2003 Audi RS6 Service & Repair Manual

1998-05 SPECIFICATIONS INDEX A6, S6, RS6 & Allroad (C5 Platform) SPECIFICATIONS INDEX 2.7L (ENGINE CODES: APB, BEL) SPECIFICATIONS INDEX - C5 PLATFORM - 2.7L (ENGINE CODES: APB, BEL) System Specification/Procedure Air Conditioning Service REFRIGERANT CIRCUIT, SERVICING A/C SYSTEM, CHECKING AND TESTING CAPACITIES Torque COMPRESSOR (WITH A/C CLUTCH - N25), REMOVING AND INSTALLING COMPRESSOR WITH A/C COMPRESSOR REGULATOR VALVE - N280, REMOVING AND INSTALLING FROM BRACKET Axle Nut/Hub Nut TORQUE SPECIFICATIONS Battery ON - VEHICLE TESTING Brakes Bleeding Sequence ELECTRONIC STABILITY PROGRAM (WITH ESP 5.3) ELECTRONIC STABILITY PROGRAM (WITH ESP 5.7) Disc Brakes BRAKE SYSTEM IDENTIFICATION DISC BRAKE SPECIFICATIONS Torque TORQUE SPECIFICATIONS Charging Generator NA Torque TORQUE SPECIFICATIONS Drive Belts Adjustment NA Belt Routing DRIVE BELT ROUTING Engine Cooling General Service Specifications NA Radiator Cap Pressure 1.4-1.6 Bar Thermostat R & I COOLANT THERMOSTAT, REMOVING AND INSTALLING Water Pump R & I COOLANT PUMP, REMOVING AND INSTALLING Engine Mechanical Compression COMPRESSION, CHECKING Oil Pressure At 2000 RPM and oil temperature of 80°C: at least 2.0 Bar Overhaul ENGINE CRANKSHAFT/CRANKCASE, DISASSEMBLY AND ASSEMBLY 1998-05 SPECIFICATIONS INDEX A6, S6, RS6 & Allroad (C5 Platform)

2.8L (ENGINE CODE: ATQ) SPECIFICATIONS INDEX - C5 PLATFORM - 2.8L (ENGINE CODE: ATQ) Torque See Appropriate Procedure Fluid Specifications See FLUIDS under MAINTENANCE tab. Flywheel/Flex Plate Torque Flywheel: 60 Nm + 180° Drive Plate: 60 Nm + 90° Fuel System Pressure Specification 3.8 to 4.2 Bar Fuel Pressure Test Procedure FUEL PRESSURE REGULATOR AND RESIDUAL FUEL PRESSURE, CHECKING Ignition Firing Order & Cylinder Identification FIRING ORDER & CYLINDER INDENTIFICATION Ignition Wires (Resistance) Coil-On-Plug Ignition Wires (Routing) Coil-On-Plug Spark Plug TEST DATA, SPARK PLUGS Starting Starter REMOVAL & INSTALLATION (6 - CYL) Torque TORQUE SPECIFICATIONS Wheel Alignment Adjustment Specifications WHEEL ALIGNMENT SPECIFICATIONS Torque FRONT - TORQUE SPECIFICATIONS REAR - TORQUE SPECIFICATIONS (FWD) REAR - TORQUE SPECIFICATIONS (AWD) Wheel & Tire Wheel Lug Nut Torque 120 Nm System Specification/Procedure Air Conditioning Service REFRIGERANT CIRCUIT, SERVICING A/C SYSTEM, CHECKING AND TESTING CAPACITIES Torque COMPRESSOR (WITH A/C CLUTCH - N25), REMOVING AND INSTALLING COMPRESSOR WITH A/C COMPRESSOR REGULATOR VALVE - N280, REMOVING AND INSTALLING FROM BRACKET Axle Nut/Hub Nut TORQUE SPECIFICATIONS Battery ON - VEHICLE TESTING 1998-05 SPECIFICATIONS INDEX A6, S6, RS6 & Allroad (C5 Platform)

