2007-2013 Audi R8 Engine Service & Repair Manual
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Workshop Manual
Audi R8 2007 ➤
Audi R8 GT 2011 ➤
Audi R8 Spyder 2010 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-
valve), mechanics
Engine ID
BUJ
CMP
A
CTY
A
CTP
A
Edition 01.2013
Service
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList 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
26 - Exhaust 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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2013 Audi AG, Ingolstadt D3E801AE1F3
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Procedure before opening high-pressure section of injection system . . . . . . . . . . . . . . . . 4
3.3 Working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Using testers and measuring instruments during a road test . . . . . . . . . . . . . . . . . . . . . . . . 5
3.6 Working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Rules for cleanliness when working on fuel supply system and injection system . . . . . . . . 6
4.2 Checking for leaks on vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.6 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.7 Fitting protective covers on bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.8 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Placing engine/gearbox assembly on scissor-type assembly platform . . . . . . . . . . . . . . . . 94
1.3 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.4 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.5 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.1 Assembly mountings - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.2 Removing and installing engine mountings with electro-hydraulic engine mounting solenoid
valves N144 / N145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.3 Engine compartment cross member - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.4 Removing and installing engine compartment cross member . . . . . . . . . . . . . . . . . . . . . . 121
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.1 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.1 Poly V-belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.4 Removing and installing bracket for alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.5 Removing and installing vibration damper with poly V-belt pulley . . . . . . . . . . . . . . . . . . . . 139
1.6 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.1 Flywheel - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.2 Renewing ball bearing for crankshaft (gearbox end) - vehicles with manual gearbox/R tronic
gearbox 086 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2.3 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2.4 Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.1 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Audi R8 2007 ➤ , Audi R8 GT 2011 ➤ , Audi R8 Spyder 2010 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve), mechanics - Edition 01.2013
Contents i
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
3.2 Allocation of main bearing shells for new crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3.3 Allocation of main bearing shells on used and machined crankshafts . . . . . . . . . . . . . . . . 156
3.4 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.5 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.6 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.1 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.3 Checking piston bores and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.4 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.1 Timing chain covers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.2 Removing and installing timing chain cover (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.3 Removing and installing timing chain cover (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.4 Removing and installing timing chain cover (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.5 Camshaft timing chains - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.6 Removing timing chains from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.7 Removing and installing camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.8 Drive chain for valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
1.9 Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.10 Drive chain for auxiliary drives - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.11 Removing and installing drive chain for auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.12 Auxiliary drives - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1.13 Renewing oil seal for air conditioner compressor drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
1.14 Renewing oil seal for power steering pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
1.15 Removing and installing spur gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.1 Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.2 Removing and installing cylinder head cover (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.3 Removing and installing cylinder head cover (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
2.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
3.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3.2 Measuring axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.4 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.5 Renewing valve stem oil seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . 234
3.6 Renewing valve stem oil seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . 237
3.7 Checking hydraulic valve compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3.8 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3.9 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3.10 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1 Oil pump and intake module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1.1 Oil pump, intake module - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1.2 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
2 Oil filter housing, engine oil cooler, oil retention valves, spray nozzle valve . . . . . . . . . . . . 249
2.1 Oil filter housing - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.2 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
2.3 Engine oil cooler (top), oil retention valves, spray nozzle valve - exploded view . . . . . . . . 254
2.4 Removing and installing engine oil cooler (top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Audi R8 2007 ➤ , Audi R8 GT 2011 ➤ , Audi R8 Spyder 2010 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve), mechanics - Edition 01.2013
ii Contents
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2.5 Removing and installing mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2.6 Removing and installing oil retention valve “1” and spray nozzle valve . . . . . . . . . . . . . . . . 259
2.7 Removing and installing oil retention valve “2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
2.8 Crankcase breather hoses - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
2.9 Removing and installing crankcase breather hoses “1” and “2” . . . . . . . . . . . . . . . . . . . . 263
2.10 Removing and installing crankcase breather hose “3” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
2.11 Removing and installing crankcase breather hose “4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
2.12 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
2.13 Checking oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
2.14 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
2.15 Removing and installing oil temperature sender 2 G664 . . . . . . . . . . . . . . . . . . . . . . . . . . 271
