. -1 … 12- Turn 90° further
6. -Arrows- 11 Nm
7. -Arrows- Turn 90° further
Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler gauge to
measure cylinder head for distortion at several points.
• Max. permissible distortion: 0.1 mm.

Cylinder head machining limit

Machining of the cylinder head (surface grinding) is only permis‐
sible down to the minimum dimension -a-.
• Minimum dimension: -a- = 139.5 mm
2.2 Removing and installing cylinder head

cover (left-side)
Removing
– Remove ignition coils on cylinder bank 2 (left-side)
⇒ page 418 .
R8 Coupé:
– Remove secondary air pump (left-side) ⇒ page 405 .

WARNING


Note
Disregard -item 2-.
– Release hose clips -arrows- and detach air hose.

– Move air hose with vacuum hose -1- for brake servo attached
clear to one side.
Note
Disregard -item 2-.


– Move clear breather hose -arrow- for gearbox.

– Release hose clip, disconnect vacuum line -1- and swivel vac‐
uum line to one side.

-2, 3, 4-.
R8 Coupé:
– Remove bolts -arrows- and move hose for secondary air sys‐
tem to rear.
– Remove bolt -1- and press refrigerant line to one side.
R8 Spyder:
– Unscrew nuts -5- and -7- and move service pipe -6- for air
conditioner to one side.
– Unscrew bolts -3- and remove bracket -4-.
Note


– Unplug electrical connector -1- at exhaust camshaft control
valve 2 - N319- .
– Remove nut -2- and move earth wire clear.
– Slacken bolts for cylinder head cover (left-side) in the se‐

quence -16 ... 1-.
– Remove bolts and take off cylinder head cover.
Installing
Note
♦ Renew gasket for cylinder head cover if damaged or leaking.

♦ Renew bolts for cylinder head cover if gasket is damaged.
♦ Fit new O-rings.

– Tighten bolts for cylinder head cover (left-side) ⇒ page 203 .
– Install service pipe for air conditioner ⇒ Rep. gr. 87 .
– Install fuel supply line ⇒ page 367 .
– Install secondary air pump ⇒ page 405 .
– Install ignition coils ⇒ page 418 .

cover (right-side)
Removing
– Remove ignition coils on cylinder bank 1 (right-side)
⇒ page 418 .

– Unplug electrical connector -1- at exhaust camshaft control

valve 1 - N318- .
– Press release tabs, disconnect crankcase breather line -2-
and move line to one side.
– Slacken bolts for cylinder head cover (right-side) in the se‐

quence -16 ... 1-.
– Remove bolts and take off cylinder head cover.
Installing
Note
♦ Renew gasket for cylinder head cover if damaged or leaking.

♦ Renew bolts for cylinder head cover if gasket is damaged.
♦ Fit new O-ring.

– Tighten bolts for cylinder head cover (right-side) ⇒ page 203 .

Removing
Note
♦ The following description is for removing and installing on cyl‐

inder head (left-side).
♦ Fit all heat insulation sleeves in the original position when in‐
stalling.

⇒ page 396 .
– Remove timing chain (left-side) from camshafts ⇒ page 176 .

– Remove bolts -1- and -2- and take off chain tensioner (left-
side).
– Detach heat insulation sleeve.

– Unplug electrical connector -2- at Hall sender 4 - G301- .
Note
Disregard -item 1-.
– Unplug electrical connectors -1- and -2-.

– Remove bolts -arrows- and move bracket with activated char‐
coal filter system solenoid valve 2 - N333- and secondary air
inlet valve - N112- to one side.

– Disconnect vacuum hose -arrow- from vacuum unit for intake

manifold flap.
– Unplug electrical connector -arrow- at camshaft control valve

2 - N208- .
– Disconnect coolant hose -1- and fuel hose -2-.
– Unplug electrical connector -3- at Hall sender 2 - G163- .
Note
– Unplug electrical connectors and move clear:

1- For fuel pressure sender 2 - G624-
2- For injectors
3- For intake manifold flap potentiometer 2 - G512-

– Remove screw plug -arrow-.


– Slacken cylinder head bolts in the sequence -1 ... 12-.
– Unscrew bolts, detach cylinder head and set it down on a soft
surface (foam plastic).
Caution
Avoid damage to open valves.

♦ Make sure that open valves are not subjected to any
weight when putting down the cylinder head.
The cylinder bores and pistons must be protected from dirt.
♦ Place clean cloths in cylinders.
Installing
⇒ “2.1 Exploded view - cylinder head”, page 201
Caution
Risk of damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and
cylinder block.
♦ Ensure that no long scores or scratches are made on the
surfaces.
♦ Do NOT use abrasive materials (sandpaper, sanding
discs, sanding pads, abrasive web, wire wool, etc.).
Risk of damage to cylinder block.
♦ When removing sealant residue, make sure none of the
residue enters the open channels of the engine.
♦ No oil or coolant must be allowed to remain in the blind
holes for the cylinder head bolts in the cylinder block.
Ensure that cylinder head gasket seals properly:
♦ Do not remove new cylinder head gasket from packaging
until it is ready to be fitted.
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
Risk of damage to open valves.
♦ When installing an exchange cylinder head, the plastic
protectors fitted to protect the open valves should not be
removed until the cylinder head is ready to be fitted.

Note
♦ Ensure that nearby workspaces are kept clean and that the
abrasive materials listed above are not being used there.
♦ Renew seals, gaskets and self-locking nuts.
♦ Note the different sealants for sealing surfaces and cylinder
head bolts.
♦ When installing an exchange cylinder head, the contact sur‐
faces between the hydraulic compensation elements, roller
rocker fingers and cams must be oiled before installing the
cylinder head cover.
♦ After fitting a new cylinder head or cylinder head gasket,
change the engine oil and coolant.
– Sealant residue may only be removed from the cylinder head

and cylinder block using a commercially available scraper
(blade width at least 4 cm).
– Remove loose residue with a lint-free cloth.
– Set camshafts to “TDC” before fitting cylinder head.

• Camshaft clamp - T40070- must be installed on the corre‐
sponding cylinder head and tightened to 25 Nm.
• The locking pin - 3242- must be screwed in.

– Place cylinder head gasket in position.

• Installation position: the word “oben” (top) or the Part No.
should be visible.
• Pay attention to dowel sleeves -arrows- in cylinder block.
– Fit cylinder head.
– Tighten cylinder head bolts ⇒ page 203 .
Note
Cylinder head bolts do not have to be torqued down again.
– Tighten screw plug -arrow-.
– Make sure that guide rail of chain tensioner for camshaft timing
chain is locked with locking pin - T40071- .
Note
♦ Note the correct installation position if the tensioning element

has been removed from the chain tensioner: drilling in base of
housing faces chain tensioner and piston faces tensioner rail.
♦ Disregard -arrow-.

– If necessary, clean oil strainer -2- of chain tensioner.
Note
Pay attention to groove in chain tensioner when fitting oil strainer.
– Fit gasket -3- on rear of chain tensioner -1- and clip in.
– Fit chain tensioner and position timing chain (left-side) as

shown in illustration (according to marks applied when remov‐
ing).
note the following:
– Install camshaft timing chains ⇒ page 180 .
– Electrical connections and routing on engine ⇒ Current flow
⇒ page 396 .
– After installing engine, change engine oil ⇒ Maintenance ;
Booklet 420 and coolant ⇒ page 279 .
2.5 Checking compression

♦ Spark plug spanner - 3122 B-
♦ Compression tester - V.A.G 1763-

Procedure
• Engine oil temperature at least 30 ℃
• Battery voltage at least 12.5 V
– Remove ignition coils on both cylinder banks ⇒ page 418 .
– Unplug electrical connectors -1- and -2- for injectors.
– Unscrew spark plugs using spark plug socket - 3122 B- .
– Check compression pressure with compression tester -
V.A.G 1763- (see ⇒ operating instructions for details of how
to use tester).
– Have a second mechanic press down the accelerator pedal
completely and at the same time operate the starter until the
pressure on the tester display no longer increases.
– Repeat procedure on each cylinder.
Compression pressure bar
When new 10.0 … 14.0
Wear limit 9.0
Maximum difference between cylinders 3.0
Installation is carried out in the reverse order; note the following:
– Install spark plugs ⇒ Maintenance ; Booklet 420 .
– Faults are stored in engine control units because connectors
were unplugged: “Generate readiness code” in “Guided Func‐
tions” ⇒ Vehicle diagnostic tester.

3 Valve gear
⇒ “3.1 Exploded view - valve gear”, page 217
⇒ “3.2 Measuring axial clearance of camshafts”, page 220
⇒ “3.3 Measuring radial clearance of camshafts”, page 221
⇒ “3.4 Removing and installing camshafts”, page 222
⇒ “3.5 Renewing valve stem oil seals with cylinder head installed”,
page 227
⇒ “3.6 Renewing valve stem oil seals with cylinder head re‐
moved”, page 230
⇒ “3.7 Checking hydraulic compensation elements”, page 234
⇒ “3.8 Valve dimensions”, page 235
⇒ “3.9 Checking valve guides”, page 236
⇒ “3.10 Checking valves”, page 236
Caution
Risk of damage to valves and piston crowns after working on

valve gear.
♦ The hydraulic tappets have to settle; wait for approx. 30
minutes after installing camshafts before starting engine.
♦ Turn the engine carefully at least 2 rotations to ensure that
none of the valves make contact when the starter is op‐
erated.
Note
Cylinder heads which have cracks between the valve seats or

between a valve seat insert and the spark plug thread can be re-
installed without reducing service life, provided the cracks are
only slight and do not exceed a maximum of 0.3 mm in width, and
no more than the first 4 turns of the spark plug threads are
cracked.
3.1 Exploded view - valve gear
Note
The diagram shows the cylinder head on cylinder bank 2 (left-side).
3. Valve gear 217

1 - Sealing plug
❑ Apply sealant when in‐
stalling; refer to ⇒ Elec‐
tronic parts catalogue
for sealant
2 - Valve stem oil seal
❑ Renewing with cylinder
head installed
⇒ page 227
❑ Renewing with cylinder
head removed
⇒ page 230
3 - Valve spring
⇒ page 219
4 - Hydraulic compensation el‐
ement
❑ Clipped into roller rocker
finger -item 8-
❑ Checking ⇒ page 234
❑ Mark installation posi‐
tion for re-installation
❑ Lubricate contact sur‐
face before installing
5 - Valve spring plate
6 - Valve cotters
7 - Securing clip
❑ Not available as sepa‐
rate part
❑ Check for firm attach‐
ment
8 - Roller rocker finger
❑ Mark installation position for re-installation
❑ Check roller bearings for ease of movement
❑ Lubricate contact surface before installing
❑ Assembly: attach to hydraulic compensation element -item 4- using securing clip -item 7-
9 - Inlet camshaft
❑ Measuring axial clearance ⇒ page 220
❑ Runout: max. 0.04 mm
10 - Gasket
❑ Renew
11 - Retaining frame
❑ With integrated camshaft bearings
❑ Removing and installing ⇒ “3.4 Removing and installing camshafts”, page 222
12 - Bolt
13 - Bolt

14 - Hall sender for inlet camshaft

❑ Cylinder bank 1 (right-side): Hall sender - G40-
❑ Cylinder bank 2 (left-side): Hall sender 2 - G163-
15 - O-ring
❑ Renew
16 - O-ring
❑ Renew
17 - Hall sender for exhaust camshaft
❑ Cylinder bank 1 (right-side): Hall sender 3 - G300-
❑ Cylinder bank 2 (left-side): Hall sender 4 - G301-
18 - Bolt
19 - Exhaust camshaft
❑ Measuring axial clearance ⇒ page 220
❑ Runout: max. 0.04 mm
20 - Cylinder head
❑ Checking valve guides ⇒ page 236
21 - Inlet valve
❑ Must not be machined; only grinding-in is permissible
❑ Valve dimensions ⇒ page 235
22 - Exhaust valve
❑ Must not be machined; only grinding-in is permissible
❑ Valve dimensions ⇒ page 235
Position of valve spring

• The closely spaced spring coils -arrow- face the cylinder head.
3. Valve gear 219

Retaining frame for camshafts - tightening torque and sequence
Note
♦ The illustration shows the retaining frame for camshafts on

cylinder head (left-side).
♦ Use old bolts when measuring radial clearance.
Caution
Risk of damage to retaining frame for camshafts.

♦ It is important to tighten the bolts securing the retaining
frame as described below.

1. -1 … 28- Screw in by hand until bolt heads
make contact with retaining frame
2. -1 … 28- Continue tightening 1 turn at a time in
several stages until retaining frame
makes full contact with cylinder head
and a torque of 8 Nm is reached
3. -1 … 28- 8 Nm
4. -1 … 28- Turn 90° further
3.2 Measuring axial clearance of camshafts


Procedure
– Remove retaining frame
⇒ “3.4 Removing and installing camshafts”, page 222 .
– Fit camshaft to be tested in retaining frame.
– Attach dial gauge - VAS 6079- with universal dial gauge brack‐
et - VW 387- to retaining frame.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
• Axial clearance: 0.100 ... 0.191 mm
3.3 Measuring radial clearance of cam‐

shafts
♦ Plastigauge
Procedure
– Remove roller rocker fingers
– Clean bearings and bearing journals.
bearing on the bearing journal or bearing shell to be measured.
• The Plastigauge must be positioned in the centre of the bear‐
ing.
– Insert camshafts, fit retaining frame and tighten ⇒ page 220
without rotating camshafts.
– Remove retaining frame again.
Radial clearance:
24 mm bearing diameter: 0.024 ... 0.066 mm.
36 mm bearing diameter: 0.050 ... 0.100 mm.
3. Valve gear 221

3.4 Removing and installing camshafts

♦ Impact extractor attachment -T10133/3- from tool set for FSI
engines - T10133 C-
♦ Locating pins - T40116-

♦ Safety goggles
Removing
Note
♦ The following description is for removing and installing on cyl‐

inder head (left-side).
stalling.

⇒ page 396 .

– Detach heat insulation sleeve and unplug electrical connector

-2- at Hall sender 4 - G301- .
Note
Disregard -item 1-.
– Remove timing chains from camshafts ⇒ page 176 .
– Unplug electrical connectors -2- for fuel metering valve 2 -

N402- and -3- for Hall sender 2 - G163- .
Note
Disregard -item 1-.
– Remove high-pressure pump ⇒ page 370 .
– Slacken retaining frame bolts in the sequence -28 ... 1-.
Note
Perform the same procedure (laterally reversed) on retaining

frame (right-side).
– Remove bolts, carefully release retaining frame from bonded

joint and set it down on a soft surface on workbench.
3. Valve gear 223

– Remove camshaft clamp - T40070- .

– Mark and remove camshafts.
Installing
• Crankshaft locked in position with locking pin - 3242- .
• Hydraulic compensation elements and roller rocker fingers in‐
stalled.
Note
Renew seals/gaskets and sealing plugs.
Caution
Protect lubrication system and bearings against contamina‐

tion.
WARNING
Risk of eye injury.

– Remove remaining sealant from cylinder head and retaining

frame -1- using rotating plastic brush or similar.
– Oil running surfaces of both camshafts.

– Fit camshafts in retaining frame.

• Camshafts must be in correct position in axial bearings
-arrows- in retaining frame.
– Turn retaining frame over with camshafts fitted, holding cam‐
shafts firmly in position.
– Turn camshafts until threaded holes -arrows- point upwards.

– Check that camshafts are still in correct position in axial bear‐
ings in retaining frame.

Note

2 mm).
3. Valve gear 225

– Turn retaining frame upside down again.

– Fit new gasket -2- in grooves on retaining frame.
Caution

– Apply sealant beads -1, 3, 4- onto clean sealing surfaces of

retaining frame as shown in illustration.
Note
The retaining frame must be installed within 5 minutes after ap‐

plying the sealant.
– Fit retaining frame with camshafts onto cylinder head.
Note
The locating pins - T40116- ensure that the retaining frame is in‐
stalled in the correct position.
– Insert locating pins - T40116- in retaining frame and cylinder

head.
– Fit bolts securing retaining frame for camshafts and tighten

⇒ page 220 .
Note
After installing the retaining frame, wait about 30 minutes for the
sealant to dry.

– Clean bores for sealing plugs in cylinder head; they must be

free of oil and grease.
– Coat outer circumference of sealing plugs -arrows- with seal‐
ant; refer to ⇒ Electronic parts catalogue for sealant.
– Drive in sealing plug until flush.
– Use impact extractor attachment -T10133/3- to remove locat‐

ing pins - T40116- .
note the following:
– Install high-pressure pump ⇒ page 370 .
– Fit timing chains on camshafts ⇒ page 180 .
⇒ page 396 .
Caution
Risk of damage to valves and piston crowns after working on

valve gear.
♦ Turn the engine carefully at least 2 rotations to ensure that
none of the valves make contact when the starter is op‐
erated.
3.5 Renewing valve stem oil seals with cylinder head installed
3. Valve gear 227


equipment required
♦ Spark plug spanner - 3122 B-

♦ Valve stem seal puller - 3364-
♦ Valve stem oil seal fitting tool - 3365-
♦ Removal and installation device for valve cotters - VAS 5161-
with guide plate -VAS 5161/19C-
♦ Adapters - T40012-
Removing
– Remove camshafts ⇒ page 222 .
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Unscrew spark plugs using spark plug socket - 3122 B- .
– Set piston of appropriate cylinder to “bottom dead centre”.

– Apply drift -VAS 5161/3A- to valve spring plate and use plastic-
headed hammer to release sticking valve cotters.
– Fit guide plate -VAS 5161/19C- from removal and installation

device for valve cotters - VAS 5161- on cylinder head.
– Secure guide plate with knurled screws -VAS 5161/12- .
– Screw adapter - T40012- with seal hand-tight into the corre‐
sponding spark plug thread.
– Connect adapter to compressed air line using a commercially
available connection piece and apply constant air pressure.
• Minimum pressure: 6 bar
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Insert assembly cartridge -VAS 5161/8A- in guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
– Release pressure fork.
– Take out assembly cartridge.
– Detach guide plate and turn to one side.
• The compressed air hose remains connected.
– Detach valve spring with valve spring plate.
– Pull off valve stem oil seal with valve stem seal puller - 3364- .
3. Valve gear 229

Caution
Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
– Lightly oil sealing lip of valve stem oil seal.

– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Take off plastic sleeve.
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above
and take up valve cotters.
– Insert valve spring and valve spring plate ⇒ page 219 .
– Secure guide plate back onto cylinder head.

– Insert assembly cartridge in guide plate.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
– Install camshafts ⇒ page 222 .
– Install spark plugs ⇒ Maintenance ; Booklet 420 .
3.6 Renewing valve stem oil seals with cylinder head removed


equipment required
♦ Valve stem seal puller - 3364-

♦ Valve stem oil seal fitting tool - 3365-
♦ Removal and installation device for valve cotters - VAS 5161
A- with guide plate -VAS 5161/19C-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
Procedure
– Remove camshafts ⇒ page 222 .
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
3. Valve gear 231

– Insert cylinder head tensioning device - VAS 6419- into engine

and gearbox support - VAS 6095- .
– Secure cylinder head in cylinder head tensioning device, as
shown in illustration.
– Connect cylinder head tensioning device to compressed air
supply.
– Using lever -arrow-, slide air pad under combustion chamber
where valve stem oil seal is to be removed.
– Apply just enough compressed air to bring air pad into contact
with valve heads.
– Apply drift -VAS 5161/3A- to valve spring plate and use plastic-
headed hammer to release sticking valve cotters.
– Fit guide plate -VAS 5161/19C- from removal and installation

device for valve cotters - VAS 5161- on cylinder head.
– Secure guide plate with knurled screws -VAS 5161/12- .
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Insert assembly cartridge -VAS 5161/8A- in guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
– Release pressure fork.
– Take out assembly cartridge.
– Detach guide plate and turn to one side.
– Detach valve spring with valve spring plate.

– Pull off valve stem oil seal with valve stem seal puller - 3364- .
Caution
Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
– Lightly oil sealing lip of valve stem oil seal.

– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Take off plastic sleeve.
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above
and take up valve cotters.
– Insert valve spring and valve spring plate ⇒ page 219 .
– Secure guide plate back onto cylinder head.

