2006 AUDI S8 Service and Repair Manual

2004-09 SPECIFICATIONS INDEX A8 & S8 SPECIFICATIONS INDEX SPECIFICATIONS INDEX NOTE: Specifications for the 6.0L engine apply to the BSB type engine only. The BSB engine application is 2005-07 and 2009. System Specification/Procedure Air Conditioning Service A/C REFRIGERANT CIRCUIT, SERVICING CAPACITIES Torque A/C COMPRESSOR, REMOVING AND INSTALLING (8 - CYL FSI ENGINE) COMPRESSOR, REMOVING AND INSTALLING (10 - CYL ENGINE) COMPRESSOR, REMOVING FROM BRACKET AND RE - INSTALLING (12 - CYL ENGINE) Axle Nut/Hub Nut Front WHEEL BEARING HOUSING AND WHEEL BEARING UNIT Rear REAR SUSPENSION COMPONENTS, ASSEMBLY OVERVIEW Battery BATTERY, TESTING Brakes Bleeding Sequence BLEEDING BRAKING SYSTEM Disc Brakes GENERAL, TECHNICAL DATA Torque BRAKES - MECHANICAL COMPONENTS BRAKES - HYDRAULIC COMPONENTS Charging Generator GENERATOR, TESTING AND SERVICING Torque 4.2L 4.2L MPI (BFM - 2004 - 06) 4.2L FSI (BVJ - 2007 - 09) 5.2L 5.2L FSI 6.0L (BSB Engine) 6.0L Drive Belts 2007 Audi S8 Quattro 2004-09 SPECIFICATIONS INDEX A8 & S8 2004-09 SPECIFICATIONS INDEX A8 & S8

Adjustment & Belt Routing 4.2L RIBBED BELT, REMOVING AND INSTALLING (BFM - 2004 - 06) RIBBED BELT, REMOVING AND INSTALLING (BVJ - 2007 - 09) 5.2L RIBBED BELT, REMOVING AND INSTALLING 6.0L (BSB Engine) RIBBED BELT, REMOVING AND INSTALLING Engine Cooling General Service Specifications 4.2L COOLING SYSTEM, DRAINING AND FILLING (BFM - 2004 - 06) COOLING SYSTEM, DRAINING AND FILLING (BVJ - 2007 - 09) 5.2L COOLING SYSTEM, DRAINING AND FILLING 6.0L (BSB Engine) COOLING SYSTEM, DRAINING AND FILLING Radiator Cap Pressure 1.4-1.6 Bar Thermostat R & I 4.2L COOLANT THERMOSTAT, REMOVING AND INSTALLING, CHECKING (BFM - 2004 - 06) MAP CONTROLLED ENGINE COOLING THERMOSTAT F265 , REMOVING AND INSTALLING (BVJ - 2007 - 09) 5.2L THERMOSTAT HOUSING, REMOVING AND INSTALLING 6.0L (BSB Engine) COOLANT THERMOSTAT, REMOVING AND INSTALLING Water Pump R & I 4.2L COOLANT PUMP, REMOVING AND INSTALLING (BFM - 2004 - 06) COOLANT PUMP, REMOVING AND INSTALLING (BVJ - 2007 - 09) 5.2L COOLANT PUMP, REMOVING AND INSTALLING 6.0L (BSB Engine) COOLANT PUMP, REMOVING AND INSTALLING Engine Mechanical 4.2L Compression COMPRESSION PRESSURES, 2007 Audi S8 Quattro 2004-09 SPECIFICATIONS INDEX A8 & S8