Brakes Bleeding Sequence ELECTRONIC STABILITY PROGRAM (WITH ESP 5.3) ELECTRONIC STABILITY PROGRAM (WITH ESP 5.7) Disc Brakes BRAKE SYSTEM IDENTIFICATION DISC BRAKE SPECIFICATIONS Torque TORQUE SPECIFICATIONS Charging Generator NA Torque TORQUE SPECIFICATIONS Drive Belts Adjustment NA Belt Routing DRIVE BELT ROUTING Engine Cooling General Service Specifications DRAINING & FILLING Radiator Cap Pressure 1.4-1.6 Bar Thermostat R & I THERMOSTAT Water Pump R & I WATER PUMP Engine Mechanical Compression ENGINE SPECIFICATIONS Oil Pressure At 2000 RPM and oil temperature of 80°C: at least 2.0 Bar Overhaul OVERHAUL Torque See Appropriate Procedure Fluid Specifications See FLUIDS under MAINTENANCE tab. Flywheel/Flex Plate Torque Flywheel: 60 Nm + 180° Drive Plate: 60 Nm + 90° Fuel System Pressure Specification 3.5 Bar Fuel Pressure Test Procedure FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING Ignition Firing Order & Cylinder Identification FIRING ORDER & CYLINDER INDENTIFICATION Ignition Wires (Resistance) Coil-On-Plug Ignition Wires Coil-On-Plug 1998-05 SPECIFICATIONS INDEX A6, S6, RS6 & Allroad (C5 Platform)

3.0L (ENGINE CODE: AVK) SPECIFICATIONS INDEX - C5 PLATFORM - 3.0L (ENGINE CODE: AVK) (Routing) Spark Plug TEST DATA, SPARK PLUGS Starting Starter REMOVAL & INSTALLATION (6 - CYL) Torque TORQUE SPECIFICATIONS Wheel Alignment Adjustment Specifications WHEEL ALIGNMENT SPECIFICATIONS Torque FRONT - TORQUE SPECIFICATIONS REAR - TORQUE SPECIFICATIONS (FWD) REAR - TORQUE SPECIFICATIONS (AWD) Wheel & Tire Wheel Lug Nut Torque 120 Nm System Specification/Procedure Air Conditioning Service REFRIGERANT CIRCUIT, SERVICING A/C SYSTEM, CHECKING AND TESTING CAPACITIES Torque COMPRESSOR (WITH A/C CLUTCH - N25), REMOVING AND INSTALLING COMPRESSOR WITH A/C COMPRESSOR REGULATOR VALVE - N280, REMOVING AND INSTALLING FROM BRACKET Axle Nut/Hub Nut TORQUE SPECIFICATIONS Battery ON - VEHICLE TESTING Brakes Bleeding Sequence ELECTRONIC STABILITY PROGRAM (WITH ESP 5.3) ELECTRONIC STABILITY PROGRAM (WITH ESP 5.7) Disc Brakes BRAKE SYSTEM IDENTIFICATION DISC BRAKE SPECIFICATIONS Torque TORQUE SPECIFICATIONS Charging Generator NA Torque TORQUE SPECIFICATIONS Drive Belts Adjustment NA Belt Routing DRIVE BELT ROUTING Engine Cooling General Service Specifications NA 1998-05 SPECIFICATIONS INDEX A6, S6, RS6 & Allroad (C5 Platform)

4.2L (ENGINE CODES: ART, AWN, BBD, BCY, BAS) Radiator Cap Pressure 1.4-1.6 Bar Thermostat R & I COOLANT REGULATOR, REMOVING, INSTALLING AND CHECKING Water Pump R & I COOLANT PUMP, REMOVING AND INSTALLING Engine Mechanical Compression COMPRESSION PRESSURE, CHECKING Oil Pressure At Idle: 1.5 Bar At 2000 RPM: At Least 3.0 Bar Overhaul ENGINE, DISASSEMBLING AND ASSEMBLING Torque See Appropriate Procedure Fluid Specifications See FLUIDS under MAINTENANCE tab. Flywheel/Flex Plate Torque Duel-Mass Flywheel: TIGHTENING TORQUES Drive Plate: TIGHTENING TORQUES Fuel System Pressure Specification 3.8-4.2 Bar Fuel Pressure Test Procedure FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING Ignition Firing Order & Cylinder Identification FIRING ORDER & CYLINDER INDENTIFICATION Ignition Wires (Resistance) Coil-On-Plug Ignition Wires (Routing) Coil-On-Plug Spark Plug TECHNICAL DATA, IGNITION Starting Starter REMOVAL & INSTALLATION (6 - CYL) Torque TORQUE SPECIFICATIONS Wheel Alignment Adjustment Specifications WHEEL ALIGNMENT SPECIFICATIONS Torque FRONT - TORQUE SPECIFICATIONS REAR - TORQUE SPECIFICATIONS (FWD) REAR - TORQUE SPECIFICATIONS (AWD) Wheel & Tire Wheel Lug Nut Torque 120 Nm 1998-05 SPECIFICATIONS INDEX A6, S6, RS6 & Allroad (C5 Platform)