2.16 Oil reservoir - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
2.17 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 275
2.18 Removing and installing oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
2.19 Engine oil cooler (left-side) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
2.20 Removing and installing engine oil cooler (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
2.21 Removing and installing temperature regulator for engine oil cooler . . . . . . . . . . . . . . . . . . 284
2.22 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
2.23 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
2.24 First filling of engine with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
1.1 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
2 Coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
2.1 Thermostat - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
2.2 Removing and installing thermostat with housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
2.3 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2.4 Coolant pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
2.6 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 304
2.7 Gearbox coolant pump V532 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
2.8 Removing and installing gearbox coolant pump V532 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
3.1 Coolant pipes at front and in centre of vehicle - exploded view . . . . . . . . . . . . . . . . . . . . . . 309
3.2 Coolant pipes (rear) to body - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
3.3 Coolant expansion tank - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
3.4 Fitting coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3.5 Removing and installing large coolant pipe (rear left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3.6 Removing and installing small coolant pipe (rear left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3.7 Removing and installing coolant pipe (rear right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
3.8 Removing and installing coolant pipe (rear right) to ATF cooler . . . . . . . . . . . . . . . . . . . . 318
3.9 Removing and installing coolant pipes located at centre of vehicle . . . . . . . . . . . . . . . . . . 320
3.10 Removing and installing coolant supply pipe (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
3.11 Removing and installing coolant supply pipe (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . 325
3.12 Removing and installing coolant return pipe (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
3.13 Removing and installing coolant return pipe (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
4 Radiators and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
4.1 Side radiators and radiator fans - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
4.2 Removing and installing side radiator with radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
4.3 Radiator (centre) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
4.4 Removing and installing radiator (centre) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Audi R8 2007 ➤ , Audi R8 GT 2011 ➤ , Audi R8 Spyder 2010 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve), mechanics - Edition 01.2013
Contents iii
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
1 Silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
1.1 Silencer - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
1.2 Heat shields - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
1.3 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
1.4 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
2 Exhaust manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
2.1 Exhaust manifold - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
2.2 Removing and installing exhaust manifold (left-side) with catalytic converter . . . . . . . . . . 348
2.3 Removing and installing exhaust manifold (right-side) with catalytic converter . . . . . . . . . . 349
3 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3.1 Secondary air system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3.2 Removing and installing secondary air pump motor V101 / V189 . . . . . . . . . . . . . . . . . . . . 357
3.3 Checking combination valves for secondary air system for correct operation and leakage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
3.4 Removing and installing combination valve for secondary air system (left-side) . . . . . . . . 362
3.5 Removing and installing combination valve for secondary air system (right-side) . . . . . . . . 366
3.6 Removing and installing senders for secondary air pressure G609 / G610 . . . . . . . . . . . . 368
4 Exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
4.1 Checking vacuum unit for exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Audi R8 2007 ➤ , Audi R8 GT 2011 ➤ , Audi R8 Spyder 2010 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve), mechanics - Edition 01.2013
iv Contents
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
00 – Technical data
1 Engine number
(ARL003132; Edition 01.2013)
♦ The engine number (“engine code” and “serial number”) can
be found on top of the cylinder block at the front -arrow-.
♦ Starting with the letter “C”, the engine codes consist of 4 let‐
ters.
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
are stamped on 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 4-character engine code can be found on the type plate
(in versions for some countries only) and on the vehicle data
sticker and the engine control unit.
♦ Fitting locations of the type plate (certain countries only) and
the vehicle data sticker ⇒ Maintenance ; Booklet 420 .
Audi R8 2007 ➤ , Audi R8 GT 2011 ➤ , Audi R8 Spyder 2010 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve), mechanics - Edition 01.2013
1. Engine number 1
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2 Engine data
Code letters BUJ CMPA CTPA CTYA
Capacity ltr. 5.204 5.204 5.204 5.204
Power
output
kW at rpm 386/8000 412/8000 404/8000 386/8000
Torque Nm at rpm 530/6500 540/6500 540/6500 530/6500
Bore ∅ mm 84.5 84.5 84.5 84.5
Stroke mm 92.8 92.8 92.8 92.8
Compression ratio 12.5 12.5 12.5 12.5
RON at least
98
1)
98
1)
98
1)
98
1)
Injection system/ignition system Bosch Motronic 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
1-6-5-10-2-7-3-8-
4-9
Turbocharging/supercharging no no no no
Knock control 4 sensors 4 sensors 4 sensors 4 sensors
Lambda control 2 probes before
catalytic convert‐
er
2 probes after
catalytic convert‐
er
2 probes before
catalytic convert‐
er
2 probes after
catalytic convert‐
er
2 probes before
catalytic convert‐
er
2 probes after
catalytic convert‐
er
2 probes before
catalytic convert‐
er
2 probes after
catalytic convert‐
er
Variable valve timing Inlet
Exhaust
Inlet
Exhaust
Inlet
Exhaust
Inlet
Exhaust
Intake manifold change-over yes yes yes yes
Secondary air system yes yes yes yes
Valves per cylinder 4 4 4 4
•
1)
Unleaded premium RON 95 can also be used, but results in reduced power
Audi R8 2007 ➤ , Audi R8 GT 2011 ➤ , Audi R8 Spyder 2010 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve), mechanics - Edition 01.2013
2 Rep. gr.00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
3 Safety precautions
⇒ “3.1 Working on the fuel system”, page 3
⇒ “3.2 Procedure before opening high-pressure section of injec‐
tion system”, page 4
⇒ “3.3 Working on the cooling system”, page 4
⇒ “3.4 Working on vehicles with start/stop system”, page 5
⇒ “3.5 Using testers and measuring instruments during a road
test”, page 5
⇒ “3.6 Working on the exhaust system”, page 5
3.1 Working on the fuel system
When working on the fuel system note the following warnings:
WARNING
The fuel system operates at extremely high pressure. This can
cause injury.