– Insert assembly cartridge in guide plate.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
– Install camshafts ⇒ page 222 .
3. Valve gear 233

3.7 Checking hydraulic compensation ele‐

ments
Note
♦ The hydraulic compensation elements cannot be serviced.

♦ Irregular valve noises when starting engine are normal.

♦ Feeler gauge
Procedure
– Start engine and run until radiator fan has started up once.
– Increase engine speed to approx. 2500 rpm for 2 minutes
(perform road test if necessary).
Note
If irregular valve noise disappears but repeatedly re-occurs when

travelling short distances, renew oil retention valve “1”
⇒ page 251 .
– If the compensation elements are still noisy, locate the defec‐

tive compensation element as follows:
– Remove cylinder head cover: left-side ⇒ page 204 ; right-side
⇒ page 207 .

– Turn crankshaft with adapter - T40058- in direction of engine

rotation -arrow- until cam of hydraulic compensation element
to be tested faces upwards.
– Press roller rocker finger down -arrow- to determine clearance

between cam and roller rocker finger.
– If it is possible to insert a feeler gauge of 0.20 mm between
cam and roller rocker finger, renew hydraulic compensation
element
Additional steps required
– Install cylinder head cover: left-side ⇒ page 204 ; right-side
⇒ page 207 .
3.8 Valve dimensions
Note
Inlet and exhaust valves must not be machined. Only grinding-in

is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 33.85 ± 0.10 28.0 ± 0.1
∅b mm 5.965 ± 0.005 5.955 ± 0.007
c mm 103.97 ± 0.20 101.87 ± 0.20
α ∠° 45 45
WARNING
Care must be taken when disposing of old sodium-cooled ex‐

haust valves - risk of injury.
♦ The valves must be sawn in two with a metal saw between
the centre of the stem and valve head. When doing so, the
valves must not come into contact with water.
♦ Then throw a maximum of ten valves into a bucket of water
and step away immediately.
♦ A sudden chemical reaction will occur upon contact with
water in which the sodium filling burns.
♦ After performing these steps the valves can be disposed
of in the normal way.
3. Valve gear 235

3.9 Checking valve guides

Procedure
Note
♦ If the valve has to be renewed as part of a repair, use a new

valve for the measurement.
♦ Only insert inlet valve into inlet valve guide and exhaust valve
into exhaust valve guide, as the stem diameters are different.
– Insert valve into guide.

• End of valve stem must be flush with valve guide.
– Measure the amount of sideways play.
– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded.
Note
Valve guides cannot be renewed.
3.10 Checking valves

– Visually inspect for scoring on valve stems and valve seat sur‐
faces.

– Renew valve if scoring is clearly visible.
3. Valve gear 237

17 – Lubrication
1 Oil pump and intake module
⇒ “1.1 Exploded view - oil pump, intake module”, page 238
⇒ “1.2 Removing and installing oil pump”, page 240
1.1 Exploded view - oil pump, intake module
Note
If large quantities of metal shavings or abrasion are found when performing engine repairs, this may be an
indication of damage to the crankshaft or conrod bearings. To prevent further damage, the following steps are
required after completion of repair work: clean the oil passages carefully and renew the oil spray jets, engine
oil cooler and oil filter.
1 - Bolt
❑ 9 Nm
2 - O-ring
❑ Renew
gine oil
3 - Oil line
❑ From oil pump to tem‐
perature regulator
4 - Oil pump
⇒ page 240
5 - Plug
❑ For “TDC” marking
6 - Seal
❑ Renew
7 - Seal
❑ Renew
8 - Plug
❑ 25 Nm
9 - Intake module
⇒ page 149
10 - Coolant drain plug
❑ 25 Nm
11 - Seal
❑ Renew
12 - Gasket
❑ With strainer
238 Rep. gr.17 - Lubrication

❑ 8x
13 - Dowel sleeve
❑ 2x
14 - Flange for protective tube
❑ Removing and installing ⇒ “3.7 Removing and installing intake module and retaining frame”, page 149
15 - Bolt
16 - O-ring
❑ Renew
17 - Protective tube
❑ For oil pump drive shaft
18 - Drive shaft
❑ For oil pump
19 - O-ring
❑ Renew
20 - Bracket
21 - Bolt
22 - Bolt
❑ Renew
❑ 6 Nm +45°
23 - Bolt
24 - Pipe/hose assembly
❑ From oil reservoir to oil pump
25 - Bolt
❑ 9 Nm
26 - O-ring
❑ Renew
27 - Oil drain plug
❑ 2x
❑ 12 Nm
28 - Seal
❑ Renew
29 - Bolt
❑ 9 Nm
1. Oil pump and intake module 239

Oil pump - tightening torque and sequence

– Tighten bolts in 2 stages in the sequence -1 ... 11- as follows:
2. Tighten to 10 Nm.
1.2 Removing and installing oil pump

♦ Pneumatic jig-saw - VAS 5108-
Removing
– Remove coolant pump ⇒ page 289 .

– For the following steps position used oil collection and extrac‐
tion unit - VAS 6622A- below engine.
– Remove bolts -2- and disconnect pipe/hose assemblies.
Note
Disregard -item 1-.
– Remove bolt -arrow- securing bracket for oil pump.

– Unscrew bolts in the sequence -11 ... 1- lower oil pump slightly
and secure in position.
– Cover openings in oil pump with a cloth -1-.

– Cut through intermediate plate -2- at the marking using pneu‐
matic jig-saw - VAS 5108- .
– Remove oil pump.
Installing
⇒ “1.1 Exploded view - oil pump, intake module”, page 238
Note

♦ Renew seals and O-rings.
• Pre-filling oil pump:
1. Oil pump and intake module 241

– Fill oil intake ducts -arrows D- and -arrow E- completely with

clean engine oil.
– Rotate drive shaft -1- clockwise -arrow A- until engine oil
emerges from openings -arrow B- and -arrow C-. Repeat pro‐
cedure if necessary.
– Tighten bolts for oil pump ⇒ page 240 .

– Install coolant pump ⇒ page 289 .
Booklet 420 .

2 Oil filter housing, engine oil cooler, oil

retention valves, spray nozzle valve
⇒ “2.1 Exploded view - oil filter housing”, page 243
⇒ “2.2 Removing and installing oil filter housing”, page 245
⇒ “2.3 Exploded view - engine oil cooler (top), oil retention valves,
spray nozzle valve”, page 246
⇒ “2.4 Removing and installing engine oil cooler (top)”,
page 249
⇒ “2.5 Removing and installing mounting plate”, page 250
⇒ “2.6 Removing and installing oil retention valve 1 and spray
nozzle valve”, page 251
⇒ “2.7 Removing and installing oil retention valve 2 ”, page 252
⇒ “2.8 Exploded view - crankcase breather hoses”, page 252
⇒ “2.9 Removing and installing crankcase breather hoses 1 and
2 ”, page 255
⇒ “2.10 Removing and installing crankcase breather hose 3 ”,
page 257
⇒ “2.11 Removing and installing crankcase breather hose 4 ”,
page 257
⇒ “2.12 Removing and installing oil pressure switch F1 ”,
page 258
⇒ “2.13 Checking oil pressure switch F1 ”, page 258
⇒ “2.14 Checking oil pressure”, page 259
⇒ “2.15 Removing and installing oil temperature sender 2 G664
”, page 260
⇒ “2.16 Exploded view - oil reservoir”, page 261
⇒ “2.17 Removing and installing oil level and oil temperature
sender G266 ”, page 264
⇒ “2.18 Removing and installing oil reservoir”, page 265
⇒ “2.19 Exploded view - engine oil cooler (left-side)”, page 268
⇒ “2.20 Removing and installing engine oil cooler (left-side)”,
page 270
⇒ “2.21 Removing and installing temperature regulator for engine
oil cooler”, page 271
⇒ “2.22 Engine oil”, page 272
⇒ “2.23 Checking oil level”, page 272
⇒ “2.24 First filling of engine with oil”, page 272
2.1 Exploded view - oil filter housing
2. Oil filter housing, engine oil cooler, oil retention valves, spray nozzle valve 243
1 - Gasket
❑ Renew
2 - Bolt
❑ 9 Nm
3 - Plug
❑ 20 Nm
4 - Seal
❑ Renew
5 - Oil filter housing
❑ With oil filter bypass
valve
⇒ page 245
6 - O-ring
❑ Part of oil filter element
gine oil
7 - Bracket
❑ For electrical connector
8 - Bolt
❑ 9 Nm
9 - Oil filter element
⇒ Maintenance ; Book‐
let 420
10 - O-ring
❑ Renew
gine oil
11 - Sealing cap
❑ 25 Nm
12 - Bolt
❑ 9 Nm
13 - Bracket
14 - Bolt
❑ 9 Nm
15 - Oil pressure switch - F1-
❑ Black insulation
❑ Opening/closing pressure 1.2 ... 1.6 bar
❑ 20 Nm
16 - Seal
❑ Renew
17 - Plug
❑ 50 Nm
18 - Bracket

19 - Bolt
❑ 9 Nm
20 - Fuel pressure sender for low pressure - G410-
21 - O-ring
❑ Renew
❑ Lubricate lightly with fuel
22 - Fuel rail
23 - Bolt
❑ 9 Nm
24 - Plug
❑ 20 Nm
25 - Seal
❑ Renew
26 - Bolt
❑ 22 Nm
27 - O-ring
❑ Renew
2.2 Removing and installing oil filter housing

Removing
– Remove oil filter element ⇒ Maintenance ; Booklet 420 .
– Unplug electrical connector -1- on oil pressure switch - F1-
-item 2-.
Caution
Risk of irreparable damage to gearbox.

♦ Cover openings with cloth to prevent bolts and nuts from
accidentally falling through the openings -arrow- into the
gearbox.

– Remove bolts -1, 2, 3- and press bracket to side.
Note
Place a cloth beneath the oil filter housing to catch escaping oil.

– Detach oil filter housing.
Installing
⇒ “2.1 Exploded view - oil filter housing”, page 243
Note
Renew seals and O-rings.
– Install oil filter element ⇒ Maintenance ; Booklet 420 .

2.3 Exploded view - engine oil cooler (top), oil retention valves, spray nozzle
valve

1 - O-ring
❑ Renew
gine oil
2 - Restrictor
❑ For oil return
❑ 5x
❑ 9 Nm
3 - Dowel sleeve
4 - Gasket
❑ Renew
5 - O-ring
❑ Renew
gine oil
6 - Oil retention valve “1”
❑ Prevents oil from flow‐
ing back from oil pas‐
sages in cylinder head
and hydraulic compen‐
sation elements when
engine stops
⇒ page 251
❑ Apply locking fluid when
installing; refer to ⇒
Electronic parts cata‐
logue
❑ 6 Nm
7 - Spray nozzle valve
❑ Supplies oil spray jets
for piston cooling with oil
as soon as a specified oil pressure is attained
8 - Mounting plate
❑ For engine oil cooler (top) and oil filter housing
9 - O-ring
❑ Renew
10 - Crankcase breather hose
11 - Bolt
❑ 9 Nm
12 - O-rings
❑ 2x
❑ Renew
13 - Oil temperature sender 2 - G664-
❑ 2 Nm
14 - Engine oil cooler (top)

15 - Bolt
16 - O-rings
❑ Renew
17 - O-rings
❑ Renew
18 - Bolt
19 - Oil retention valve “2”
❑ Prevents oil from flowing back from engine oil cooler and oil filter when engine stops
20 - O-ring
❑ Renew
21 - Coolant temperature sender - G62-
❑ 2 Nm
22 - O-rings
❑ 2x
❑ Renew
❑ Lubricate with coolant
23 - Dowel sleeve
Mounting plate - tightening torque and sequence

– Tighten bolts for mounting plate -arrow- in stages, working
from inside to outside; final torque 9 Nm.

Engine oil cooler (top) - tightening torque and sequence

– Tighten bolts for engine oil cooler (top) in 2 stages and in di‐
agonal sequence as follows:
2. Tighten to 9 Nm.
2.4 Removing and installing engine oil cool‐

er (top)
Removing
– Drain coolant in engine ⇒ page 277 .
Note
Place a cloth underneath engine oil cooler to catch escaping en‐

gine oil.
– Unscrew bolts -arrows- and detach engine oil cooler.

Installing
⇒ “2.3 Exploded view - engine oil cooler (top), oil retention
valves, spray nozzle valve”, page 246
Note
Fit new O-rings.
Note

2.5 Removing and installing mounting plate

Removing
– Remove engine oil cooler (top) ⇒ page 249 .
– Remove oil filter housing ⇒ page 245 .
– Remove intake manifold bottom section (left and right)
⇒ page 358 .
– Remove bolt -1-, detach crankcase breather hose and move
clear to one side.
– Unplug electrical connector -2- at coolant temperature sender

- G62- -item 1-.
– Unplug electrical connector -arrow- at oil temperature send‐

er 2 - G664- .
– Detach intake manifold flap valve - N316- -arrow- from mount‐

ing plate.


– Detach knock sensor 2 - G66- -item 1- and knock sensor 1 -
G61- -item 2- and move clear.
Note
Spread out rags around cover to catch escaping engine oil.
– Remove bolts and lift off cover -arrow- from cylinder block and
coolant pipe.
Installing
Note
Renew gasket and O-rings.
– Tighten bolts securing cover ⇒ page 248 .

– Install knock sensors ⇒ page 419 .
– Install intake manifold bottom section (left and right)
⇒ page 358 .
– Install oil filter housing ⇒ page 245 .
– Install engine oil cooler (top) ⇒ page 249 .
2.6 Removing and installing oil retention

valve “1” and spray nozzle valve
Note
In the event of irregular valve noise which disappears after a

lengthy drive but repeatedly re-occurs on short trips, the oil re‐
tention valve “1” must be renewed.
Removing
– Remove mounting plate ⇒ page 250 .
– Unscrew spray nozzle valve -1- and remove.
– Pull out oil retention valve “1” -item 2-.
Installing
Note

♦ Apply locking fluid when installing spray nozzle valve -1-; for
locking fluid refer to ⇒ Electronic parts catalogue .
– Install mounting plate ⇒ page 250 .

2.7 Removing and installing oil retention

valve “2”
Removing
– Remove mounting plate ⇒ page 250 .
– Pull out oil retention valve “2” -arrow-.
Installing
Note
Fit new O-ring.
– Install mounting plate ⇒ page 250 .

2.8 Exploded view - crankcase breather ho‐

ses
⇒ “2.8.1 Exploded view - crankcase breather hoses, vehicles with
manual gearbox/R tronic gearbox 086”, page 252
⇒ “2.8.2 Exploded view - crankcase breather hoses, vehicles with
dual clutch gearbox 0BZ”, page 254
2.8.1 Exploded view - crankcase breather hoses, vehicles with manual gearbox/
R tronic gearbox 086

1 - Oil reservoir
2 - Bolt
❑ 9 Nm
3 - O-ring
❑ Renew
gine oil
“1”
⇒ page 255
5 - O-ring
❑ Renew
gine oil
6 - O-ring
❑ Renew
gine oil
7 - O-ring
❑ Renew
gine oil
8 - O-ring
❑ Renew
gine oil
“3”
⇒ page 257
10 - O-ring
❑ Renew
11 - Crankcase breather hose “4”
12 - O-ring
❑ Renew
13 - O-ring
❑ Renew
14 - Bolt
❑ 9 Nm
15 - O-ring
❑ Renew
17 - O-ring
❑ Renew
2.8.2 Exploded view - crankcase breather hoses, vehicles with dual clutch gear‐
box 0BZ
1 - Oil reservoir
2 - O-ring
❑ Renew
gine oil
“1”
⇒ page 256
4 - O-ring
❑ Renew
gine oil
“4”
⇒ page 257
“3”
⇒ page 256
7 - O-ring
❑ Renew
gine oil
8 - O-ring
❑ Renew
gine oil
9 - O-ring
❑ Renew
10 - O-ring
❑ Renew
11 - O-ring
❑ Renew
12 - O-ring
❑ Renew

13 - Bolt
❑ 9 Nm
14 - O-ring
❑ Renew
16 - O-ring
❑ Renew
2.9 Removing and installing crankcase

breather hoses “1” and “2”
⇒ “2.9.1 Removing and installing crankcase breather hose 1 - ve‐
⇒ “2.9.2 Removing and installing crankcase breather hose 2 - ve‐
⇒ “2.9.3 Removing and installing crankcase breather hoses 1 and
2 - vehicles with dual clutch gearbox 0BZ”, page 256
2.9.1 Removing and installing crankcase

breather hose “1” - vehicles with manual
Removing
– R8 GT: Remove engine compartment trim panel (left-side) ⇒
Rep. gr. 53 .
– R8 Spyder: Remove engine compartment trim panel ⇒ Rep.
gr. 53 .
– Press release tabs -1- and -2- at connections, disconnect
crankcase breather hose “1”, detach hose at -arrows- and re‐
move.
Installing
Note


– Install engine compartment trim ⇒ Rep. gr. 53 .

breather hose “2” - vehicles with manual
Removing
– Remove bolt -arrow-.
– Press release tabs -1- and -2- at connections, disconnect
crankcase breather hose “2” and remove.
Installing
Note


breather hoses “1” and “2” - vehicles
with dual clutch gearbox 0BZ
Removing
Crankcase breather hose “1”:
gr. 53 .
– R8 Coupé: Remove engine compartment trim panel (left-side)
⇒ Rep. gr. 53 .
– Press release tabs -1- and -2- at connections and disconnect
crankcase breather hose “1”. Then move hose clear and re‐
move.
– Press release tabs -3- and -4- at connections and disconnect
crankcase breather hose “2”. Then move hose clear and re‐
move.
Installing
Note

– Install engine cover panel ⇒ page 128 .



breather hose “3”
Removing
– Remove throttle valve module -J338- / -J544- ⇒ page 351 .
gr. 53 .
– Press release tabs -arrows- at connections, disconnect crank‐
case breather hose “3” and remove.
Installing
Note


– Install throttle valve modules ⇒ page 351 .

breather hose “4”
Removing
– Press release tabs at connections -arrows-, disconnect crank‐
case breather hose “4” and remove.
Installing
Note
Fit new O-rings.
2.12 Removing and installing oil pressure

switch - F1-
Removing
R8 Coupé:
– Release hose clips -2- and -3- and remove air hose.
– Move air hose with crankcase breather hose -1- attached clear
to one side.
R8 Spyder:
– Remove wide air cleaner housing/air cleaner housing (right-
side) ⇒ page 345 .

– Remove oil pressure switch - F1- -item 2-.
Installing
Note
♦ Renew seal.
2.13 Checking oil pressure switch - F1-

♦ Oil pressure tester - V.A.G 1342-

♦ Voltage tester - V.A.G 1527B-
♦ Auxiliary measuring set - V.A.G 1594C-
Procedure
• Oil level OK
• Engine oil temperature approx. 80 °C
– Remove oil pressure switch - F1- ⇒ page 258 .
– Connect oil pressure tester - V.A.G 1342- to bore for oil pres‐
sure switch.
– Screw oil pressure switch -2- into oil pressure tester.
– Connect brown wire of oil pressure tester to earth (“–”).
– Connect voltage tester - V.A.G 1527B- with adapter lead from
auxiliary measuring set - V.A.G 1594C- to oil pressure switch
and battery positive (“+”).
• LED should not light up.
– Renew oil pressure switch if LED lights up at this stage.
– Start engine.
Note
Observe tester and LED while starting, as switching point of oil

pressure switch may already be exceeded when starting.
• LED should light up at 1.2 ... 1.6 bar.

– Renew oil pressure switch if LED does not light up
⇒ page 258 .
2.14 Checking oil pressure

♦ Oil pressure tester - V.A.G 1342-
♦ Adapter set - V.A.G 1342/22-

Procedure
• Oil level OK
• Engine oil temperature approx. 80 °C
– Remove oil pressure switch - F1- ⇒ page 258 .
– Connect oil pressure tester - V.A.G 1342- to bore for oil pres‐
sure switch.
– Screw oil pressure switch -2- into oil pressure tester.
– Connect brown wire of oil pressure tester to earth (“–”).
– Start engine.
• Oil pressure at idling speed: at least 1.7 bar.
• Oil pressure at 2000 rpm: at least 3.5 bar.
– Install oil pressure switch - F1- ⇒ page 258 .
2.15 Removing and installing oil temperature

sender 2 - G664-
Removing

– Unplug electrical connector -arrow-.