SPECIFICATIONS INDEX - C5 PLATFORM - 4.2L (ENGINE CODES: ART, AWN, BBD, BCY, BAS) System Specification/Procedure Air Conditioning Service REFRIGERANT CIRCUIT, SERVICING A/C SYSTEM, CHECKING AND TESTING CAPACITIES Torque DENSO COMPRESSOR, REMOVING AND INSTALLING FROM BRACKET (8 CYL. ENGINE WITH A/C CLUTCH - N25) COMPRESSOR WITH A/C COMPRESSOR REGULATOR VALVE - N280, REMOVING AND INSTALLING FROM BRACKET Axle Nut/Hub Nut TORQUE SPECIFICATIONS Battery ON - VEHICLE TESTING Brakes Bleeding Sequence ELECTRONIC STABILITY PROGRAM (WITH ESP 5.3) ELECTRONIC STABILITY PROGRAM (WITH ESP 5.7) Disc Brakes BRAKE SYSTEM IDENTIFICATION DISC BRAKE SPECIFICATIONS Torque TORQUE SPECIFICATIONS Charging Generator NA Torque TORQUE SPECIFICATIONS Drive Belts Adjustment/Belt Routing RIBBED BELT, REMOVING AND INSTALLING (ART, AWN, BBD) RIBBED BELT, REMOVING AND INSTALLING (BAS) RIBBED BELT, REMOVING AND INSTALLING (BCY) Engine Cooling General Service Specifications COOLING SYSTEM, DRAINING AND FILLING (ART, AWN, BBD) DRAINING OFF AND FILLING WITH COOLANT (BAS) COOLING SYSTEM, DRAINING AND FILLING (BCY) Radiator Cap Pressure 1.4-1.6 Bar Thermostat R & I THERMOSTAT, REMOVING AND INSTALLING (ART, AWN, BBD) THERMOSTAT, REMOVING AND INSTALLING (BAS) COOLING SYSTEM, DRAINING AND FILLING (BCY) Water Pump R & I COOLANT PUMP, REMOVING AND INSTALLING (ART, AWN, BBD) COOLANT PUMP, REMOVING AND INSTALLING (BAS) MECHANICAL COOLANT PUMP, REMOVING AND INSTALLING (BCY) Engine Mechanical Compression COMPRESSION, CHECKING (BAS) COMPRESSION, CHECKING (BCY) 1998-05 SPECIFICATIONS INDEX A6, S6, RS6 & Allroad (C5 Platform)

Oil Pressure ART, AWN, BBD Engines: At Idle RPM: Min.1.0 to 2.5 Bar At 3000 RPM: Min.3.0 to 5.0 Bar BAS Engine (Allroad): At 2000 RPM: Min. 2.0 Bar At 3500 RPM: Min. 3.5 Bar Max: 4.0 Bar Overhaul ENGINE, DISASSEMBLING AND ASSEMBLING (ART, AWN, BBD) ENGINE, DISASSEMBLING AND ASSEMBLING (BAS) ENGINE, DISASSEMBLING AND ASSEMBLING (BCY) Torque See Appropriate Procedure Fluid Specifications See FLUIDS under MAINTENANCE tab. Flywheel/Flex Plate Torque Flywheel: 60 Nm + 180° Drive Plate: 60 Nm + 90° Fuel System Pressure Specification ART, AWN Engines (A6): Approx.4.0 Bar S6, RS6 & Allroad: Approx. 3.5 Bar Fuel Pressure Test Procedure FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING (ART, AWN, BBD) FUEL PRESSURE REGULATOR AND HOLDING PRESSURE, CHECKING (BAS) FUEL PRESSURE REGULATOR AND HOLDING PRESSURE, CHECKING (BCY) Ignition Firing Order & Cylinder Identification FIRING ORDER & CYLINDER INDENTIFICATION Ignition Wires (Resistance) Coil-On-Plug Ignition Wires (Routing) Coil-On-Plug Spark Plug Torque 30 Nm Starting Starter NA Torque TORQUE SPECIFICATIONS Wheel Alignment Adjustment Specifications WHEEL ALIGNMENT SPECIFICATIONS Torque FRONT - TORQUE SPECIFICATIONS REAR - TORQUE SPECIFICATIONS (FWD) REAR - TORQUE SPECIFICATIONS (AWD) Wheel & Tire Wheel Lug Nut Torque 120 Nm 1998-05 SPECIFICATIONS INDEX A6, S6, RS6 & Allroad (C5 Platform)