♦ The fuel pressure in the high-pressure section of the in‐
jection system must be reduced to a residual pressure
prior to opening the system.
♦ Wrap a clean cloth around the connection and carefully
loosen the connection to allow the residual pressure to
dissipate.
– Procedure before opening high-pressure section of injection
system ⇒ Rep. gr. 24 .
WARNING
Escaping fuel can cause a fire risk.
♦ The power supply for the fuel system pressurisation pump
-G6- must be disconnected before opening the fuel sys‐
tem, since -G6- will be activated briefly when the driver's
door is opened with the battery still connected.
– Remove fuse for fuel pump control unit -J538- ; for identifica‐
tion of fuses refer to ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
Observe the following to prevent injuries to persons and damage
to the injection and ignition system:
♦ Always switch off the ignition before connecting or discon‐
necting electrical wiring for the injection or ignition system or
tester cables.
♦ Always switch off ignition before washing engine.
♦ Entries are stored in the event memory of the engine control
units if electrical connectors were unplugged and the engine
was started: Generate readiness code in Guided Func-
tions ⇒ vehicle diagnostic tester .
Audi R8 2007 ➤ , Audi R8 GT 2011 ➤ , Audi R8 Spyder 2010 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve), mechanics - Edition 01.2013
3. Safety precautions 3
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Caution
To prevent irreparable damage to the electronic components
when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .
3.2 Procedure before opening high-pres‐
sure section of injection system
WARNING
♦ The injection system consists of a high-pressure section
(maximum approx. 120 bar) and a low-pressure section
(approx. 6 bar).
♦ The fuel pressure in the high-pressure section must be
reduced to a residual pressure of approx. 6 bar prior to
opening the system. Procedure ⇒ Rep. gr. 24 .
3.3 Working on the cooling system
When working on the cooling system note the following warnings:
WARNING
Hot steam/hot coolant can escape - risk of scalding.
♦ 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.
Overheating can occur if the filler cap is not fitted properly.
♦ The filler cap must engage positively and audibly when it
is closed.
Audi R8 2007 ➤ , Audi R8 GT 2011 ➤ , Audi R8 Spyder 2010 ➤
10-cylinder direct petrol injection engine (5.2 ltr. 4-valve), mechanics - Edition 01.2013
4 Rep. gr.00 - Technical data
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Models covered:
- Audi R8
- Audi R8 GT
- Audi R8 Spyder
The 2007-2013 Audi R8 (R8/R8 GT/R8 Spyder) Service & Repair Manual is an essential resource for maintaining and repairing these high-performance vehicles. Developed by Audi, this manual provides precise instructions and detailed specifications to ensure accurate maintenance and effective troubleshooting.
Inside, you'll find comprehensive procedures for routine maintenance tasks such as oil changes, brake inspections, and tire rotations. It also covers complex repairs including engine diagnostics, transmission servicing, and electrical system troubleshooting. Detailed diagrams, exploded views, and wiring schematics aid in identifying components and understanding their functions, ensuring tasks are performed correctly and efficiently.
This manual is designed for professional technicians and experienced DIY enthusiasts who want to maintain the peak performance and reliability of their Audi R8. By following the detailed guidance provided, you can ensure long-term reliability and optimal performance of your R8, R8 GT, or R8 Spyder, maintaining the excellence that Audi is known for.
Printable: Yes
Language: English
Compatibility: Pretty much any electronic device, incl. PC & Mac computers, Android and Apple smartphones & tablet, etc.
Requirements: Adobe Reader (free)