– Unscrew oil temperature sender 2 - G664- .
Installing
Note
Fit new O-rings.
2.16 Exploded view - oil reservoir

⇒ “2.16.1 Exploded view - oil reservoir, vehicles with manual
⇒ “2.16.2 Exploded view - oil reservoir, vehicles with dual clutch
gearbox 0BZ”, page 263
2.16.1 Exploded view - oil reservoir, vehicles with manual gearbox/R tronic gear‐
box 086
❑ From oil reservoir to en‐
gine
2 - O-rings
❑ Renew
gine oil
3 - Oil level and oil temperature
sender - G266-
⇒ page 264
4 - Bolt
❑ 8 Nm
5 - Grommet
❑ To oil reservoir
7 - Bolt
❑ 8 Nm
8 - O-ring
❑ Renew
gine oil
“1”
“2”
❑ From oil reservoir
11 - O-rings
❑ Renew
12 - Spacer
13 - Bolt
❑ 8 Nm
14 - Filler cap
15 - Oil dipstick
16 - Bolt
❑ 8 Nm
17 - Bolt
❑ 8 Nm
18 - Heat shield
19 - Oil reservoir
20 - Bolt
❑ 8 Nm

21 - Spacer
22 - Grommet
23 - Seal
❑ Renew
24 - Oil drain plug
❑ 22 Nm
25 - Bolt
❑ 8 Nm
2.16.2 Exploded view - oil reservoir, vehicles with dual clutch gearbox 0BZ
2 - Bolt
❑ 8 Nm
3 - Oil level and oil temperature
sender - G266-
⇒ page 264
4 - Seal
❑ Renew
5 - Crankcase breather hoses
6 - O-rings
❑ Supplied with
gine oil
7 - Oil reservoir
⇒ page 265
8 - Oil dipstick
❑ With filler cap
9 - Bolt
❑ 8 Nm
10 - Spacer sleeve
11 - Rubber buffer
12 - O-rings
❑ Renew
gine oil
13 - Bolt
❑ 8 Nm
15 - Seal
❑ Renew
16 - Plug
❑ 10 Nm
17 - Bolt
❑ 8 Nm
18 - Seal
❑ Renew
19 - Plug
❑ 10 Nm
2.17 Removing and installing oil level and oil

temperature sender - G266-
⇒ “2.17.1 Removing and installing oil level and oil temperature
sender G266 - vehicles with manual gearbox/R tronic gearbox
086”, page 264
sender G266 - vehicles with dual clutch gearbox 0BZ”,
page 265
2.17.1 Removing and installing oil level and oil

temperature sender - G266- - vehicles
with manual gearbox/R tronic gearbox
086
Removing
– Remove bolts -arrows- and push heat shield to the side.
– Remove bolts -arrows- and move oil reservoir slightly to rear.


– Remove bolts -arrows- and detach oil level and oil temperature
sender - G266- -item 1- from oil reservoir.
Installing
Note
Fit new O-ring.
2.17.2 Removing and installing oil level and oil

temperature sender - G266- - vehicles
with dual clutch gearbox 0BZ
Removing
– Remove bolts -arrows- and detach oil level and oil temperature
sender - G266- .
Installing
sender G266 - vehicles with dual clutch gearbox 0BZ”,
page 265
Note
Fit new O-rings.
2.18 Removing and installing oil reservoir

⇒ “2.18.1 Removing and installing oil reservoir - vehicles with
⇒ “2.18.2 Removing and installing oil reservoir - vehicles with dual
2.18.1 Removing and installing oil reservoir -

vehicles with manual gearbox/R tronic
gearbox 086
Removing
– Remove silencer ⇒ page 390 .
Note
Disregard -item 1-.

-arrows- from oil reservoir.

– Unscrew bolts -4- and remove oil return line -3- from oil res‐
ervoir.
– Unplug electrical connector -5- at oil level and oil temperature
sender - G266- .
– Remove bolts -1- and -2- and remove oil reservoir.
Note
Installing
Note


Booklet 420 .
2.18.2 Removing and installing oil reservoir -

vehicles with dual clutch gearbox 0BZ
Removing
– Remove rear noise insulation ⇒ Rep. gr. 66 .
– Drain engine oil from oil reservoir ⇒ Maintenance ; Booklet
420 .

of oil reservoir.
Caution

– Remove air cleaner housing (left and right) ⇒ page 347 .

-1, 4-.
Note

– Remove oil reservoir and unplug electrical connector -1-.
Installing
⇒ “2.16.2 Exploded view - oil reservoir, vehicles with dual
Note


Booklet 420 .
2.19 Exploded view - engine oil cooler (left-side)

1 - Grommets
2 - Engine oil cooler (left-side)
⇒ page 270
3 - Grommet
4 - Spacer
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 8 Nm
7 - Temperature regulator for
engine oil cooler
⇒ page 271
8 - O-rings
❑ Renew
gine oil
9 - Connecting piece
11 - Bolt
❑ 9 Nm
12 - O-ring
❑ Renew
gine oil
13 - O-rings
❑ Renew
❑ From oil pump
15 - Retaining clamp
16 - Nut
❑ Tightening torque ⇒ Rep. gr. 48
17 - Bolt
❑ 8 Nm
18 - Oil pipe
19 - O-ring
❑ Renew
20 - Bolt
❑ 8 Nm
21 - Seal
❑ Renew
22 - Oil drain plug
❑ 22 Nm
23 - Bolt
❑ 9 Nm
24 - Spacers
2.20 Removing and installing engine oil cool‐

er (left-side)
Removing
– Remove rear left wheel housing liner ⇒ Rep. gr. 66 .
– Detach air duct -1- towards the rear -arrows-.


-1-.
– Remove bolt -arrow- and disconnect oil line -1- from temper‐
Installing
Note
Fit new O-rings.
– Install rear wheel housing liner ⇒ Rep. gr. 66 .

Booklet 420 .
2.21 Removing and installing temperature

regulator for engine oil cooler
Removing
– Remove engine oil cooler (left-side) ⇒ page 270 .
– Remove bolts -1- and -4-.
– Press temperature regulator -3- for engine oil cooler down‐
wards -arrow B-.
– Rotate oil pipe -2- 180° -arrow A- and disconnect pipe from
engine oil cooler together with temperature regulator.
Installing
Note
Fit new O-rings.
– Clean sealing surfaces.

– Install engine oil cooler (left-side) ⇒ page 270 .
2.22 Engine oil

Oil capacities, oil specifications and viscosity grades ⇒ Mainte‐
nance tables .
2.23 Checking oil level

Check oil level ⇒ Maintenance ; Booklet 420 .
Caution
Risk of damage to catalytic converter.

♦ The oil level must not be above the top marking on the
dipstick.
2.24 First filling of engine with oil
Caution
Irreparable engine damage can be caused if it not filled with a

sufficient amount of oil.
♦ New engines and genuine exchange engines are filled
with 2 litres of engine oil at the factory. The same applies
if the oil circuit has been opened and engine oil has been
drained for repairs.
♦ Engines which have been serviced are usually not filled
with engine oil.

Procedure
To prevent damaging the engine, it is important to perform the
first filling with engine oil as follows:
– Fill oil reservoir with 7 ltr. of engine oil.
– Pull out the oil dipstick, wipe off with a clean cloth and insert it
again as far as it will go.
– Pull out oil dipstick and check oil level.
• Before starting the engine for the first time, the oil level will be
approximately at the top of the “Do not fill” section -arrow 3-.
– Start engine and run at idling speed for 30 seconds.
– Switch off engine.
– Pull out oil dipstick and check oil level.
• The oil level will be 15 ... 20 mm below the bottom edge of the
“Fill” section -arrow 4-.
– With the engine off, fill engine oil into oil reservoir as follows:
• New engines and genuine exchange engines: fill in 2.5 litres
of engine oil.
• Engines which have been serviced: fill in 4.5 litres of engine
oil.
– Pull out oil dipstick again and check oil level.
• The oil level should now be in the “Do not fill” section -2-.
19 – Cooling
1 Cooling system
⇒ “1.1 Connection diagram - coolant hoses”, page 274
⇒ “1.2 Draining and filling cooling system”, page 277
⇒ “1.3 Checking cooling system for leaks”, page 283
1.1 Connection diagram - coolant hoses

Vehicles with manual gearbox/R tronic gearbox 086
Note
♦ Blue = Large coolant circuit

♦ Red = Small coolant circuit
♦ Brown = Heating circuit
♦ Arrows show direction of coolant flow.
1 - Cylinder head and cylinder

block
❑ If renewed, refill system
with fresh coolant
2 - Engine oil cooler
with fresh coolant
3 - Coolant pump
4 - Thermostat
5 - Coolant circulation pump -
V50-
⇒ Rep. gr. 87
6 - Heat regulation valve unit
❑ Left heat regulation
valve - N175- , right heat
regulation valve - N176-
⇒ Rep. gr. 87
7 - Heat exchanger for heater
⇒ Rep. gr. 87
with fresh coolant
8 - Radiator (left-side)
with fresh coolant
9 - Radiator (centre)
with fresh coolant
274 Rep. gr.19 - Cooling

10 - Bleeder screw
❑ In bleeder hose on coolant return pipe
11 - Radiator (right-side)
❑ If renewed, refill system with fresh coolant
13 - Filler cap for expansion tank
❑ Tighten cap until you hear and feel it engage
❑ Checking pressure relief valve ⇒ page 285
14 - Coolant expansion tank
15 - Alternator
Vehicles with dual clutch gearbox 0BZ
Note
♦ Blue = Large coolant circuit

♦ Red = Small coolant circuit
♦ Brown = Heating circuit
♦ Green = Coolant circuit for gearbox
♦ Arrows show direction of coolant flow.
1. Cooling system 275

1 - Gearbox coolant pump -

V532-
2 - Cylinder head and cylinder
block
with fresh coolant
3 - Engine oil cooler
with fresh coolant
4 - Coolant pump
5 - Thermostat
6 - Coolant circulation pump -
V50-
⇒ Rep. gr. 87
7 - Heat regulation valve unit
❑ Left heat regulation
valve - N175- , right heat
regulation valve - N176-
⇒ Rep. gr. 87
8 - Heat exchanger for heater
⇒ Rep. gr. 87
with fresh coolant
9 - Radiator (left-side)
with fresh coolant
with fresh coolant
11 - Bleeder screw
❑ In bleeder hose on coolant return pipe
12 - Radiator (right-side)
13 - Thermostat
❑ For ATF cooler
15 - Filler cap for expansion tank
❑ Tighten cap until you hear and feel it engage
❑ Checking pressure relief valve ⇒ page 285
17 - Alternator
18 - ATF cooler

1.2 Draining and filling cooling system

equipment required
♦ Adapter for cooling system tester - V.A.G 1274/8-

♦ Cooling system charge unit - VAS 6096-
♦ Refractometer - T10007 A-

♦ Front-end hook - 3370- for vehicles with dual clutch gearbox

0BZ
Procedure
Note
Collect drained coolant in a clean container for re-use or disposal.
WARNING

hot.

Draining coolant in engine
gine.
coolant.

coolant.
Note
On vehicles with dual clutch gearbox 0BZ, remove drain plug us‐
ing front-end hook - 3370- .

Draining coolant in complete system

If the coolant has to be drained off completely, perform the fol‐
lowing additional work steps:
– Remove underbody cover (front) ⇒ Rep. gr. 66 .
– Place drip tray for workshop hoist - VAS 6208- beneath radi‐
ator.
– Disconnect coolant hose -arrow- from radiator and drain off
coolant.
Filling
• Ignition switched off.
Tightening torques
• ⇒ “2.1 Exploded view - thermostat”, page 286
• ⇒ “1.1 Exploded view - oil pump, intake module”, page 238
Caution
To ensure optimal corrosion protection, only distilled water

may be mixed with coolant additives.

Note
♦ The effectiveness of the coolant is greatly influenced by the

quality of the water with which it is mixed. Because water may
contain different substances depending on the country or even
the region, the water quality to be used for cooling systems
has been specified. Distilled water meets all the requirements
and is therefore recommended for use when topping up or fill‐
ing up with coolant.
♦ Use only coolant additives listed in the ⇒ Electronic parts
catalogue (ETKA) . If you use other coolant additives, this can
significantly impair in particular the corrosion protection effect.
The resulting damage could lead to loss of coolant and con‐
sequently to serious engine damage.
♦ Coolant with the recommended mixture ratio prevents frost
and corrosion damage and stops scaling. At the same time it
raises the boiling point of the fluid in the system. For this rea‐
son the cooling system must be filled all year round with the
correct coolant additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Refractometer - T10007A- or refractometer - T10007B- MUST
be used to determine the current level of frost protection.
♦ Scale -1- on the refractometer applies to coolant additives G12
++ and G12evo.
♦ Scale -2- on the refractometer applies to coolant additive G13.
♦ If more than one type of coolant additive has been used: Al‐
ways use the scale for G13 to determine the anti-freeze pro‐
tection.
♦ The mixture must guarantee frost protection down to at least
-25 ℃ (in countries with arctic climate: down to -36 ℃). The
amount of antifreeze should only be increased if greater frost
protection is required in very cold climates. This must only be
down to -48 ℃, however, as otherwise the cooling efficiency
of the coolant is impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be provided to at least -25 ℃.
♦ The temperature indicated on the refractometer corresponds
to the temperature at which the first ice crystals can form in
the coolant.
♦ Do not reuse coolant.
♦ Only use water/coolant additive as a lubricant for coolant ho‐
ses.
Recommended mixture ratio for coolant

• Coolant (40 %) and water (60 %) for frost protection to -25 °C
• Coolant (50 %) and water (50 %) for frost protection to –35 °
C
• Coolant ⇒ Electronic parts catalogue

Procedure
– Tighten drain plug -arrow- with new seal on thermostat hous‐
ing.
– Fit drain plug -arrow- with new seal on intake module and
tighten plug.
– Connect coolant hose to radiator -arrow-.

– Install front noise insulation and front underbody cover ⇒ Rep.
gr. 66 .
– Fill reservoir of -VAS 6096- with 25 litres of premixed coolant
(according to recommended ratio).
– Fit adapter for cooling system tester - V.A.G 1274/8- onto

coolant expansion tank.
– Attach cooling system charge unit - VAS 6096- to adapter -
V.A.G 1274/8- .
– Run vent hose -1- into a small container -2-.
Note
The vented air draws along a small amount of coolant, which

should be collected.
– Close both valves -A- and -B- (turn lever at right angles to di‐
rection of flow).
– Connect hose -3- to compressed air supply.
• Pressure: 6 ... 10 bar.

– Open valve -B- by setting lever in direction of flow.

• The suction jet pump generates a partial vacuum in the cooling
system; the needle on the gauge should move into the green
zone.
– Also briefly open valve -A- (turn lever in direction of flow) so
that hose on reservoir of -VAS 6096- can fill with coolant.
– Close valve -A- again.
– Leave valve -B- open for another 2 minutes.
• The suction jet pump continues to generate a partial vacuum
in the cooling system; the needle on the gauge should remain
in the green zone.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
Note
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
♦ Check cooling system for leaks if the vacuum is not main‐
tained.
– Detach compressed air hose.

– Open valve -A-.
• The vacuum in the cooling system causes the coolant to be
drawn out of the reservoir of -VAS 6096- ; the cooling system
is then filled.
– Detach cooling system charge unit - VAS 6096- from adapter
-V.A.G 1274/8- on coolant expansion tank.
– Release quick-release fasteners -1- and -3-.

– Press bumper trim -2- towards luggage compartment pan
-arrow A-, the retaining tabs -arrows- are thus released.
– Then remove bumper trim from groove in luggage compart‐
ment -arrow B-.

– Open bleeder screw -arrow- until coolant flows out at bleeder

hole.
– Close bleeder screw.
– Top up coolant.
Caution
Overheating can occur if the filler cap is not fitted properly.

♦ The filler cap must engage positively and audibly when it
is closed.
– Tighten filler cap on expansion tank.

– Start engine.
– Set heater to maximum heat by moving temperature regulator
all the way to “Warm”.
– Switch off air conditioner compressor (press AC button).
• LED in button should not light up.
– Run engine for 3 minutes at 2000 rpm.
– Allow engine to run at idling speed until the two large coolant
hoses attached to coolant pipes located at centre of vehicle
become warm.
– Run engine for 1 minute at 2000 rpm.
– Switch off ignition and allow engine to cool down.
– Check coolant level.

• The coolant level should be at the “MAX” marking -arrow-
when the engine is cold.
• The coolant level can be above the “MAX” marking when the
engine is warm.
1.3 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-

Procedure
• Engine must be warm.
WARNING

hot.
♦ Cover filler cap on coolant expansion tank with a cloth and
open carefully to dissipate pressure.

– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- onto coolant expansion tank.
– Using hand pump on cooling system tester, build up a pres‐
sure of approx. 1.0 bar.
– If this pressure is not maintained, locate and rectify leaks.
Checking pressure relief valve in filler cap

– Fit cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/9- onto filler cap.
– Build up pressure with hand pump on cooling system tester.
• The pressure relief valve should open at a pressure of
1.6 ... 2.0 bar.
– Renew filler cap if pressure relief valve does not open as de‐
scribed.
Caution

is closed.

2 Coolant pump, thermostat

⇒ “2.1 Exploded view - thermostat”, page 286
⇒ “2.2 Removing and installing thermostat”, page 286
⇒ “2.3 Checking thermostat”, page 288
⇒ “2.4 Exploded view - coolant pump”, page 288
⇒ “2.5 Removing and installing coolant pump”, page 289
⇒ “2.6 Removing and installing coolant temperature sender G62
”, page 292
⇒ “2.7 Exploded view - gearbox coolant pump V532 ”,
page 293
⇒ “2.8 Removing and installing gearbox coolant pump V532 ”,
page 294
2.1 Exploded view - thermostat
1 - Seal
❑ Renew
2 - Thermostat
⇒ page 286
❑ Checking thermostat
⇒ page 288
3 - Bolt
❑ 2 Nm
4 - Seal
❑ Renew
5 - Housing
❑ For coolant pump
6 - Insulating sleeve
❑ Tapered side faces to‐
wards thermostat
❑ Supplied together with
thermostat
7 - Thermostat housing
8 - Seal
❑ Renew
9 - Coolant drain plug
❑ 5 Nm
10 - Bolt
❑ 9 Nm
2.2 Removing and installing thermostat


♦ Drip tray for workshop hoist - VAS 6208- for vehicles with dual
clutch gearbox 0BZ
Removing
– Drain coolant in engine ⇒ page 277 .
– Place drip tray for workshop hoist - VAS 6208- underneath.
– Press small coolant pipe (rear left) to one side.

– Release hose clips -1- and -2- and disconnect coolant hoses
from thermostat housing.
– Unscrew bolts -arrows- and remove thermostat with housing.
– Unbolt thermostat from housing -arrows- and remove.
2. Coolant pump, thermostat 287

Installing
Note
♦ Make sure that insulating sleeve is fitted. If installing a new

thermostat, renew insulating sleeve (supplied together with
thermostat).
♦ The tapered side of the insulating sleeve must face towards
the thermostat.
– Bolt thermostat (together with insulating sleeve) into housing

-arrows-.
note the following:
Note
♦ Renew seal.
Note

Tightening torques
• ⇒ “2.1 Exploded view - thermostat”, page 286
• ⇒ “3.2 Exploded view - coolant pipes (rear) to body”,
page 297
2.3 Checking thermostat

Procedure
– Remove thermostat ⇒ page 286 .
– Heat thermostat in water bath.
Starts to open Fully open Opening travel
approx. 87 °C approx. 102 °C1) at least 8 mm
• 1) Cannot be tested.
2.4 Exploded view - coolant pump

1 - Not fitted
2 - Bolt
❑ 10 Nm
3 - Bolt
❑ 9 Nm
4 - Seal
❑ Renew
5 - Dowel sleeve
6 - Housing
⇒ page 289
7 - O-ring
❑ Renew
8 - Coolant pump
⇒ page 289
9 - Dowel sleeve
10 - Oil pump
11 - Drive shaft
12 - O-ring
❑ Renew
13 - Connecting pipe
❑ For coolant
❑ Renew after coolant
pump has been removed
14 - Bracket
15 - Bolt
❑ Do not unscrew when renewing coolant pump
❑ Renew
❑ 6 Nm +45°
16 - Bolt
❑ Renew
❑ 6 Nm +45°
2.5 Removing and installing coolant pump


♦ Silicone-free lubricant
Removing
– Remove thermostat housing ⇒ page 286 .
– For the following steps position used oil collection and extrac‐
tion unit - VAS 6622A- below engine.
– Remove bolts -1- and disconnect pipe/hose assemblies.
Note
Disregard -item 2-.