2002-03 ENGINE PERFORMANCE Audi Introduction 2002 MODEL COVERAGE MODEL MODEL CODE (1) ENGINE CODE (2) ENGINE ID (3) FUEL & IGNITION SYSTEM A4 1.8L Turbo, 4-Cyl. Sedan 8E AMB C Bosch Motronic Quattro 8E AMB C Bosch Motronic Avant Quattro 8E AMB C Bosch Motronic A4 3.0L, V6 Sedan 8E AVK T Bosch Motronic Quattro 8E AVK T Bosch Motronic Avant Quattro 8E AVK T Bosch Motronic A6 2.7L Turbo, V6 Quattro 4B APB D Bosch ME-7 A6 3.0L, V6 Sedan 4B AVK T Bosch ME-7 Quattro 4B AVK T Bosch ME-7 Avant Quattro 4B AVK T Bosch ME-7 A6 4.2L, V8 Quattro 4B AWN L Bosch ME-7 A8 4.2L, V8 Quattro 4D AUX L Bosch ME-7 Allroad 2.7L Turbo, V6 Quattro 4B APB D Bosch ME-7 S4 2.7L Turbo, V6 Quattro 8D APB D Bosch ME-7 Avant Quattro 8D APB D Bosch ME-7 S6 4.2L, V8 Avant Quattro 4B AWN L Bosch ME-7 Avant Quattro 4B BBD U Bosch ME-7 S8 4.2L, V8 Sedan 4D AYS U Bosch ME-7 TT 1.8L Turbo, 4-Cyl. Coupe/Convertible 8N ATC Or AWP C Or X Bosch ME-7 Coupe/Convertible Quattro 8N ATC Or C Or X Bosch ME-7 2002-03 ENGINE PERFORMANCE Audi Introduction

2003 MODEL COVERAGE AWP Coupe/Convertible Quattro 8N AMU T Bosch ME-7 (1) Model code is designated by 7th and 8th digit of Vehicle Identification Number (VIN). (2) See ENGINE CODE LOCATION . (3) Engine type is identified by 5th digit of Vehicle Identification Number (VIN). MODEL MODEL CODE (1) ENGINE CODE (2) ENGINE ID (3) FUEL & IGNITION SYSTEM A4 1.8L Turbo, 4-Cyl. Sedan 8E AMB C Bosch Motronic Quattro 8E AMB C Bosch Motronic Avant Quattro 8E AMB C Bosch Motronic A4 3.0L, V6 Sedan 8E AVK T Bosch ME 7.1.1 Quattro 8E AVK T Bosch ME 7.1.1 Avant Quattro 8E AVK T Bosch ME 7.1.1 A6 2.7L Turbo, V6 Quattro 4B APB D Bosch ME-7 A6 3.0L, V6 Sedan 4B AVK T Bosch ME-7 Quattro 4B AVK T Bosch ME-7 Avant Quattro 4B AVK T Bosch ME-7 A6 4.2L, V8 Quattro 4B AWN Or BBD L Bosch ME-7 A8 4.2L, V8 Quattro 4D AYS or AUX L Bosch ME-7 Allroad 2.7L Turbo, V6 Quattro 4B APB D Bosch ME-7 Quattro 4B AWN Or BBD L Bosch ME-7 S6 4.2L, V8 Avant Quattro 4B AWN L Bosch ME-7 Avant Quattro 4B BBD U Bosch ME-7 S8 4.2L, V8 2002-03 ENGINE PERFORMANCE Audi Introduction

VEHICLE IDENTIFICATION NUMBER NATION OF ORIGIN - POSITION 1 T Hungary W Germany MANUFACTURER - POSITION 2 & 3 AU Germany, AudiPassenger Car A1 Germany, AudiMPV RU Hungary, Passenger Car SERIES - POSITION 4 A 2003 A4 Cabriolet Sedan 4D AYS U Bosch ME-7 TT 1.8L Turbo, 4-Cyl. Coupe/Convertible 8N ATC Or AWP C Or X Bosch ME 7.5 Coupe/Convertible Quattro 8N ATC Or AWP C Or X Bosch ME 7.5 Coupe/Convertible Quattro 8N AMU T Bosch ME 7.5 (1) Model code is designated by 7th and 8th digit of Vehicle Identification Number (VIN). (2) See ENGINE CODE LOCATION . (3) Engine type is identified by 5th digit of Vehicle Identification Number (VIN). NOTE: Unless specified otherwise, the series code applies to 2002 and 2003 vehicles. 2002-03 ENGINE PERFORMANCE Audi Introduction

2003 Audi RS6 Service & Repair Manual

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