– Remove bolts -1- and -2- and disconnect oil line.

– Detach dowel sleeve -1-.

– Remove bolt -1- and detach housing -3- for coolant pump.
– To pull off coolant pump, screw two M6x15 bolts -arrows- into
threaded holes on coolant pump -1-.
– Screw in bolts alternately, 1/2 turn at a time, until coolant pump
can be detached.
Installing
⇒ “2.4 Exploded view - coolant pump”, page 288
Note
♦ Renew seal, O-rings and connecting pipe for coolant.


– Slide coolant pump onto drive shaft; at the same time dowel
sleeve -arrow- must engage in opening in coolant pump.
– Coat connecting pipe -1- for coolant and O-rings with silicone-
free lubricant.
– Position connecting pipe for coolant so that it can be inserted
into hole in housing -2- for coolant pump when attaching it.
– Install oil lines ⇒ page 261 .
– Install thermostat housing ⇒ page 286 .
Booklet 420 .
2.6 Removing and installing coolant temper‐

ature sender - G62-
Note
Fitting location of coolant temperature sender -G62-

⇒ page 246 .
Removing
• Engine cold.
Caution

is closed.
– Open filler cap on coolant expansion tank briefly to allow re‐

sidual pressure in cooling system to dissipate and close cap
(make sure it engages).


– Unscrew coolant temperature sender - G62- -item 1-.
Installing
Note
♦ Fit new O-ring.

♦ Screw new coolant temperature sender - G62- immediately
into bore to avoid loss of coolant.

– Check coolant level ⇒ page 283 .
2.7 Exploded view - gearbox coolant pump - V532-
1 - Coolant hose
2 - Gearbox coolant pump -
V532-
⇒ page 294
3 - Coolant hose
4 - Bracket
❑ For gearbox coolant
pump - V532-
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 2.7 Nm
7 - Washer
8 - Rubber mounting

2.8 Removing and installing gearbox cool‐

ant pump - V532-
Removing
– Remove rear wheel (left-side) ⇒ Wheels and tyres; Rep. gr.
44 .
– Clamp off coolant hoses using hose clamps -3094- , release
hose clips -2- and disconnect coolant hoses.
– Detach gearbox coolant pump - V532- with bracket.
– Remove bolts -4- to detach pump from bracket.
Installing
⇒ “2.7 Exploded view - gearbox coolant pump V532 ”,
page 293
Note
Secure all hose connections with the correct type of hose clips
– Install rear wheel (left-side) ⇒ Wheels and tyres; Rep. gr. 44 .


3 Coolant pipes
⇒ “3.1 Exploded view - coolant pipes at front and in centre of ve‐
hicle”, page 295
⇒ “3.2 Exploded view - coolant pipes (rear) to body”, page 297
⇒ “3.3 Exploded view - coolant expansion tank”, page 298
⇒ “3.4 Fitting coolant hoses”, page 299
⇒ “3.5 Removing and installing large coolant pipe (rear left)”, page
299
⇒ “3.6 Removing and installing small coolant pipe (rear left)”, page
301
⇒ “3.7 Removing and installing coolant pipe (rear right)”,
page 301
⇒ “3.8 Removing and installing coolant pipe (rear right) to ATF
cooler”, page 303
⇒ “3.9 Removing and installing coolant pipes located at centre of
vehicle”, page 305
⇒ “3.10 Removing and installing coolant supply pipe (left-side)”,
page 309
⇒ “3.11 Removing and installing coolant supply pipe (right-side)”,
page 311
⇒ “3.12 Removing and installing coolant return pipe (front)”, page
313
⇒ “3.13 Removing and installing coolant return pipe (rear)”, page
314
3.1 Exploded view - coolant pipes at front and in centre of vehicle
Note
The arrow markings on coolant pipes and on ends of hoses must align.
3. Coolant pipes 295

1 - Front coolant return pipe

⇒ page 313
2 - Bleeder screw
❑ 0.5 Nm
3 - Bolt
❑ 8 Nm
4 - Rear coolant return pipe
⇒ page 314
6 - Bolts
❑ 8 Nm
7 - Bolts
❑ 20 Nm
8 - Bolt
❑ 8 Nm
9 - Retaining clamp
10 - Bolts
❑ 20 Nm
11 - Breather line
12 - Coolant pipes located at
centre of vehicle
⇒ page 305
13 - Coolant supply pipe, right-
side
⇒ page 311
14 - Coolant supply pipe, left-side
15 - Bolts
❑ 8 Nm
17 - Bolts
❑ 8 Nm

3.2 Exploded view - coolant pipes (rear) to body
Note
The arrow markings on coolant pipes and on ends of hoses must align.
1 - Bolt
❑ 9 Nm
2 - Coolant pipe (rear right)
⇒ page 301
3 - Bolt
❑ 9 Nm
4 - Bolt
❑ 9 Nm
5 - Coolant hose
6 - Coolant pipe (rear right) to
ATF cooler
⇒ page 303
7 - Bolt
Rep. gr. 66
8 - Coolant hose
9 - Nut
❑ 9 Nm
10 - Coolant hose
11 - Bolt
❑ 9 Nm
12 - Large coolant pipe (rear
left)
⇒ page 299
13 - Bolt
❑ 9 Nm
14 - Bolt
❑ 9 Nm
15 - Coolant hose
16 - Bolt
❑ 9 Nm
17 - Bolt
❑ 9 Nm
18 - Small coolant pipe (rear left)

19 - Coolant hose
20 - Coolant hose
22 - Coolant hose
3.3 Exploded view - coolant expansion tank
1 - Bolt
❑ 20 Nm
2 - Bracket
❑ Insert in mountings on
bracket -item 9- and
slide towards rear
4 - Bolt
❑ 8 Nm
5 - Bracket
6 - Filler cap
❑ For R8 Coupé
WARNING
Risk of scalding due to
hot steam and hot cool‐
ant.
The
♦ cooling system is un‐
der pressure when the
engine is hot.
To
♦ allow pressure to dis‐
sipate, cover filler cap on
coolant expansion tank
with cloth and open care‐
fully.
Overheating can occur if
the filler cap is not fitted
properly.
The
♦ filler cap must en‐
gage positively and audi‐
bly when it is closed.
7 - Filler cap
❑ For R8 Spyder

WARNING
Risk of scalding due to
hot steam and hot cool‐
ant.
The
♦ cooling system is un‐
der pressure when the
engine is hot.
To
♦ allow pressure to dis‐
sipate, cover filler cap on
coolant expansion tank
with cloth and open care‐
fully.
Overheating can occur if
the filler cap is not fitted
properly.
The
♦ filler cap must en‐
gage positively and audi‐
bly when it is closed.
8 - Bolt
❑ 8 Nm
9 - Bracket
3.4 Fitting coolant hoses

– Fit coolant hose on connection as follows:
• Push coolant hose -6- onto connection -1- as far as stop -3-.
• If stop is not fitted, push coolant hose 28 mm onto connection.
• Arrow marking -4- on coolant hose must align with arrow mark‐
ing -2- on connection. Some parts have line markings instead
of arrows.
• Use only undamaged hose clips -5- (same as original equip‐
ment).
• Position hose clips between coloured markings -7-.
• Position lugs of hose clips for maximum clearance from sur‐
rounding parts.
3.5 Removing and installing large coolant

pipe (rear left)

Removing
– Detach front section of rear left wheel housing liner and press
slightly to left ⇒ Rep. gr. 66 .
hose clips -1, 2- and disconnect coolant hoses.
– Detach coolant pipe (rear left).
Installing
⇒ “3.2 Exploded view - coolant pipes (rear) to body”,
page 297
Note
Note

3.6 Removing and installing small coolant

pipe (rear left)
Removing
Note
Place a cloth under the connection to catch escaping coolant.

hose clips -1, 2- and disconnect coolant hoses.
– Detach small coolant pipe (rear left).
Installing
page 297
Note

3.7 Removing and installing coolant pipe

(rear right)

Removing
– Place drip tray for workshop hoist - VAS 6208- under connec‐
tion.
– Release hose clip -3-, disconnect coolant hose (right-side) and
drain off coolant.
– Remove bolt -arrow- and move coolant hose clear.
Note

– Release hose clips -arrows- and detach coolant hoses.
– Unscrew bolts -1, 2, 3- and detach coolant pipe (rear right).


– Unscrew bolts -1, 2, 3- and detach coolant pipe (rear right).
Installing
page 297
Note
– Install propshaft ⇒ Rep. gr. 39 .

Note
3.8 Removing and installing coolant pipe

(rear right) to ATF cooler

Removing
– Remove rear wheel (right-side) ⇒ Wheels and tyres; Rep. gr.
44 .
– Unplug electrical connector -arrow- and move wiring clear.

tion.
– Unscrew nut -1-.
hose clips -arrows- and disconnect hoses.
– Detach coolant pipe (rear right) to ATF cooler towards rear.
Installing
page 297
Note
– Fit rear wheel (right-side) ⇒ Wheels and tyres; Rep. gr. 44 .

– Install noise insulation panels ⇒ Rep. gr. 66 .
Note
3.9 Removing and installing coolant pipes

located at centre of vehicle

Removing
Note

(vehicle unladen).
housing.
– Drain coolant completely ⇒ page 277 .

– Remove front final drive ⇒ Rep. gr. 39 .
– Remove luggage compartment pan ⇒ Rep. gr. 70 .
– Remove air intake unit ⇒ Rep. gr. 87 .
– Remove alarm horn - H12- for ultrasonic interior monitor ⇒
Rep. gr. 96 .
– Remove coolant hoses -1 ... 3-.

– Remove bolts -arrows- at retaining clips for refrigerant lines

-1, 2-.
– Remove nut -arrow- and detach retainer for refrigerant line.
– Remove bolts for anti-roll bar -arrows- on both sides.
– Remove bolts -1- and -2- from retaining clip for power steering
hydraulic lines.
– Remove bolts -3- on bracket for lines.
– Remove bolts -4- for coolant pipes located at centre of vehicle.


– Loosen bolt -2- and remove bolt -1-.

Note
There will still be some coolant in the coolant pipes.
tions.
– Remove bolts -1- and -2-, slacken bolt -3-, but do not remove
it completely.
– Pull coolant pipes at centre of vehicle slightly downwards and
push carefully to front.
– Turn coolant pipes located at centre of vehicle through 180°
and carefully take out downwards.
Installing
⇒ “3.1 Exploded view - coolant pipes at front and in centre of
Note
– Secure anti-roll bar with suspension in unladen position ⇒

Rep. gr. 40 .
– Install alarm horn - H12- for ultrasonic interior monitor ⇒ Rep.
gr. 96 .
– Install air intake unit ⇒ Rep. gr. 87 .
– Install refrigerant lines ⇒ Rep. gr. 87 .
– Install luggage compartment pan ⇒ Rep. gr. 70 .
– Install front final drive ⇒ Rep. gr. 39 .
– Install propshaft ⇒ Rep. gr. 39 .
Note
3.10 Removing and installing coolant supply

pipe (left-side)

Removing
– Remove battery ⇒ Electrical system; Rep. gr. 27 .
– Remove air intake unit ⇒ Rep. gr. 87 .

tions.
– Release hose clips -arrows- and disconnect coolant hoses
from coolant supply pipe (left-side).
– Remove bolts -1- and -2-.
– Turn coolant supply pipe (left-side) upwards in clockwise di‐
rection and remove.
Installing
Note
– Install air intake unit ⇒ Rep. gr. 87 .

– Install battery ⇒ Electrical system; Rep. gr. 27 .
Note
3.11 Removing and installing coolant supply

pipe (right-side)

Removing
– Remove battery ⇒ Electrical system; Rep. gr. 27 .
tions.
from coolant supply pipe (left-side).
– Remove bolts -1- and -2- and take off coolant supply pipe
(right-side) downwards.
Note
The coolant hose -bottom arrow- can be accessed from the wheel
housing (right-side).
Installing
Note
– Install battery ⇒ Electrical system; Rep. gr. 27 .

Note

3.12 Removing and installing coolant return

pipe (front)
Removing

tion.
from coolant return pipe (front).
– Remove bolts -1- and -2- and detach coolant return pipe
(front).
Installing
Note

Note
3.13 Removing and installing coolant return

pipe (rear)

Removing
– Remove coolant supply pipe (right-side) ⇒ page 311 .
tion.
from coolant return pipe (rear).
– Remove bolts -1- and -3- and remove coolant return pipe (rear)
upwards.
Note
Disregard -item 2-.
Installing
Note
– Install coolant supply pipe (right-side) ⇒ page 311 .


4 Radiator and radiator fans

⇒ “4.1 Exploded view - side radiators and radiator fans”,
page 316
⇒ “4.2 Removing and installing side radiator”, page 317
⇒ “4.3 Removing and installing radiator cowl with radiator fans”,
page 320
⇒ “4.4 Removing and installing radiator fan”, page 321
⇒ “4.5 Exploded view - radiator (centre)”, page 322
⇒ “4.6 Removing and installing radiator (centre)”, page 323
4.1 Exploded view - side radiators and radiator fans
Note
The illustration shows the left-side radiator.
1 - Air duct
2 - Hydraulic fluid cooler
❑ For power steering
⇒ Rep. gr. 48
3 - Hydraulic fluid hoses
4 - Bolt
Rep. gr. 87
5 - Refrigerant lines
6 - Condenser
❑ For air conditioning sys‐
tem
⇒ Rep. gr. 87
7 - Coolant hose
❑ Return line
8 - Mounting
9 - Side radiator
⇒ page 317
with fresh coolant
10 - Nut
❑ 6 Nm
11 - Radiator fan
❑ Left-side: radiator fan -
V7- with radiator fan
control unit - J293-
❑ Right-side: radiator
fan 2 - V177- with radiator fan control unit 2 - J671-

12 - Bolt
❑ 8 Nm
13 - Radiator cowl
14 - Coolant hose
❑ Supply line
15 - Mounting for radiator
16 - Bolts
❑ 20 Nm
17 - Mounting
18 - Bolt
❑ 5 Nm
19 - Bolt
❑ Tightening torque ⇒ Rep. gr. 48
20 - Bolt
❑ 2.5 Nm
4.2 Removing and installing side radiator
Note
The radiator must be removed and installed together with the ra‐
diator cowl.

4. Radiator and radiator fans 317

Removing
WARNING

hot.

– Remove bumper cover (front) ⇒ Rep. gr. 63 .
Radiator (left-side):
– Unscrew bolts -arrows- and detach air duct.
Radiator (right-side):
– Unplug electrical connector -1- at ambient temperature sensor
- G17- .
– Unscrew bolts -arrows- and detach air duct.


tion.
– Disconnect coolant hoses -1- and -2- from radiator and drain
off coolant.
WARNING
Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.
Caution
Risk of damage to condenser, refrigerant lines and refrigerant

hoses.
– Remove bolts -arrows- and secure condenser to prevent it

dropping.
WARNING
Risk of injury as the radiator fans may start up automatically.

♦ Unplug electrical connectors before working in vicinity of
radiator cowl.
– Unplug electrical connector -1- for radiator fan and move clear.
– Remove bolts -arrows-, detach bracket with radiator and move
to side.

– Unscrew nuts -arrows- and remove radiator cowl with radiator

fan from below.
Note
Disregard -item 1-.
Installing
⇒ “4.1 Exploded view - side radiators and radiator fans”, page
316
Note
♦ If there are slight impressions on the fins, refer to ⇒ page 11 .

♦ The coolant in the entire system must be changed if the radi‐
ator is renewed.
– Install condenser ⇒ Rep. gr. 87 .

– Install bumper cover (front) ⇒ Rep. gr. 63 .
– Install underbody cover ⇒ Rep. gr. 66 .
Note
4.3 Removing and installing radiator cowl

with radiator fans
Removing
– Remove front wheel housing liner on relevant side ⇒ Rep. gr.
66 .
– Remove trim for headlight and wheel housing liner on relevant
side ⇒ Rep. gr. 50 .
WARNING

♦ Unplug electrical connectors before performing work on
radiator cowl.
– Remove bolts -arrows- and push radiator forwards slightly.

– Unscrew bolts -arrows- and remove radiator cowl with radiator

fan downwards.
Note
For illustration purposes, the installation position is shown with

the radiator and radiator cowl removed.
Installing
316
– Install trim for headlight and wheel housing liner ⇒ Rep. gr.
50 .
– Install underbody cover (front) and wheel housing liner (front)
⇒ Rep. gr. 66 .
4.4 Removing and installing radiator fan

Removing
– Remove front wheel housing liner on relevant side ⇒ Rep. gr.
66 .
– Remove trim for headlight and wheel housing liner on relevant
WARNING

♦ Unplug electrical connectors before working in vicinity of
radiator cowl.
– Remove bolts -arrows- and push radiator forwards slightly.


– Remove nuts -arrows- and take out radiator fan from below.
Note
Disregard -item 1-.
Installing
316
– Install trim for headlight and wheel housing liner ⇒ Rep. gr.
50 .
– Install underbody cover (front) and wheel housing liner (front)
⇒ Rep. gr. 66 .
4.5 Exploded view - radiator (centre)
1 - Bolt
❑ 2.5 Nm
2 - Front air duct
3 - Mounting
4 - Bolt
❑ 20 Nm
5 - Bracket (right-side) for radi‐
ator
6 - Bolt
❑ 20 Nm
7 - Coolant hose
❑ Supply line
8 - Coolant hose
❑ Return line
9 - Bolt
❑ 2.5 Nm
10 - Mounting
11 - Bracket (centre) for radia‐
tor
12 - Bolt
❑ 8 Nm
13 - Rear air duct
14 - Bolt
❑ 20 Nm
15 - Bracket (left-side) for radi‐
ator
16 - Bolt
❑ 20 Nm

17 - Mounting
18 - Coolant hose
❑ Supply line
4.6 Removing and installing radiator (cen‐

tre)
Removing
WARNING

hot.

– Remove bumper cover (front) ⇒ Rep. gr. 63 .
– Unscrew bolts -arrows- and remove air duct (front).
tion.
– Release hose clips -1- and -2-, disconnect coolant hoses from
radiator and drain off coolant.
– Release hose clip -arrow- and disconnect coolant hose from

radiator.
– Remove bolt -1- on bracket for radiator.
Note
Disregard -item 2-.

– Remove bolt -1- on bracket for radiator.

– Swivel radiator forwards -arrow B-, move to left side
-arrow A- and detach.
– Remove bolts -arrows- and detach air duct (rear) from radiator.
Installing
⇒ “4.5 Exploded view - radiator (centre)”, page 322
Note
♦ If there are slight impressions on the fins, refer to ⇒ page 11 .

♦ The coolant in the entire system must be changed if the radi‐
ator is renewed.

– Install bumper cover (front) ⇒ Rep. gr. 63 .
Note

24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Technical data”, page 325
⇒ “1.2 Overview of fitting locations”, page 325
1.1 Technical data

Engine data 5.2 ltr. / 4-valve engine
Idling speed is not adjustable (con‐ 640 ... 840 rpm
trolled by idling speed stabilisation).
Maximum rpm governed by deacti‐ 6500 rpm
vation of fuel injectors
Fuel pressure Initial fuel pressure up to high-pres‐ 3.0 ... 6.0 bar
sure pump (generated by electric
fuel pump in fuel tank)
Pressure in high-pressure fuel cir‐ between 20 and 40 bar at idling
cuit (generated by mechanical sin‐ speed
gle-plunger pump) at a coolant up to approx. 125 bar in certain
temperature of approx. 85°C. parts of operating range
1.2 Overview of fitting locations

Part 1 - R8 Coupé and R8 GT
Note
The illustration shows a vehicle with manual gearbox/R tronic gearbox.
1. Injection system 325

1 - Air mass meter 2 - G246- /

intake air temperature send‐
er 2 - G299-
⇒ page 348
2 - Lambda probe 2 after cata‐
lytic converter - G131- with
Lambda probe 2 heater after
catalytic converter - Z30-
❑ Fitting location
⇒ page 335
❑ Fitting location of con‐
nector ⇒ page 335
⇒ page 375
3 - Engine speed sender -
G28-
♦ ⇒ Fig. ““ Engine speed
sender -G28- , vehicles
with manual gearbox/R
tronic gearbox 086”“ , page
333
♦ ⇒ Fig. ““ Engine speed
sender -G28- , vehicles
with dual clutch gearbox
0BZ”“ , page 333
⇒ page 421
❑ 9 Nm
4 - Lambda probe 2 before cat‐
alytic converter - G108- with
Lambda probe 2 heater - Z28-
⇒ page 335
❑ Fitting location of connector ⇒ page 335
5 - Throttle valve module 2 - J544-
❑ After renewing, perform “Adaption” in “Guided Functions”
❑ 9 Nm
6 - Engine control unit 2 - J624-
❑ Fitting location ⇒ page 332
7 - Secondary air pump motor 2 - V189-
❑ Exploded view - secondary air system ⇒ page 399
❑ Checking secondary air system ⇒ page 407
❑ Removing and installing secondary air pump motor 2 - V189- ⇒ page 405
8 - Engine control unit - J623-
9 - Throttle valve module - J338-
❑ 9 Nm
326 Rep. gr.24 - Mixture preparation - injection

10 - Lambda probe - G39- (before catalytic converter) with Lambda probe heater - Z19-
11 - Lambda probe after catalytic converter - G130- with Lambda probe 1 heater after catalytic converter - Z29-
12 - Exhaust flap 1 valve - N321-
13 - Secondary air pump motor - V101-
❑ Removing and installing secondary air pump motor - V101- ⇒ page 405
❑ Secondary air pump relay - J299- ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
14 - Air mass meter - G42- / intake air temperature sender - G70-
Part 1 - R8 Spyder
Note
The illustration shows a vehicle with manual gearbox/R tronic gearbox.

1 - Secondary air pump motor

2 - V189-
❑ Exploded view - secon‐
dary air system
⇒ page 399
❑ Checking secondary air
system ⇒ page 407
secondary air pump mo‐
tor 2 - V189-
⇒ page 405
❑ Secondary air pump 2
relay - J545- ⇒ Current
flow diagrams, Electri‐
cal fault finding and Fit‐
ting locations
2 - Engine control unit 2 - J624-
⇒ page 333
⇒ page 383
3 - Lambda probe 2 after cata‐
lytic converter - G131- with
Lambda probe 2 heater after
catalytic converter - Z30-
⇒ page 335
❑ Fitting location of con‐
nector ⇒ page 335
⇒ page 375
4 - Engine speed sender -
G28-
⇒ page 333
❑ 9 Nm
5 - Lambda probe 2 before catalytic converter - G108- with Lambda probe 2 heater - Z28-
6 - Throttle valve module 2 - J544-
❑ 9 Nm
7 - Throttle valve module - J338-
❑ 9 Nm
8 - Lambda probe - G39- (before catalytic converter) with Lambda probe heater - Z19-
9 - Lambda probe after catalytic converter - G130- with Lambda probe 1 heater after catalytic converter - Z29-


10 - Engine control unit - J623-
11 - Exhaust flap 1 valve - N321-
12 - Secondary air pump motor - V101-
❑ Removing and installing secondary air pump motor - V101- ⇒ page 405
❑ Secondary air pump relay - J299- ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
13 - Air mass meter - G42- / intake air temperature sender - G70-
14 - Air mass meter 2 - G246- / intake air temperature sender 2 - G299-
Part 2
1 - Exhaust camshaft control

valve 2 - N319-
2 - Activated charcoal filter sys‐
tem solenoid valve 2 - N333-
❑ Routing of pipes/hoses
⇒ Rep. gr. 20 ; Activa‐
ted charcoal filter sys‐
tem and tank leak diag‐
nostic system - USA
vehicles; Routing of
pipes/hoses for activa‐
ted charcoal filter sys‐
tem and tank leak diag‐
nostic system
3 - Left electrohydraulic engine
mounting solenoid valve -
N144-
⇒ page 334
4 - Fuel metering valve 2 -
N402-
5 - Hall sender 4 - G301-
⇒ page 420
❑ 10 Nm
⇒ page 420
❑ 10 Nm
7 - Intake manifold flap poten‐
tiometer 2 - G512-
❑ After renewing, perform
“Adaption” in “Guided
Functions” under
“Adapting potentiometer for air flow control flaps”


9 - Intake manifold flap potentiometer - G336-
❑ After renewing, perform “Adaption” in “Guided Functions” under “Adapting potentiometer for air flow
control flaps”
10 - Hall sender - G40-
❑ 10 Nm
❑ 10 Nm
12 - Fuel metering valve - N290-
13 - Right electrohydraulic engine mounting solenoid valve - N145-
14 - Activated charcoal filter solenoid valve 1 - N80-
❑ Routing of pipes/hoses ⇒ Rep. gr. 20 ; Activated charcoal filter system and tank leak diagnostic system
- USA vehicles; Routing of pipes/hoses for activated charcoal filter system and tank leak diagnostic
system
15 - Exhaust camshaft control valve 1 - N318-
16 - Camshaft control valve 1 - N205-
17 - Sender 1 for secondary air pressure - G609-
18 - Intake manifold flap valve - N316-
19 - Secondary air inlet valve - N112-
❑ Depending on country-specific version: with secondary air inlet valve 2 - N320-
21 - Camshaft control valve 2 - N208-
Part 3

1 - Injector, cylinder 10 - N300-

⇒ page 362
2 - Ignition coil 10 with output
stage - N328-
⇒ page 418
stage - N327-
stage - N326-
stage - N325-
stage - N324-
11 - Knock sensor 3 - G198-
⇒ page 334
⇒ page 419
12 - Oil temperature sender 2 -
G664-
⇒ page 260
⇒ page 334
14 - Ignition coil 1 with output stage - N70-
25 - Fuel pressure sender - G247-

26 - Electrical connector
❑ Orange
❑ For knock sensor 1 - G61-
❑ Green
❑ Grey
❑ Brown
30 - Fuel pressure sender for low pressure - G410-
31 - Fuel pressure sender 2 - G624-
Fitting location of engine control unit - J623- - R8 Coupé

1- Electrical connector
2- Metal locking plate
3- Engine control unit - J623-
♦ Beneath engine compartment trim panel (right-side)
Removing and installing ⇒ page 381
Fitting location of engine control unit 2 - J624- - R8 Coupé

3- Engine control unit 2 - J624-
♦ Beneath engine compartment trim panel (left-side)

Fitting location of engine control unit - J623- - R8 Spyder

3- Engine control unit - J623-
♦ In engine compartment (right-side)
Fitting location of engine control unit 2 - J624- - R8 Spyder

1- Engine control unit 2 - J624-
♦ On left of engine compartment
Engine speed sender - G28- , vehicles with manual gearbox/R

tronic gearbox 086
1- Bolt for bracket for engine speed sender - G28-
♦ On left of gearbox housing
Engine speed sender - G28- , vehicles with dual clutch gearbox

0BZ
♦ Fitting location: on left or right side of gearbox housing, de‐
pending on version
2- Bolt
3- Engine speed sender - G28-

Electrohydraulic engine mounting solenoid valve -N144- / -N145-

1- Bolt for engine mounting (left-side)
Knock sensors
5 - Electrical connector for knock sensor 1 - G61-
Fitting location of Lambda probes on cylinder bank 1 (right-side)

1- Lambda probe after catalytic converter - G130-
2- Lambda probe - G39- (before catalytic converter)
Electrical connectors for Lambda probes on cylinder bank 1 (right-

side)
2- For Lambda probe - G39- (before catalytic converter)

Fitting location of Lambda probes on cylinder bank 2 (left-side)

1- Lambda probe 2 - G108- (before catalytic converter)
2- Lambda probe 2 after catalytic converter - G131-
Electrical connectors for Lambda probes on cylinder bank 2 (left-

side)
2- For Lambda probe 2 - G108- (before catalytic converter)

2 Air cleaner
⇒ “2.1 Exploded view - air cleaner”, page 336
⇒ “2.2 Removing and installing air filter elements”, page 341
⇒ “2.3 Removing and installing air cleaner housing”, page 345
⇒ “2.4 Removing and installing air mass meter G70 / air mass
meter 2 G246 ”, page 348
2.1 Exploded view - air cleaner

⇒ “2.1.1 Exploded view - air cleaner, R8 Coupé/R8 Spyder with
⇒ “2.1.2 Exploded view - air cleaner, R8 GT”, page 338
⇒ “2.1.3 Exploded view - air cleaner, R8 Coupé/R8 Spyder with
2.1.1 Exploded view - air cleaner, R8 Coupé/R8 Spyder with manual gearbox/R
tronic gearbox 086
1 - Air hose
❑ Between air mass meter
- G70- and throttle valve
module - J338-
❑ Observe marking
2 - Bolt
❑ 1.5 Nm
3 - Air mass meter - G70-
⇒ page 348
4 - Bolt
❑ On carbon air cleaner
(top section), only tight‐
en bolt with rubber
washer inserted be‐
tween bolt and air clean‐
er
❑ 8 Nm
5 - Adapter
❑ 4 Nm
6 - Grommet
7 - Sleeve
8 - Bolt
❑ 8 Nm
9 - Bolt
❑ 8 Nm
10 - Sleeve
11 - Air duct
❑ Clean out dirt and
leaves, etc.
12 - Air duct
❑ Clean out dirt and leaves, etc.

13 - Bush
14 - Bolt
❑ 8 Nm
15 - Bolt
❑ 8 Nm
16 - Bush
17 - Air duct
18 - Bolt
❑ 8 Nm
19 - Bush
20 - Grommet
21 - Boot
❑ Make sure it engages correctly when fitting
22 - Grommets
23 - Air cleaner (top section)
❑ Clean out salt deposits, dirt and leaves, etc.
24 - Bolt
❑ 1.2 Nm
25 - Strainer
26 - Bolt
❑ 8 Nm
27 - Washer
28 - Bush
29 - Water drain
❑ Clean
30 - Air cleaner (bottom section)
31 - Heat shield
32 - Bolt
❑ 3 Nm
33 - Air filter element
❑ Use genuine air filter element ⇒ Electronic parts catalogue
❑ Observe maintenance intervals ⇒ Maintenance tables ⇒ Maintenance ; Booklet 420
34 - Hose clips
❑ 5.5 Nm
2. Air cleaner 337

2.1.2 Exploded view - air cleaner, R8 GT
1 - Air hose
❑ Between air mass meter
- G70- and throttle valve
module - J338-
❑ Observe marking
2 - Bolt
❑ 1.5 Nm
3 - Air mass meter - G70-
⇒ page 348
❑ Use genuine air filter el‐
ement ⇒ Electronic
parts catalogue
⇒ page 346
❑ Observe maintenance
intervals ⇒ Mainte‐
nance tables ⇒ Mainte‐
nance ; Booklet 420
5 - Bolt
❑ 3 Nm
6 - Heat shield
7 - Sealing cap
8 - Bolt
❑ Insert rubber washer
before tightening bolt
❑ 8 Nm
❑ Clean out salt deposits,
dirt and leaves, etc.
10 - Air duct
11 - Bolt
❑ 3 Nm
12 - Bolt
❑ 1.2 Nm
13 - Strainer
14 - Bolt
❑ 8 Nm
15 - Washer
16 - Bush

18 - Heat shield
19 - Bolt
❑ 3 Nm
20 - Water drain
❑ Clean
21 - Hose clips
❑ 5.5 Nm
2.1.3 Exploded view - air cleaner, R8 Coupé/R8 Spyder with dual clutch gearbox
0BZ
1 - Air hose
2 - Air mass meter
❑ Cylinder bank 1 (right-
side): air mass meter -
G70-
❑ Cylinder bank 2 (left-
side): air mass meter 2 -
G246-
⇒ page 341
3 - Bolt
❑ 1.5 Nm
❑ Use genuine air filter el‐
ement ⇒ Electronic
parts catalogue
⇒ page 341
❑ Observe change inter‐
vals ⇒ maintenance ta‐
ble
5 - Bolt
❑ 3 Nm
6 - Adapter
❑ 4 Nm
7 - Grommet
8 - Sleeves
9 - Bolt
❑ 8 Nm
10 - Bolt
❑ 8 Nm
11 - Air duct
❑ Clean any leaves and dirt out of air duct
12 - Air duct
13 - Bolt
❑ 8 Nm
2. Air cleaner 339

14 - Sleeves
15 - Bolt
❑ 8 Nm
16 - Air duct
17 - Bolt
❑ 8 Nm
18 - Sleeve
19 - Grommet
20 - Boot
❑ Make sure it engages correctly when fitting
21 - Grommet
22 - Grommet
23 - Bolt
❑ On carbon air cleaner (top section), only tighten bolt with rubber washer inserted between bolt and air
cleaner
❑ 8 Nm
24 - Ball stud
❑ 2.5 Nm
❑ Clean any salt residue, leaves and dirt out of air cleaner (top section)
❑ Clean any salt residue, leaves and dirt out of air cleaner (bottom section)
❑ Clean water drain hose
❑ Tighten to 8 Nm
27 - Bolt
❑ 8 Nm
28 - Sleeve
29 - Grommet
30 - Bolt
❑ 1.2 Nm
31 - Heat shield

2.2 Removing and installing air filter ele‐

ments
⇒ “2.2.1 Removing and installing air filter elements - vehicles with
⇒ “2.2.2 Removing and installing air filter elements - vehicles with
2.2.1 Removing and installing air filter ele‐

ments - vehicles with manual gearbox/R
tronic gearbox 086
Removing
– Fit protective cover on bodywork ⇒ page 11 .
2. Air cleaner 341

– Unplug electrical connectors from air mass meter 2 - G246-

-2- and unplug electrical connector from air mass meter - G70-
-4-.
– Unscrew bolts -arrows- for air cleaner (top section).
– Loosen hose clips -1- and -3-.
– Detach air cleaner (top section).
– Take out air filter elements.
Note
Installing
⇒ “2.1.1 Exploded view - air cleaner, R8 Coupé/R8 Spyder
To ensure the proper function of the two air mass meters it is
important to observe the following notes and instructions.
Note
♦ If the air filter elements are severely contaminated or soaked,

dirt particles or moisture could enter as far as the air mass
meters and falsify the measured air mass value. This will
cause a loss of power as the calculated injection quantities will
be too low.
♦ Always use genuine air filter elements (same as original equip‐
ment).
♦ The air cleaner housing must always be clean.
♦ To prevent malfunctions, cover all critical parts of the engine
air intake tract (air mass meter, intake pipes, etc.) with a clean
cloth when blowing out the air cleaner housing with com‐
pressed air.
♦ Please observe requirements for disposal.
– Blow out water drain (small hole in bottom section of air clean‐
er) with compressed air.
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections); use a vacuum cleaner if necessary.
– Check for salt residue, dirt and leaves in air mass meters and
air intake hoses (engine intake side).
– Check air ducts leading to air cleaner housing for dirt and
leaves.

– The two air filter elements must be inserted carefully into

grooves -1- and -2-.
– Carefully fit top section of air cleaner onto bottom section,

without applying any force.
Caution
Risk of damage to carbon air cleaner (top section).

♦ Only tighten bolts -arrows- for air cleaner (top section) af‐
ter inserting rubber washers between bolts and air clean‐
er.
– Make sure that the air intake hoses are correctly seated on the
two air mass meters.
– Install air mass meter ⇒ page 348 .
2.2.2 Removing and installing air filter ele‐

ments - vehicles with dual clutch gear‐
box 0BZ
Note
The following description is for removing and installing the left-

side air cleaner. The procedure for the other side is similar.

– Remove air mass meter 2 - G246- ⇒ page 348 .
– Remove bolts -arrows- and detach air cleaner (top section).
2. Air cleaner 343

– Release screw-type clip -1- and remove bolt -3-.

– Detach air filter element.
Note
Disregard -item 2-.
Installing
important to observe the following notes and instructions.
Note
♦ If the air filter elements are severely contaminated or soaked,

dirt particles or moisture could enter as far as the air mass
meters and falsify the measured air mass value. This will
cause a loss of power as the calculated injection quantities will
be too low.
♦ Always use genuine air filter elements (same as original equip‐
ment).
pressed air.
♦ Please observe requirements for disposal.
– Blow out water drain (small hole in bottom section of air clean‐
er) with compressed air.
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections); use a vacuum cleaner if necessary.
– Check air ducts leading to air cleaner housing for dirt and
leaves.
– Carefully insert air filter element into grooves -arrows-.

– Carefully fit air cleaner (top section) on air cleaner (bottom
section) without applying any force.
– Make sure that air hoses are secured correctly.
– Plug electrical connector back in.

2.3 Removing and installing air cleaner

housing
⇒ “2.3.1 Removing and installing air cleaner housing - R8 Coupé
⇒ “2.3.2 Removing and installing air cleaner housing - R8 Spyder
⇒ “2.3.3 Removing and installing air cleaner housing - R8 GT”,
page 346
⇒ “2.3.4 Removing and installing air cleaner housing - R8 Coupé/
Spyder with dual clutch gearbox 0BZ”, page 347
2.3.1 Removing and installing air cleaner

housing - R8 Coupé with manual gear‐
box/R tronic gearbox 086
Removing
– Remove engine compartment trim panels ⇒ Rep. gr. 53 .
-5-.
– Remove air cleaner housing together with air mass meters.
Installing
Note

pressed air.
– Check air duct leading to air cleaner housing for dirt and leaves
2. Air cleaner 345


housing - R8 Spyder with manual gear‐
box/R tronic gearbox 086
Removing
– Remove air filter elements ⇒ page 341 .
– Remove bolts -arrows- and push secondary air pipe (left-side)
-1- to the side.

Installing
Note

pressed air.
– Install secondary air pipes ⇒ page 399 .
– Install air filter elements
⇒ “2.2.1 Removing and installing air filter elements - vehicles
with manual gearbox/R tronic gearbox 086”, page 341 .

housing - R8 GT
Removing


-5-.
Note

Installing
⇒ “2.1.2 Exploded view - air cleaner, R8 GT”, page 338
Note

pressed air.

housing - R8 Coupé/Spyder with dual
clutch gearbox 0BZ
Note
The following description is for removing and installing the left-

side air cleaner. The procedure for the other side is similar.
Removing
R8 Coupé:
– Remove engine compartment trim panel on relevant side ⇒
Rep. gr. 53 .
2. Air cleaner 347

R8 Spyder:
– Remove bolts -arrows- and push secondary air pipe (left-side)
-1- to the side.
Both versions:
– Release hose clip -3- and detach air hose.
– Move crankcase breather hose -2- clear at air cleaner housing.
– Detach boot -1- from air cleaner housing.
– Unplug electrical connector -4- at air mass meter 2 - G246- .
– Remove air cleaner housing.
Installing
with dual clutch gearbox 0BZ”, page 339
Note

– Install engine cover panel ⇒ page 128 .
2.4 Removing and installing air mass meter

- G70- / air mass meter 2 - G246-
Removing
Note
The following description is for removing and installing the air

mass meter 2 - G246- (left-side) on a vehicle with manual gear‐
box/R tronic gearbox 086.



– Remove air mass meter from air filter element -arrows-.
Installing
Note

important to observe the notes and instructions ⇒ page 342 .
2. Air cleaner 349

3 Intake manifold, fuel rail and injectors

⇒ “3.1 Exploded view - intake manifold (top section)”, page 350
⇒ “3.2 Removing and installing throttle valve module J338 / throt‐
tle valve module 2 J544 ”, page 351
⇒ “3.3 Removing and installing intake manifold (top section)”,
page 352
⇒ “3.4 Exploded view - intake manifold (bottom section), fuel rail
and injectors”, page 356
⇒ “3.5 Removing and installing intake manifold (bottom section)
with fuel rail”, page 358
⇒ “3.6 Removing and installing injectors”, page 362
3.1 Exploded view - intake manifold (top section)
1 - Vacuum reservoir
2 - Intake manifold (top sec‐
tion)
⇒ page 352
3 - Cover
4 - Bolt
❑ 5.5 Nm
5 - Gasket
6 - Seal
❑ Renew
7 - Bolt
❑ 9 Nm
8 - Throttle valve module -
J338-
side)
⇒ page 351
Functions”
9 - Seal
10 - Seal
❑ Renew
11 - Bolt
❑ 9 Nm
12 - Throttle valve module 2 -
J544-
side)
13 - Bolt
❑ 2.5 Nm

14 - Fuel connection
15 - Bolt
❑ Tightening sequence ⇒ page 351
16 - Seals
❑ Renew
17 - Vacuum hose
18 - Grommet
19 - Bolt
❑ 5 Nm
Intake manifold (top section) - tightening torque and sequence

– Tighten bolts for intake manifold (top section) diagonally and
in three stages.
Stage 1: Tighten bolts -1 to 4- to 11 Nm.
• Intake manifold (top section) is brought into contact with cyl‐
inder head.
Stage 2: Tighten bolts -9 to 12- to 11 Nm.
Stage 3: Tighten bolts -1 to 12- to 11 Nm again.
3.2 Removing and installing throttle valve

module - J338- / throttle valve module 2
- J544-
Removing
Throttle valve module - J338- (right-side)
– Move air hose with crankcase breather hose -1- attached clear
to one side.
3. Intake manifold, fuel rail and injectors 351

Throttle valve module 2 - J544- (left-side)

– Move air hose with vacuum hose -1- for brake servo attached
clear to one side.

– Remove bolts -arrows- and detach throttle valve module.
Installing
⇒ “3.1 Exploded view - intake manifold (top section)”,
page 350 and
⇒ Fig. ““Intake manifold (top section) - tightening torque and
sequence”“ , page 351
Note
♦ Renew seals and/or gaskets.

♦ To ensure that the air hoses can be properly secured at their
connections, spray rust remover onto the worm thread of used
hose clips before installing.
– After renewing, perform “Adaption” in “Guided Functions”

⇒ Vehicle diagnostic tester
3.3 Removing and installing intake manifold

(top section)
Removing
– Remove throttle valve module -J338- / -J544- ⇒ page 351 .
R8 Coupé
– Remove engine compartment trim panels ⇒ Rep. gr. 53 .
R8 Spyder
– Remove engine compartment trim ⇒ Rep. gr. 53 .


– Move vent hose clear -arrow-.
– Remove bolts -1- and -arrows- and detach bracket for engine
cover panel.
– Press release tabs on both sides and detach breather line

-1- for fuel tank.
– Release breather line for fuel tank -arrows- and move upwards
slightly.
All vehicles (continued)

Note
Disregard -item 1-.

Note
Disregard -item 1-.
– Disconnect vacuum hose -1- and move clear coolant hose

-2-.
– Move electrical wiring harness clear -arrows-.
– Detach vacuum hoses -1, 2, 3-.
– Unplug electrical connector -1- at fuel metering valve 2 -

N402- .
– Move electrical wiring harness clear -arrows-.

– Unscrew bolts -arrows- and remove cover -1-.
– Remove bolts in the sequence -12 ... 1-.

– Lift intake manifold (top section) at front -arrow- and guide out
under cross piece.
Note
Seal off the intake ports in the cylinder heads with clean cloths.
Installing
⇒ “3.1 Exploded view - intake manifold (top section)”,
page 350 and
⇒ Fig. ““Intake manifold (top section) - tightening torque and
sequence”“ , page 351
Note
♦ Renew seals and/or gaskets.

– Install throttle valve modules ⇒ page 351 .

R8 Spyder:
– Install bracket for engine cover panel ⇒ page 116 .
3.4 Exploded view - intake manifold (bottom section), fuel rail and injectors
Note
The illustration shows the intake manifold (bottom section) for cylinder bank 2 (left-side).

1 - Gaskets
❑ Renew
2 - Intake manifold (bottom
section)
❑ With vacuum unit for in‐
take manifold flaps
⇒ page 358
❑ After renewing, check
vacuum system for
leaks ⇒ page 11
3 - Bolt
❑ 2.5 Nm
4 - Intake manifold flap poten‐
tiometer
side): intake manifold
flap potentiometer -
G336-
side): intake manifold
flap potentiometer 2 -
G512-
Functions”
5 - Seal
❑ When renewing lever
out with screwdriver
❑ Press in by hand
6 - Vacuum hose
❑ From intake manifold
flap valve - N316-
7 - Fuel rail
8 - Threaded connection
❑ 40 Nm
9 - High-pressure pipe
❑ Connections must not be damaged
❑ Do not alter shape
❑ Lubricate thread lightly with engine oil
❑ 25 Nm
10 - Sleeve
11 - Bolt
12 - Nut
13 - Retaining bracket
❑ For fuel rail

14 - Bolt
❑ 2.5 Nm
15 - Bolt
❑ 9 Nm
16 - Bracket
17 - Bolt
❑ Renew
❑ 7 Nm + turn 90° further
18 - Fuel pressure sender
❑ Cylinder bank 1 (right-side): fuel pressure sender - G247-
❑ Cylinder bank 2 (left-side): fuel pressure sender 2 - G624-
❑ 25 Nm
19 - Support ring
❑ Renew
❑ Via this support ring, the fuel rail exerts the clamping force that holds the injector in the cylinder head
❑ Clipped to radial compensation element -item 24-
20 - O-ring
❑ Renew
❑ Lubricate lightly with clean engine oil
21 - Spacer ring
22 - Injector
23 - Combustion chamber ring seal
❑ Do not apply grease or use any other lubricants
❑ Renewing ⇒ “3.6 Removing and installing injectors”, page 362
24 - Radial compensation element or sealing element
❑ Version 1 injector: clip radial compensation element onto support ring -item 19-
❑ Version 2 injector: sealing element
Intake manifold (bottom section) - tightening torque and sequence

– Tighten bolts and nuts -arrows- for intake manifold (bottom
section) in stages and in diagonal sequence; final torque 9 Nm.
3.5 Removing and installing intake manifold

(bottom section) with fuel rail

Removing
Note
The following description is for removing and installing the intake

manifold (bottom section) on the left side. The procedure on the
right side is similar.


WARNING

– Remove bolt -1- and union nut -4- and move fuel supply line
to one side.
– Remove bolts -2 and 6- and union nuts -3 and 5- and detach
high-pressure pipe.
Note
Do not attempt to bend high-pressure pipe to a different shape.
– Disconnect vacuum hose -arrow- for vacuum unit for intake

manifold flaps.
– Unplug electrical connectors and move clear:

1- For fuel pressure sender 2 - G624-
2- For injectors
3- For intake manifold flap potentiometer 2 - G512-

Note
Lay cloths under the fuel rail to catch escaping fuel.
– Remove bolts and nuts -arrows- and detach intake manifold

(bottom section) with fuel rail.
Caution
Risk of irreparable damage to engine.

♦ Block off the intake manifolds (bottom section) with clean
cloths to prevent small objects from dropping into the en‐
gine through the intake ports in the cylinder heads.
Installing
⇒ Fig. ““Intake manifold (bottom section) - tightening torque
and sequence”“ , page 358
Note
♦ If an injector has been pulled out of the cylinder head, the tef‐
lon ring seal must be renewed.
♦ Renew gaskets and O-rings.
♦ Lubricate O-rings of injectors lightly with clean engine oil.
Caution
Risk of damage to intake manifold flaps.

♦ If the intake manifold flaps are closed, they can catch on
the guide plates in the cylinder head when the intake
manifold (bottom section) is installed.
– Connect hand vacuum pump - VAS 6213- to vacuum unit for

actuating intake manifold flaps, as shown in illustration.
– Operate hand vacuum pump to produce a vacuum.
• This will cause the intake manifold flaps to open.
– Install intake manifold (bottom section) and press fuel rail
evenly onto injectors.
– Disconnect vacuum hose of hand vacuum pump - VAS 6213-
from vacuum unit for actuating intake manifold flaps.
– Install high-pressure pipe ⇒ page 368 .
Note
After installation, check vacuum system for leaks ⇒ page 11 .

3.6 Removing and installing injectors

♦ Tool set for FSI engines - T10133 C-
Note
Special tool -T10133/2- (puller) has been modified and now has
the designation puller -T10133/2 A- . If you have not yet received
the new tool you can make the modification yourself.
Modifying puller -T10133/2- to make it equivalent to puller -

T10133/2 A-
♦ Round file, approx. 6 mm
– File out a semi-circular recess as shown in the illustration. The
recess allows the tool to be pushed further onto the injector so
the contact surface is increased.
– For identification purposes, mark the modified tool with the
letter "A" after the tool number.
Removing
– Remove intake manifold (bottom section) ⇒ page 358 .
If injectors cannot be pulled out of cylinder head by hand, proceed

as follows:
Version 1 injectors:
– Using a screwdriver, bend retaining tabs -1- of radial compen‐
sation element out to the side -arrow-.
All injectors:
– Pull support ring -2- off injector.
– Unplug electrical connector.

– Apply puller -T10133/2A- to groove on injector.

– Apply puller -T10133/16A- and pull out injector by turning bolt
-1-.
Note
♦ When inserting the puller, there is a risk of destroying the radial

compensation element due to the retainer tabs breaking.
♦ The combustion chamber ring seal must always be renewed
prior to re-installing the high-pressure injector.
Dismantling injector (version 1)

– Pull O-ring -5- and spacer ring -4- off injector -3-.
– Remove old combustion chamber ring seal -2- ⇒ page 364 .
Dismantling injector (version 2)

– Pull O-ring -3- and spacer ring -2- off injector -1-.
– Unclip sealing element -5-.
– Remove old combustion chamber ring seal -6- ⇒ page 364 .

Renewing combustion chamber ring seal (teflon ring seal)

– Carefully remove old teflon ring -arrow- using suitable tools
(e.g. cut open ring using razor blade, or prise open ring with
small screwdriver and then pull off forwards). It is important to
ensure that the groove and the continuous ridge in the bottom
of the groove are not damaged.
Note
The injector must be renewed if the groove is damaged.
Installing
Note
♦ Renew combustion chamber ring seal and O-ring.

♦ Renew spacer ring if damaged.
♦ Lightly lubricate O-rings for injectors with clean engine oil.
– Fit assembly cone - T10133/5- with new combustion chamber

ring seal -1- onto injector -2-.
– Push combustion chamber ring seal onto assembly cone -

T10133/6- as far as it will go using assembly sleeve -
T10133/5- .
– Turn assembly sleeve - T10133/6- upside down and push

combustion chamber ring seal into groove.

Note
The combustion chamber ring seal is widened when it is pushed

onto the injector. After pushing it on, it therefore has to be com‐
pressed again. This is done in two stages, as described below.
– Push calibration sleeve - T10133/7- onto injector as far as it

will go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/7- off again by turning it in the
opposite direction.
– Push calibration sleeve -T10133/8- onto injector as far as it will

go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve - T10133/8- off again by turning it in the
opposite direction.
– Fit parts from repair kit onto injector -3-:
1 - Radial compensation element
4 - Spacer ring
5 - O-ring
6 - Support ring
– Clip radial compensation element -1- into support ring -2-.

– Fit parts from repair kit onto injector -1-:
2 - Spacer ring
3 - O-ring
4 - Support ring
5 - Sealing washer
All injectors:
– When re-installing an injector, clean any combustion residue
off groove for combustion chamber ring seal and injector stem
with a clean cloth.
– To make it easier to install injector in fuel rail, lubricate new O-
ring lightly with clean engine oil before installing it.
Note
♦ The combustion chamber ring seal on the injector must not be

oiled or greased.
♦ Make sure that there is no cleaning fluid or oil in the holes in
the cylinder head when installing the injectors.
Installing
– Clean bore in cylinder head with nylon cylinder brush -
T10133/4- .
– Lubricate new O-ring lightly with clean engine oil before in‐
stalling.
– Use assembly tool -T10133/9- to insert injector as far as it will

go into hole in cylinder head; note correct installation position.
• Electrical connector of injector must engage in recess in cyl‐
inder head.
Note
It should be possible to insert the injector easily. If necessary wait

until the combustion chamber ring seal has contracted sufficient‐
ly.
– Check that injector is seated correctly in cylinder head:

• Electrical connector of injector must engage in recess in cyl‐
inder head.
The remaining installation steps are carried out in the reverse se‐
quence.
– Install intake manifold (bottom section) ⇒ page 358 .

4 High-pressure pump
⇒ “4.1 Exploded view - high-pressure pump”, page 367
⇒ “4.2 Removing and installing high-pressure pipe”, page 368
⇒ “4.3 Removing and installing high-pressure pumps”,
page 370
⇒ “4.4 Removing and installing fuel pressure sender G247 / fuel
pressure sender 2 G624 ”, page 372
4.1 Exploded view - high-pressure pump
1 - High-pressure pipe
⇒ page 368
❑ Connections must not
be damaged
❑ Do not alter shape
❑ Lubricate thread lightly
with engine oil
2 - Bolt
❑ 3x
❑ Renew
❑ 7 Nm + 90°
3 - Union nut
❑ Connections must not
be damaged
❑ Lubricate thread lightly
with engine oil
❑ 25 Nm
4 - Connection
❑ Tighten to 40 Nm
❑ Check tightening torque
of connecting piece be‐
fore installing high-pres‐
sure pipe
5 - High-pressure pump
⇒ page 370
6 - Bolt
❑ 22 Nm
7 - Plug
❑ Renew
❑ 15 Nm
8 - O-ring
❑ Renew
❑ Lubricate lightly with clean engine oil
9 - Roller tappet
10 - Connection
❑ Tighten to 40 Nm
4. High-pressure pump 367

❑ Check tightening torque of connecting piece before installing fuel supply line
11 - Union nut
❑ Connections must not be damaged
❑ 25 Nm
12 - Fuel supply line
4.2 Removing and installing high-pressure

pipe
♦ Torque wrench - V.A.G 1331-
♦ Open end spanner insert, AF 17 - V.A.G 1331/6-
Removing
Note
The following description is for removing and installing the high-

pressure pipe on the left side. The procedure on the right side is
similar.



– Remove bolt -1- and union nut -4- and move fuel supply line
to one side.
WARNING

– Remove bolts -2 and 6- and union nuts -3 and 5- and detach

high-pressure pipe.
Note
Do not attempt to bend high-pressure pipe to a different shape.
Installing
Note
♦ The connections of the high-pressure pipe must not be dam‐

aged.
♦ Do not attempt to bend high-pressure pipe to a different shape.
– Lubricate thread of union nut lightly with engine oil.

– First tighten union nut by hand until it makes contact, making

sure that high-pressure pipe is not under tension.
– Tighten bolt for retainer.
– Tighten union nut with torque wrench - V.A.G 1331- and open
end spanner insert, AF 17 - V.A.G 1331/6- ; to do so, coun‐
terhold at hexagon flats of threaded connection on fuel rail with
an open-end spanner.
4.3 Removing and installing high-pressure

pumps
Removing
Note
The following description is for removing and installing the high-

pressure pump on the left side.

WARNING

– Remove high-pressure pipes from high-pressure pump.


– Carefully pull out high-pressure pump -1-. It is possible that
the roller tappet may remain lodged inside.
Note
♦ Do not bend fuel pipes to a different shape.

♦ Do NOT bend open retaining clamps for fuel pipe.
♦ If one of the retaining clamps has been bent open or the fuel
pipe has to be renewed, the retaining clamps must also be
renewed.
Installing
Note
♦ Renew O-ring for high-pressure pump.

♦ The connections of the high-pressure pipes must not be dam‐
aged.
Note
♦ The connections of the high-pressure pipe must not be dam‐

aged.
♦ Do not bend fuel pipes to a different shape.
♦ Do NOT bend open retaining clamps for fuel pipe.
♦ If one of the retaining clamps has been bent open or the fuel
pipe has to be renewed, the retaining clamps must also be
renewed.
– Renew O-ring for high-pressure pump.
– Check roller tappet -1- for damage and renew if necessary.

– Lightly lubricate roller tappet with oil and fit in cylinder head so
that guide -2- is in correct position -arrow-.
– Fit high-pressure pump and press downwards in guide as far
as stop.

– Now tighten bolts -arrows- hand-tight in small steps.

– Then initially tighten securing bolts alternately to 5 Nm (do not
tilt high-pressure pump).
Note
The high-pressure pump can be damaged if it is tightened too

much on one side (keep it straight).
• Final tightening torque for securing bolts

– Install high-pressure pipe ⇒ page 368 .
Note
Check fuel system for leaks.
4.4 Removing and installing fuel pressure

sender - G247- / fuel pressure sender 2
- G624-
Removing
Note
The following description is for removing and installing the fuel

pressure sender 2 - G624- on the left side.


– Unplug electrical connector -arrow-.

– Unscrew fuel pressure sender.
Installing
⇒ “3.4 Exploded view - intake manifold (bottom section), fuel
rail and injectors”, page 356

5 Lambda probes
⇒ “5.1 Overview - Lambda probes”, page 374
⇒ “5.2 Removing and installing Lambda probes”, page 375
5.1 Overview - Lambda probes

Lambda probe - G39- (before catalytic converter) and Lambda
probe after catalytic converter - G130- for cylinder bank 1 (right-
side)
1- Lambda probe after catalytic converter - G130-
2- Lambda probe - G39- (before catalytic converter)
• Tightening torque: 55 Nm
Lambda probe 2 - G108- (before catalytic converter) and Lambda

probe 2 after catalytic converter - G131- for cylinder bank 2 (left-
side)
1- Lambda probe 2 - G108- (before catalytic converter)
2- Lambda probe 2 after catalytic converter - G131-
• Tightening torque: 55 Nm
Electrical connectors of Lambda probes on cylinder bank 1 (right-

side)

Electrical connectors of Lambda probes on cylinder bank 2 (left-

side)
Note
♦ Threads of new Lambda probes are already coated with as‐

sembly paste; the paste must not get into the slots on the probe
body.
♦ In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the Lambda probe body. High-temperature paste ⇒
Parts catalogue
♦ When installing, the Lambda probe wire must always be reat‐
tached at the same locations to prevent it from coming into
contact with the exhaust pipe.
5.2 Removing and installing Lambda

probes
♦ Lambda probe open ring spanner set - 3337-
Removing
– R8 Spyder: Remove service flap ⇒ Rep. gr. 55 .
– R8 GT: Remove engine compartment trim panel on relevant
Lambda probe - G39- (before catalytic converter) and Lambda
probe after catalytic converter - G130- for cylinder bank 1 (right-
side)
– Detach appropriate electrical connector from bracket and un‐
plug:
5. Lambda probes 375

– Unscrew Lambda probe - G39- -2- using a tool from Lambda

probe open ring spanner set - 3337- .
– Unscrew Lambda probe after catalytic converter - G130- -1-
using a tool from Lambda probe open ring spanner set - 3337- .
Lambda probe 2 - G108- (before catalytic converter) and Lambda

probe 2 after catalytic converter - G131- for cylinder bank 2 (left-
side)
– Detach appropriate electrical connector from bracket and un‐
plug:

Note
For illustration purposes, the installation position is shown with

the engine removed.
– Unscrew Lambda probe 2 - G108- -1- using a tool from Lamb‐

da probe open ring spanner set - 3337- .
– Unscrew Lambda probe 2 after catalytic converter - G131-
-2- using a tool from Lambda probe open ring spanner set -
3337- .
Installing
⇒ “5.1 Overview - Lambda probes”, page 374
Note
♦ Threads of new Lambda probes are already coated with as‐

sembly paste; the paste must not get into the slots on the probe
body.
♦ In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the Lambda probe body. High-temperature paste ⇒
Parts catalogue
♦ When installing, the Lambda probe wire must always be reat‐
tached at the same locations to prevent it from coming into
contact with the exhaust pipe.

– R8 Spyder: Install service flap ⇒ Rep. gr. 55 .
5. Lambda probes 377

6 Engine control units

⇒ “6.1 Exploded view - engine control unit”, page 378
⇒ “6.2 Wiring and component check with test box V.A.G 1598/42
”, page 378
⇒ “6.3.1 Removing and installing engine/motor control unit J623
”, page 381
⇒ “6.3.2 Removing and installing engine control unit 2 J624 ”,
page 383
6.1 Exploded view - engine control unit
1 - Bracket
❑ For engine control unit
2 - Bolt
❑ 9 Nm
3 - Protective housing
❑ 2 parts
4 - Shear bolt
5 - Retaining clip
❑ For engine control unit
6 - Nut
❑ 7 Nm
7 - Engine control unit
engine control unit -
J623- ⇒ page 381
engine control unit 2 -
J624- ⇒ page 383
6.2 Wiring and component check with test

box - V.A.G 1598/42-
♦ Adapter cable - V.A.G 1598/39-1-

♦ Adapter cable - V.A.G 1598/39-2-
♦ Test box - V.A.G 1598/42-
6. Engine control units 379

Note
♦ The test box has 105 sockets. The connecting cable can be
disconnected from the test box. This means that only the cable
(and not the test box) has to be purchased for future engine
control units with different types of connectors.
♦ The smaller of the two connectors on the engine control unit
has the contacts 1 to 60. The larger of the two connectors has
the contacts 1 to 94.
♦ To carry out tests on the 60-pin wiring harness connector, the
adapter cable - V.A.G 1598/39-1- is connected to connector
“A” on the test box. For components connected to 60-pin wiring
harness connector ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
♦ To carry out tests on the 94-pin wiring harness connector, the
adapter cable - V.A.G 1598/39-2- must be connected to con‐
nectors “A” and “B” on the test box. For components connec‐
ted to 94-pin wiring harness connector ⇒ Current flow
♦ The test box - V.A.G 1598/42- is designed so it can be con‐
nected both to the wiring harness for the engine control unit
and to the engine control unit itself at the same time.
♦ The advantage of this is that the electronic engine control sys‐
tem remains fully functional when the test box is connected
(for example, for measuring signals when the engine is run‐
ning).
♦ The relevant test procedure will state whether it is necessary
to also connect the engine control unit to the test box.

The relevant engine control unit has to be removed before the
connectors can be unplugged.
♦ Removing and installing engine control unit - J623-
⇒ page 381
♦ Removing and installing engine control unit 2 - J624-
⇒ page 383
Caution
To prevent damage to electronic components, select appro‐

priate measuring range before connecting measuring leads
and observe test requirements.

– Connect the test box - V.A.G 1598/42- to wiring harness with

adapter cable - V.A.G 1598/39-1- or adapter cable - V.A.G
1598/39-2- . Connect earth clip of test box to negative terminal
of battery. The instructions for performing the individual tests
indicate whether or not the engine control unit itself also needs
to be connected to the test box.
– Carry out test as described in relevant repair procedure.
Installing engine control unit
Installation is performed in the reverse sequence.
– After installation, the locking plate must be re-fitted on the cor‐
responding engine control unit.
– Clean threaded holes for shear bolts to remove any residue
from locking fluid. This can be done using a thread tap.
– Always use new shear bolts.
– Interrogate event memory and erase if necessary ⇒ Vehicle
diagnostic tester.
Note
After completion of the Guided Fault Finding routine, the tester

will attempt to erase the event memories of all control units. If this
is not successful, the remaining events registered in the event
memories must be rectified before all event entries can be erased.
6.3 Removing and installing engine control

units
⇒ “6.3.1 Removing and installing engine/motor control unit J623
”, page 381
⇒ “6.3.2 Removing and installing engine control unit 2 J624 ”,
page 383
6.3.1 Removing and installing engine/motor

control unit - J623-
♦ Hot air blower - VAS 1978/14A- -item 1- with shrink element
for hot air blower - VAS 1978/15A- -2- from wiring harness
repair set - VAS 1978B-
♦ Small, commercially available mole grips -3-

Note
♦ The engine control unit -1- is bolted to a protective casing

-2 and 5-. To make it more difficult to unscrew the shear bolts
-4- for locking plate -2-, their threads have been coated with
locking fluid.
♦ The metal locking plate has to be removed before the con‐
nectors can be unplugged from the engine control unit (e.g. to
connect the test box or renew the engine control unit).
Removing
– When renewing engine control unit, select diagnosis object
“Replace engine control unit” in “Guided Functions” mode of
⇒ Vehicle diagnostic tester.
– Switch off ignition and remove ignition key.
R8 Coupé and R8 GT
– Remove engine compartment trim panel (right-side) ⇒ Rep.
gr. 53 .
– Unscrew the nuts from the four retaining clips for engine con‐
trol unit - J623- and swivel the retaining clips to the side.
– Take out engine control unit - J623- -3-.
R8 Spyder
– Detach cover -1-.
– Unscrew bolts -arrows- and remove together with retaining
clips.
– Remove engine control unit - J623- .

To help prevent unauthorised access to the connectors on the
engine control unit, the engine control unit -1- is bolted to a pro‐
tective housing -5- by means of shear bolts -3 and 4- and a locking
plate -2-.
♦ The threads of the two shear bolts -4- which are not screwed
into the engine control unit are secured with locking fluid. To
unscrew these two bolts, the threads must therefore be heated
with the hot air blower.
♦ The threads of the two shear bolts -3- which are screwed into
the engine control unit are not secured with locking fluid. Do
not apply heat to the threads in the control unit housing; this
is not necessary and would cause overheating of the control
unit.

– Select settings on hot air blower -4- as shown in illustration,

i.e. set temperature potentiometer -2- to maximum heat output
and two-stage air flow switch -3- to position 3.
WARNING
The shear bolts and protective housing also become very hot
when heating the threads of the locking mechanism. Take care
to avoid burns. It is also important to ensure that only the thread
is heated and none of the surrounding components if at all
possible. These should be covered if necessary.
Grinding or drilling is not permitted.
– Apply heat to the threads of the shear bolts on the connector

side for approx. 25 to 30 seconds.
– Unscrew shear bolts using mole grips (see arrow in illustra‐

tion).
– The two shear bolts screwed into the engine control unit do
not need to be heated. They should be removed without being
heated.
– Detach protective housing from control unit connectors.
– Release connectors on engine control unit - J623- and unplug
connectors.
Installing
– After installation, the protective housing must be re-fitted on
the engine control unit - J623- .
After installing a new engine control unit, the following operation
must be performed:
– Activate engine control unit using ⇒ Vehicle diagnostic tester
in “Guided Functions” mode, “Replace engine control unit”.
6.3.2 Removing and installing engine control

unit 2 - J624-

♦ Hot air blower - VAS 1978/14A- -item 1- with shrink element

for hot air blower - VAS 1978/15A- -2- from wiring harness
repair set - VAS 1978B-
♦ Small, commercially available mole grips -3-
Note
♦ The engine control unit -1- is bolted to a protective casing

-2 and 5-. To make it more difficult to unscrew the shear bolts
-4- for locking plate -2-, their threads have been coated with
locking fluid.
♦ The metal locking plate has to be removed before the con‐
nectors can be unplugged from the engine control unit (e.g. to
connect the test box or renew the engine control unit).
Removing
– When renewing engine control unit, select diagnosis object
“Replace engine control unit” in “Guided Functions” mode of
⇒ Vehicle diagnostic tester.
– Switch off ignition and remove ignition key.
R8 Coupé and R8 GT
– Remove engine compartment trim panel (left-side) ⇒ Rep. gr.
53 .
– Unscrew the nuts from the four retaining clips for engine con‐
trol unit 2 - J624- and swivel the retaining clips to the side.
– Take out engine control unit 2 - J624- -3-.
R8 Spyder
– Detach cover -1-.
– Unscrew bolts -arrows- and remove together with retaining
clips.
– Remove engine control unit 2 - J624- .


To help prevent unauthorised access to the connectors on the
engine control unit, the engine control unit -1- is bolted to a pro‐
tective housing -5- by means of shear bolts -3 and 4- and a locking
plate -2-.
♦ The threads of the two shear bolts -4- which are not screwed
into the engine control unit are secured with locking fluid. To
unscrew these two bolts, the threads must therefore be heated
with the hot air blower.
♦ The threads of the two shear bolts -3- which are screwed into
the engine control unit are not secured with locking fluid. Do
not apply heat to the threads in the control unit housing; this
is not necessary and would cause overheating of the control
unit.
– Select settings on hot air blower -4- as shown in illustration,

i.e. set temperature potentiometer -2- to maximum heat output
and two-stage air flow switch -3- to position 3.
WARNING
The shear bolts and protective housing also become very hot
when heating the threads of the locking mechanism. Take care
to avoid burns. It is also important to ensure that only the thread
is heated and none of the surrounding components if at all
possible. These should be covered if necessary.
Grinding or drilling is not permitted.
– Apply heat to the threads of the shear bolts on the connector

side for approx. 25 to 30 seconds.

– Unscrew shear bolts using mole grips (see arrow in illustra‐

tion).
– The two shear bolts screwed into the engine control unit do
not need to be heated. They should be removed without being
heated.
– Detach protective housing from control unit connectors.
– Release connectors on engine control unit 2 - J624- and un‐
plug connectors.
Installing
– After installation, the protective housing must be re-fitted on
the engine control unit 2 - J624- .
After installing a new engine control unit, the following operation
must be performed:
– Activate engine control unit using ⇒ Vehicle diagnostic tester
in “Guided Functions” mode, “Replace engine control unit”.

26 – Exhaust system
1 Silencers
⇒ “1.1 Exploded view - silencers”, page 387
⇒ “1.2 Exploded view - heat shields”, page 389
⇒ “1.3 Removing and installing silencers”, page 390
⇒ “1.4 Renewing exhaust pipe with exhaust flap”, page 391
⇒ “1.5 Checking exhaust system for leaks”, page 392
1.1 Exploded view - silencers
1 - Exhaust manifold with cat‐

alytic converter
⇒ page 396
2 - Clamp
⇒ page 388 ,
⇒ page 388
❑ 7 Nm
3 - Bolt
❑ 25 Nm
4 - Sleeve
5 - Bracket
6 - Bolt
❑ 25 Nm
7 - Spacers
❑ Not fitted on all versions
⇒ Electronic parts cata‐
logue
8 - Vacuum hose
❑ To vacuum unit for ex‐
haust flap
9 - Exhaust pipe with exhaust
flap
10 - Bracket
11 - Bolt
❑ 25 Nm
12 - Spacers
❑ Not fitted on all versions ⇒ Electronic parts catalogue
13 - Bolt
❑ 25 Nm
1. Silencers 387
14 - Washer
15 - Clamp
❑ Tighten bolted connections evenly
❑ 30 Nm
16 - Silencer
❑ Renewing exhaust pipe with exhaust flap ⇒ page 391
Installation position of clamps

1- Clamp (left-side) - installation angle ⇒ page 388
2- Clamp (right-side) - installation angle: threads in vertical po‐
sition
Note
Viewed from rear as seen in direction of travel.
Installation position of clamp (left-side)

• Position clamp (left-side) -1- so that distance -a- = 10 mm is
maintained between tool (socket wrench) -2- and body.
388 Rep. gr.26 - Exhaust system

1.2 Exploded view - heat shields
1 - Bolt or nut
❑ Depending on version
❑ 6 Nm
2 - Bolts
❑ 1.5 Nm
3 - Heat shield (bottom right)
4 - Heat shield for wheel hous‐
ing liner (rear right)
5 - Bolt
❑ 6 Nm
6 - Heat shield (front)
7 - Silencer
8 - Heat shield for tail light
(right-side)
9 - Heat shield (rear)
10 - Bolt
❑ 6 Nm
11 - Washer
12 - Spring
13 - Retaining clip
14 - Speed nut
15 - Clip
16 - Bolt
❑ 1.5 Nm
17 - Heat shield for tail light
(left-side)
18 - Speed nut
❑ 2 Nm
19 - Speed nut
20 - Bolt
21 - Heat shield for wheel housing liner (rear left)
22 - Bolt
❑ 4 Nm
23 - Bolt
❑ 1.5 Nm
24 - Speed nut
❑ 2 Nm
25 - Speed nut
26 - Heat shield (bottom left)
27 - Nut
❑ 2 Nm
1. Silencers 389
1.3 Removing and installing silencers

Removing
– Remove wide air cleaner housing/both air cleaner housings
⇒ page 345 .
Vehicles with secondary air system:
– Remove secondary air pump motor - V101- and, if fitted, sec‐
ondary air pump motor 2 - V189- ⇒ page 405 .
– Remove tail lights (left and right) ⇒ Electrical system; Rep. gr.
94 .
– Remove bolts -arrows- on heat shield.
– Loosen nuts -1, 3- and remove bolt -4- on both sides.

– Release clamp -1- on exhaust pipe (left-side), pivot clamp and

Note


Note

lencer.

– Unscrew bolts -2- and -4- and remove sleeve -3-.
Installing
Tightening torques
• ⇒ “1.1 Exploded view - silencers”, page 387
• ⇒ “1.2 Exploded view - heat shields”, page 389
Note
Renew gaskets and self-locking nuts.
– Note installation position of clamps ⇒ page 388 ,

⇒ page 388 .
– Install tail lights ⇒ Electrical system; Rep. gr. 94 .
– Install rear impact bar ⇒ Rep. gr. 63 .
1.4 Renewing exhaust pipe with exhaust

flap
♦ Chain pipe cutter - VAS 6254-
1. Silencers 391
Procedure
– Remove silencer ⇒ page 390 .
– Detach heat shield for air cleaner housing from silencer.
– Cut through exhaust pipe with exhaust flap -2- at a right angle
at position marked -1- using chain pipe cutter - VAS 6254-
(note dimension -a-).
• Dimension -a- = 66 mm
– Position centre of clamp -arrow- over cutting location and ap‐

ply slight tension.
• Bolt connections face front.
• Nuts face downwards.
– Align exhaust pipe with exhaust flap -1- parallel to exhaust

pipe -2- -arrows-, maintaining distance -a- from centre of each
pipe.
• Dimension -a- = 90 mm
– Tighten clamp.
Tightening torques
• ⇒ “1.1 Exploded view - silencers”, page 387
1.5 Checking exhaust system for leaks

– Start the engine and run at idling speed.
– Plug tailpipes (e. g. with rags or stopper) and leave plugged
until the check is complete.
– Listen for noise at connection points (cylinder head/exhaust
manifold, exhaust manifold/silencer, etc.) to locate any leaks.
– Rectify any leaks that are found.

2 Exhaust manifold
⇒ “2.1 Exploded view - exhaust manifold”, page 393
⇒ “2.2 Removing and installing exhaust manifold”, page 396
2.1 Exploded view - exhaust manifold
Note
The illustration shows the left-side exhaust manifold.
1 - Exhaust manifold with cat‐

alytic converter
❑ Mounting components:
left-side ⇒ page 394 /
⇒ page 395 , right-side
⇒ page 395 /
⇒ page 395
❑ Removing and instal‐
ling: left-side
⇒ page 396 , right-side
⇒ page 397
2 - Nut
❑ Renew
❑ Coat with high-tempera‐
ture paste; for high-tem‐
perature paste refer to
⇒ Electronic parts cata‐
logue
tightening sequence:
exhaust manifold (left-
side) ⇒ page 394 ; ex‐
haust manifold (right-
side) ⇒ page 394
3 - Gasket
❑ Renew
4 - Mounting
❑ Components of exhaust
mountings (left-side)
⇒ page 394 /
⇒ page 395
❑ Components of exhaust
mountings (right-side)
⇒ page 395 /
⇒ page 395
5 - Bolt
❑ Tightening torque ⇒ page 394 / ⇒ page 395 and ⇒ page 395 / ⇒ page 395
6 - Bolt
❑ Tightening torque ⇒ page 394 / ⇒ page 395 and ⇒ page 395 / ⇒ page 395
7 - Mounting strip
❑ Remains installed when exhaust manifold is removed
8 - Nut
❑ Renew
2. Exhaust manifold 393

❑ Coat with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
❑ 25 Nm
Exhaust manifold (left-side) - tightening torque and sequence

– Tighten nuts in 3 stages in the sequence shown:
Stage Nuts Tightening torque
1. -1 … 6- Screw in by hand until nuts make con‐
tact with exhaust manifold
2. -1 … 6- 20 Nm
3. -1 … 6- 30 Nm
Exhaust manifold (right-side) - tightening torque and sequence

– Tighten nuts in 3 stages in the sequence shown:
Stage Nuts Tightening torque
1. -1 … 6- Screw in by hand until nuts make con‐
tact with exhaust manifold
2. -1 … 6- 20 Nm
3. -1 … 6- 30 Nm
Components of exhaust mountings (left-side) on vehicles with

1- Bolt, 25 Nm
2- Washer
3- Compression spring
4- Spacer sleeve
5- Bolt, 9 Nm
6- Bracket
7- Bolt, 9 Nm
8- Spacer sleeve
9- Buffer
10 - Bracket
11 - Spacer sleeve
12 - Bolt, 45 Nm

Components of exhaust mountings (left-side) on vehicles with

dual clutch gearbox 0BZ
1- Bolt, 25 Nm
2- Spacer sleeve
3- Spacer sleeve
4- Bracket
6- Washer
7- Bolt, 25 Nm
8- Bracket
9- Bolt, 25 Nm
10 - Spacer sleeve
11 - Buffer
Components of exhaust mountings (right-side) on vehicles with

1- Bolt, 10 Nm
2- Bracket
3- Bolt, 10 Nm
4- Spacer sleeve
6- Washer
7- Bolt, 25 Nm
8- Bolt, 45 Nm
9- Washer
10 - Spacer sleeve
11 - Bracket
12 - Buffer
13 - Spacer sleeve
Components of exhaust mountings (right-side) on vehicles with

dual clutch gearbox 0BZ
1- Nut, 45 Nm
2- Spacer sleeve
3- Bracket
4- Buffer
5- Spacer sleeve
6- Bolt
7- Bolt, 25 Nm
8- Washer
10 - Spacer sleeve

2.2 Removing and installing exhaust mani‐

fold
⇒ “2.2.1 Removing and installing exhaust manifold (left-side) with
catalytic converter”, page 396
⇒ “2.2.2 Removing and installing exhaust manifold (right-side)
with catalytic converter”, page 397
2.2.1 Removing and installing exhaust mani‐

fold (left-side) with catalytic converter
Removing

– Remove bolt -arrow- at bracket for catalytic converter (left-
side).

– Remove bolt -1- at bracket for catalytic converter (left-side).
Note
Disregard -item 2-.


– Remove nuts in the sequence -6 ... 1-.
– Remove exhaust manifold (left-side) with catalytic converter.
Installing
Tightening torques
• ⇒ Fig. ““Components of exhaust mountings (left-side) on ve‐
hicles with manual gearbox/R tronic gearbox 086”“ ,
page 394
• ⇒ Fig. ““Components of exhaust mountings (left-side) on ve‐
hicles with dual clutch gearbox 0BZ”“ , page 395
Note
Renew gasket and self-locking nuts.
– Fit gasket onto threaded pins.

– Fit exhaust manifold in mounting strips and tighten
⇒ page 394 .
2.2.2 Removing and installing exhaust mani‐

fold (right-side) with catalytic converter
Removing


– Remove bolts -1- and -2- and detach bracket (right-side) for
catalytic converter.

– Remove bolt -2- at bracket for catalytic converter (right-side).
Note
Disregard -item 1-.

– Remove nuts in the sequence -6 ... 1-.
– Remove exhaust manifold (right-side) with catalytic converter.
Installing
Tightening torques
• ⇒ Fig. ““Components of exhaust mountings (right-side) on ve‐
hicles with manual gearbox/R tronic gearbox 086”“ ,
page 395
• ⇒ Fig. ““Components of exhaust mountings (right-side) on ve‐
hicles with dual clutch gearbox 0BZ”“ , page 395
– Fit gasket onto threaded pins.
– Fit exhaust manifold in mounting strips and tighten
⇒ page 394 .

3 Secondary air system

⇒ “3.1 Exploded view - secondary air system”, page 399
⇒ “3.2 Removing and installing secondary air pump motor V101 /
V189 ”, page 405
⇒ “3.3 Checking combination valves for secondary air system for
correct operation and leakage”, page 407
⇒ “3.4 Removing and installing combination valve for secondary
air system (left-side)”, page 409
⇒ “3.5 Removing and installing combination valve for secondary
air system (right-side)”, page 411
⇒ “3.6 Removing and installing senders for secondary air pres‐
sure G609 / G610 ”, page 412
3.1 Exploded view - secondary air system

⇒ “3.1.1 Exploded view - secondary air system, R8 Coupé”, page
399
⇒ “3.1.2 Exploded view - secondary air system, R8 Spyder”, page
403
3.1.1 Exploded view - secondary air system, R8 Coupé

Cylinder bank 1 (right-side)
3. Secondary air system 399

1 - Gasket
❑ Renew
2 - Connecting pipe for secon‐
dary air
❑ To cylinder head
3 - Bolt
❑ 9 Nm
4 - Bolt
❑ 9 Nm
5 - Gasket
❑ Renew
6 - Combination valve for sec‐
ondary air system (left-side)
❑ Fitting location: at rear
of cylinder head (left-
side)
⇒ page 409
7 - Bolt
❑ 9 Nm
8 - Connection
❑ For combination valve
for secondary air sys‐
tem
9 - O-ring
❑ Renew
10 - Secondary air hose
❑ From secondary air
pump motor 2 - V189- to
combination valve for secondary air system
11 - Bolt
❑ 9 Nm
12 - Secondary air pump motor 2 - V189-
13 - Air cleaner
❑ For secondary air pump motor 2 - V189-
14 - Hose clip
❑ Use correct type (as original equipment) ⇒ Electronic parts catalogue
15 - O-ring
❑ Renew
❑ From air cleaner to secondary air pump motor 2 - V189-
17 - Nut
❑ 9 Nm
18 - Bracket
❑ For secondary air pump motor 2 - V189-

19 - Rubber mounting
20 - O-ring
❑ Renew
21 - Vacuum hose
❑ From secondary air inlet valve - N112- to combination valves for secondary air system
22 - Vacuum hose
23 - Bolt
❑ 9 Nm
24 - Bracket
❑ For secondary air inlet valve - N112-
❑ Fitting location: beneath intake manifold
27 - O-ring
❑ Renew
Cylinder bank 2 (left-side)

1 - Secondary air inlet valve -

N112-
❑ Fitting location: beneath
intake manifold
2 - Vacuum hose
❑ From secondary air inlet
valve - N112- to combi‐
nation valves for secon‐
dary air system
3 - Bolt
❑ 9 Nm
4 - Bolt
❑ 9 Nm
5 - Bracket
❑ For secondary air pump
motor - V101-
6 - Nut
❑ 9 Nm
7 - Rubber mounting
pump motor - V101- to
combination valve for
secondary air system
9 - Bolt
❑ 9 Nm
10 - Bolt
❑ 9 Nm
- V101-
❑ In engine compartment (front left)
12 - Bolt
❑ 9 Nm
13 - Connection
❑ For combination valve for secondary air system
14 - O-ring
❑ Renew
16 - Combination valve for secondary air system (right-side)
❑ Fitting location: at rear of cylinder head (right-side)
17 - Gasket
❑ Renew
18 - Connecting pipe for secondary air

19 - Gasket
❑ Renew
20 - Bolt
❑ 9 Nm
21 - Bolt
❑ 9 Nm
22 - Vacuum hose
23 - Bracket
24 - Bolt
❑ 9 Nm
3.1.2 Exploded view - secondary air system, R8 Spyder
Note
The diagram shows the secondary air system on cylinder bank 1 (right-side).
1 - Gasket
❑ Renew
2 - Connecting pipe for secon‐
dary air
3 - Bolt
❑ 9 Nm
4 - Bolt
❑ 9 Nm
5 - Gasket
❑ Renew
6 - Combination valve for sec‐
ondary air system (left-side)
❑ Fitting location: at rear
of cylinder head (left-
side)
⇒ page 409
7 - Bolt
❑ 9 Nm
8 - Connection
❑ For combination valve
for secondary air sys‐
tem
9 - O-ring
❑ Renew

pump motor - V101- to

combination valve for secondary air system
11 - Bolt
❑ 9 Nm
12 - O-ring
❑ Renew
13 - O-ring
❑ Renew
❑ From secondary air pump motor 2 - V189- to combination valve for secondary air system
15 - Hose clip
❑ Use correct type (as original equipment) ⇒ Electronic parts catalogue
16 - Air cleaner
❑ For secondary air pump motor
❑ Cylinder bank 1 (right-side): secondary air pump motor - V101- ,
❑ Cylinder bank 2 (left-side): secondary air pump motor 2 - V189-
18 - Rubber mounting
19 - Nut
❑ 9 Nm
20 - Bracket
❑ For secondary air pump motor - V101-
21 - Vacuum hose
❑ From secondary air inlet valve - N112- to combination valves for secondary air system
22 - Vacuum hose
23 - Bolt
❑ 9 Nm
24 - Bracket
❑ Fitting location: beneath intake manifold
26 - Sender for secondary air pressure
❑ Cylinder bank 1 (right-side) sender 1 for secondary air pressure - G609-
❑ Cylinder bank 2 (left-side) sender 2 for secondary air pressure - G610-
27 - O-ring
❑ Renew

3.2 Removing and installing secondary air

pump motor -V101- / -V189-
⇒ “3.2.1 Removing and installing secondary air pump motor V101
- R8 Coupé”, page 405
⇒ “3.2.2 Removing and installing secondary air pump motor 2
V189 - R8 Coupé”, page 406
⇒ “3.2.3 Removing and installing secondary air pump motor
V101 / V189 - R8 Spyder”, page 406
3.2.1 Removing and installing secondary air

pump motor - V101- - R8 Coupé
Removing
gr. 53 .
– Extend spoiler with drive unit ⇒ Owner's Manual .
– Unscrew bolts -arrows- and remove cover -1- for tail light clus‐
ter.
– R8 GT: Remove centre section for bumper cover ⇒ Rep. gr.
63 .

– Remove nuts -arrows-.
– Remove rear right wheel housing liner ⇒ Rep. gr. 66 .


-arrows-.
– Remove nut -1-, detach secondary air pump motor - V101- and
move electrical wiring clear.
Installing
⇒ “3.1.1 Exploded view - secondary air system, R8 Coupé”,
page 399
– Install cover for tail light cluster ⇒ Rep. gr. 66 .
– Install centre section for bumper cover ⇒ Rep. gr. 63 .

pump motor 2 - V189- - R8 Coupé
Removing
– Remove engine compartment trim panel (left-side) ⇒ Rep. gr.
53 .
– Detach hose -1- for secondary air (press release tabs).
– Remove nuts -arrows- and detach secondary air pump.
Installing
⇒ “3.1.1 Exploded view - secondary air system, R8 Coupé”,
page 399

pump motor -V101- / -V189- - R8 Spyder
Removing
Note
The following description is for removing and installing the sec‐

ondary air pump motor 2 - V189- on the left side. The procedure
for the right side is similar.

– Extend spoiler ⇒ Owner's Manual .

– Unscrew bolts -arrows- and remove cover -1- for tail light clus‐
ter.
– Remove rear left wheel housing liner ⇒ Rep. gr. 66 .
-2-.
Installing
⇒ “3.1.2 Exploded view - secondary air system, R8 Spyder”,
page 403
– Install cover for tail light cluster ⇒ Rep. gr. 66 .
3.3 Checking combination valves for secon‐

dary air system for correct operation and
leakage
Procedure
– Remove wide air cleaner housing/both air cleaner housings
⇒ page 345 .

– Detach vacuum hose -2- from combination valve for secon‐

dary air system.
Note
♦ The illustration shows the left-side combination valve for sec‐

ondary air system.
♦ For better accessibility on R8 Spyder vehicles, detach hose at
secondary air pump and not at secondary air combination
valve.
♦ Disregard -items 1, 3, 5-.
– Connect hand vacuum pump - VAS 6213- to vacuum connec‐

tion -1- on relevant combination valve for secondary air sys‐
tem.
– Connect a suitable test hose -2- onto combination valve for
secondary air system.
– Blow lightly into test hose with your mouth (do not use com‐
pressed air).
• The combination valve for secondary air system should be
closed; it should not be possible to blow through the hose.
• The combination valve for secondary air system should open;
it should now be possible to blow through the hose.
– Renew combination valve for secondary air system if valve
does not react as described: left-side ⇒ page 409 , right-side
⇒ page 411 .

3.4 Removing and installing combination

valve for secondary air system (left-
side)
⇒ “3.4.1 Removing and installing combination valve for secondary
air system (left-side) - vehicles with manual gearbox/R tronic
gearbox 086”, page 409
⇒ “3.4.2 Removing and installing combination valve for secondary
air system (left-side) - vehicles with dual clutch gearbox 0BZ”,
page 410
3.4.1 Removing and installing combination

side) - vehicles with manual gearbox/R
tronic gearbox 086
Removing
Note

– R8 GT: Remove engine compartment trim panel (left-side) ⇒
Rep. gr. 53 .
– Remove rear noise insulation ⇒ Rep. gr. 66 .
Caution

gearbox.

– Detach heat shield sleeve -5-.

– Unplug electrical connector -3- and disconnect vacuum hose
-2-.
Note
For better accessibility on R8 Spyder vehicles, detach hose at

secondary air pump and not at secondary air combination valve.
– Unscrew bolts -1- and detach combination valve (left-side) for

Note
The bolts -1- can be accessed from below.
Installing
Note
Renew gasket and O-ring.
– Install rear noise insulation ⇒ Rep. gr. 66 .

– Install engine compartment trim panel (left-side) ⇒ Rep. gr.
53 .
3.4.2 Removing and installing combination

side) - vehicles with dual clutch gearbox
0BZ
Removing
Note

– Remove rear wheel (left-side) ⇒ Wheels and tyres; Rep. gr.
44 .

– Detach heat shield sleeve -5-.

– Unplug electrical connector -3- and disconnect vacuum hose
-2-.
Note
For better accessibility on R8 Spyder vehicles, detach hose at

secondary air pump and not at secondary air combination valve.
– Unscrew bolts -1- and detach combination valve (left-side) for

Note
The bolts -1- can be accessed from below.
Installing
Note
– Install rear wheel (left-side) ⇒ Wheels and tyres; Rep. gr. 44 .

– Install rear noise insulation ⇒ Rep. gr. 66 .
3.5 Removing and installing combination

valve for secondary air system (right-
side)
Removing
Note


– Remove wide air cleaner housing/air cleaner housing (right-
side) ⇒ page 345 .
– R8 GT: Remove engine compartment trim panel (right-side)
⇒ Rep. gr. 53 .
Caution

gearbox.


– Unplug electrical connector -3- and detach vacuum hose -2-.
– Unscrew bolts -1- and detach combination valve (right-side)
for secondary air system.
Installing
Note

– Install engine compartment trim panel (right-side) ⇒ Rep. gr.
53 .
3.6 Removing and installing senders for

secondary air pressure -G609- / -G610-
Removing
– Remove wide air cleaner housing or corresponding air cleaner
housing ⇒ page 345 .


– Carefully press catches outwards -arrows- and detach sender
-1- for secondary air pressure.
Installing
Note
Fit new O-ring.


4 Exhaust flap
⇒ “4.1 Checking vacuum unit for exhaust flap”, page 414
4.1 Checking vacuum unit for exhaust flap

Procedure
R8 Coupé:
gr. 53 .
– Detach vacuum hoses -1- (leading to vacuum unit for exhaust
flap, left-side) and -3- (leading to vacuum unit, right-side) from
T-piece -2-.
– Connect hand vacuum pump - VAS 6213- to corresponding
vacuum hose.
R8 Spyder:
– Remove rear right wheel housing liner ⇒ Rep. gr. 66 .
– Detach vacuum hoses -1- (leading to vacuum unit for exhaust
flap, left-side) and -3- (leading to vacuum unit, right-side) from
T-piece -2-.
– Connect hand vacuum pump - VAS 6213- to corresponding
vacuum hose.


• The linkage should move towards vacuum unit -arrow-.
– Vent vacuum pump.
• The linkage should move out of the vacuum unit -arrow-.
– If linkage does not move, check linkage for ease of movement
and check vacuum unit for leaks.
4. Exhaust flap 415

28 – Ignition system
1 Ignition system
⇒ “1.1 Test data”, page 416
⇒ “1.2 Exploded view - ignition system”, page 416
⇒ “1.3 Removing and installing ignition coils”, page 418
⇒ “1.4 Removing and installing knock sensors G61 / G66 / G198 /
G199 ”, page 419
⇒ “1.5 Removing and installing Hall senders G40 / G163 / G300 /
G301 ”, page 420
1.1 Test data

Engine data 5.2 ltr. / 4-valve engine
Idling speed (not adjustable) 640 ... 840 rpm
Ignition timing Not adjustable (determined by control unit)
Ignition system Multi-coil system with 10 ignition coils (output stages
integrated) connected directly to spark plugs via
spark plug connectors
Spark plugs Designations ⇒ Electronic parts catalogue
Tightening torque ⇒ Maintenance ; Booklet 420
Firing order 1-6-5-10-2-7-3-8-4-9
1.2 Exploded view - ignition system
416 Rep. gr.28 - Ignition system

1 - Connector for ignition coil

❑ 4-pin
2 - Bolt
❑ 10 Nm
3 - 3-pin connector
4 - Hall sender
❑ Hall sender - G40- (cyl‐
inder bank 1)
❑ Hall sender 3 - G300-
(cylinder bank 1)
(cylinder bank 2)
(cylinder bank 2)
⇒ page 420
5 - O-ring
❑ Lubricate lightly with
clean engine oil
6 - Bolt
❑ 20 Nm
❑ The tightening torque in‐
fluences the function of
the knock sensor
7 - Knock sensors
❑ Contact surfaces be‐
tween knock sensor and
cylinder block must be
free of corrosion, oil and
grease
❑ Knock sensor 1 - G61-
(cylinder bank 1)
❑ Knock sensor 2 - G66- (cylinder bank 1)
8 - Spark plug
❑ Remove and install with spark plug socket and extension - 3122 B- ⇒ Maintenance ; Booklet 420
❑ 30 Nm
9 - Ignition coil
❑ Ignition coil 1 with output stage - N70-
1. Ignition system 417

❑ To remove, use puller - T40039-
1.3 Removing and installing ignition coils

♦ Puller - T40039-
Removing
R8 Coupé and R8 GT
– Remove engine compartment trim panel on relevant side ⇒
Rep. gr. 53 .
R8 Spyder
– Remove engine compartment trim ⇒ Rep. gr. 53 .
Cylinder bank 1 (right-side)
– Tie coolant expansion tank up onto hinge for rear lid with cool‐
ant hoses -1, 3 and 4- connected and connector -2- attached.

sion tank.


– Release electrical connectors and unplug connectors from ig‐
nition coils -1 to 5- simultaneously.
Cylinder bank 2 (left-side)

– Release electrical connectors and unplug connectors from ig‐
nition coils -6 to 10- simultaneously.
Both sides (continued)

– Slide puller - T40039- onto ignition coil with output stage, and
pull off ignition coil in direction of -arrow-.
Installing
– Fit all ignition coils loosely into spark plug holes.
– Align ignition coils with connectors and attach all connectors
onto coils simultaneously.
– Press ignition coils onto spark plugs by hand with uniform
pressure (do not use tools).
Tightening torque
Component Nm
Electrical wiring guide for ignition coils to cylin‐ 5
der head cover
1.4 Removing and installing knock sensors

-G61- / -G66- / -G198- / -G199-

♦ Release tool - T40138-
Removing
– Remove corresponding intake manifold (bottom section)
⇒ page 358 .
– Unplug corresponding electrical connector.
1- Knock sensor 4 - G199-
5 - Electrical connector for knock sensor 1 - G61- (orange)
6 - Electrical connector for knock sensor 2 - G66- (green)
7 - Electrical connector for knock sensor 4 - G199- (grey)
8 - Electrical connector for knock sensor 3 - G198- (brown)
– Remove corresponding knock sensor.
Installing
– Install intake manifold (bottom section) ⇒ page 358 .
1.5 Removing and installing Hall senders -

G40- / -G163- / -G300- / -G301-
Removing
Note
♦ The following description is for removing and installing at the

cylinder bank 2 (left-side).
stalling.

Hall sender for exhaust camshaft

• Engine removed
– Remove exhaust manifold ⇒ page 396 .
– Detach heat insulation sleeve.

– Unscrew bolt -1- and detach Hall sender.
Hall sender for inlet camshaft

– Unscrew bolt -2- and detach Hall sender.
Installing
Note
Renew seals and O-rings.
– Install exhaust manifold ⇒ page 396 .
1.6 Removing and installing engine speed

sender - G28-
⇒ “1.6.1 Removing and installing engine speed sender G28 - ve‐
⇒ “1.6.2 Removing and installing engine speed sender G28 - ve‐
hicles with dual clutch gearbox 0BZ”, page 422
1.6.1 Removing and installing engine speed

sender - G28- - vehicles with manual
Removing


– Unscrew bolt -1- and remove engine speed sender - G28- .
Installing
⇒ “1.2 Overview of fitting locations”, page 325
1.6.2 Removing and installing engine speed

sender - G28- - vehicles with dual clutch
gearbox 0BZ
Note
The gearbox input speed sender - G182- is located on the left or

right side of the gearbox, depending on the version.
Removing
– Remove underbody cover ⇒ Rep. gr. 66 .
– Take out gearbox input speed sender - G182- -item 3-.
Installing
♦ Tightening torques: refer to overview of fitting locations
⇒ page 325 .

Manual-Estudio (5 2L)

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Service

Service Department. Technical Information

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Copyright © 2019 Audi AG, Ingolstadt D3E801AE1F3

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

2.3 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

4.1 Exploded view - side radiators and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387

4.1 Checking vacuum unit for exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

♦ The engine code is also included on the vehicle data sticker.

Code letters CTPB CTYA

2 Rep. gr.00 - Technical data

3.1 Safety precautions when working on the fuel supply system

Risk of fire due to escaping fuel

3.2 Safety precautions when working on vehicles with start/stop system

3.3 Safety precautions when working on the cooling system

4 Rep. gr.00 - Technical data

3.5 Safety precautions when working on the ignition system

Risk of damage to components

6 Rep. gr.00 - Technical data

4 General repair instructions

4.1 Rules for cleanliness when working on

4.2 Checking for leaks on vehicle

– Let engine idle with vehicle stationary until oil temperature

4. General repair instructions 7

If leaks are found although the connections have been tightened

– Interrogate entries in event memory ⇒ Vehicle diagnostic test‐

– Assemble vehicle completely in accordance with the proce‐

– Assemble vehicle completely.

4.3 General notes on self-diagnosis

4.4 General notes on ignition system

8 Rep. gr.00 - Technical data

♦ A voltage of at least 11.5 V is required for proper operation of

4.5 Foreign particles in engine

4.6 Contact corrosion

4.7 Routing and attachment of pipes, hoses

4.8 Nuts, bolts

4. General repair instructions 9

♦ Bolts and nuts which secure covers and housings should be

4.9 Identification plates

4.10 Use of impact wrenches

10 Rep. gr.00 - Technical data

4.11 Installing radiators and condensers

4.12 Fitting protective covers on bodywork

– Wash affected parts of body and dry with chamois leather.

4.13 Checking vacuum system

4. General repair instructions 11

♦ Hand vacuum pump - VAS 6213-

12 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

1.1.1 Removing engine - R8 Coupé with manual gearbox/R tronic gearbox

1. Removing and installing engine 13

Special tools and workshop

♦ Adapter - 10 - 222 A /7-

14 Rep. gr.10 - Removing and installing engine

♦ Used oil collection and extraction unit - VAS 6622A- or used

1. Removing and installing engine 15

♦ The engine is removed upwards together with the gearbox.