CHECKING (BFM - 2004 - 06) COMPRESSION PRESSURE, MEASURING (BVJ - 2007 - 09) Oil Pressure BFM - 2004-06: At Idle: Min. 1.0 Bar At 2000 RPM: Min. 3.5 Bar BVJ - 2007-09: At Idle: Min. 1.5 Bar At 2000 RPM: Min. 3.5 Bar Overhaul ENGINE, DISASSEMBLING AND ASSEMBLING (BFM - 2004 - 06) ENGINE - CRANKSHAFT, CYLINDER BLOCK (BVJ - 2007 - 09) Torque See Appropriate Procedure 5.2L Compression COMPRESSION, CHECKING Oil Pressure At Idle: Min. 1.5 Bar At 2000 RPM: Min. 3.5 Bar Overhaul 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK Torque See Appropriate Procedure 6.0L (BSB Engine) Compression NA Oil Pressure At Idle: Min.0.8 Bar At 2000 RPM: Min.3.0 Bar Max: 7.0 Bar Overhaul ENGINE, DISASSEMBLING AND ASSEMBLING Torque See Appropriate Procedure Fluid Specifications See FLUIDS under MAINTENANCE tab. Flywheel/Flex Plate Torque 60 Nm + 90° Fuel System Pressure Specification 4.2L BFM: Approx: 3.5 Bar BVJ: Approx: 4.5 to 6.5 Bar (Before high- pressure pump) 5.2L Approx: 5.0 to 7.0 Bar (Before high- pressure pump) 6.0L (BSB Engine) Approx: 4.0 Bar Fuel Pressure Test Procedure 4.2L FUEL PRESSURE REGULATOR 2007 Audi S8 Quattro 2004-09 SPECIFICATIONS INDEX A8 & S8

AND HOLDING PRESSURE, CHECKING (BFM - 2004 - 06) FUEL PRESSURE AND RESIDUAL PRESSURE BEFORE HIGH PRESSURE PUMP, CHECKING (BVJ - 2007 - 09) 5.2L FUEL PRESSURE AND RESIDUAL PRESSURE BEFORE HIGH PRESSURE PUMP, CHECKING 6.0L (BSB Engine) FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING Ignition Firing Order & Cylinder Identification 4.2L FIRING ORDER & CYLINDER INDENTIFICATION 5.2L FIRING ORDER & CYLINDER INDENTIFICATION 6.0L (BSB Engine) FIRING ORDER & CYLINDER INDENTIFICATION Ignition Wires (Resistance) Coil-On-Plug Ignition Wires (Routing) Coil-On-Plug Spark Plug 4.2L IGNITION, TECHNICAL DATA (BFM - 2004 - 06) TEST DATA (BVJ - 2007 - 09) 5.2L SPARK PLUG TEST DATA 6.0L (BSB Engine) TECHNICAL DATA, SPARK PLUGS Starting Starter/Torque 4.2L MPI (BFM - 2004 - 06) 2007 Audi S8 Quattro 2004-09 SPECIFICATIONS INDEX A8 & S8

4.2L FSI (BVJ - 2007 - 09) 5.2L FSI 6.0L MPI Wheel Alignment Adjustment Specifications WHEEL ALIGNMENT SPECIFICATIONS Torque FRONT - WHEEL BEARING HOUSING AND WHEEL BEARING UNIT, ASSEMBLY OVERVIEW REAR - SUSPENSION COMPONENTS, ASSEMBLY OVERVIEW Wheel & Tire Wheel Lug Nut Torque 120 Nm 2007 Audi S8 Quattro 2004-09 SPECIFICATIONS INDEX A8 & S8

Maintenance Maintenance Procedures - A8 & S8 01 - MAINTENANCE ENGINE OVERVIEW Gasoline engines * 95 RON Super unleaded gasoline is permissible, however with decreased power output. *91 RON standard unleaded gasoline is permissible, however with decreased power output. NOTE:  Some engines listed below are for European models and are not applicable to the North American market. Engine code BFL BVJ BFM ASN BPK BBJ BSM BHT Emissions category EU IV EU IV EU IV EU IV EU IV EU IV EU IV EU IV No. of cylinders 8 8 8 6 6 6 10 12 Valves per cylinder 5 4 5 5 4 5 4 4 Displacement L 3.7 4,2 4,2 3,0 3,2 3.0 5.2 6.0 Output kW at RPM 206 / 6000 257/6800 246 / 6500 162 / 6300 191 / 6000 162/6300 331/7000 331/6200 Torque Nm at RPM 360 / 3750 440/3500 400 / 3500 300 / 3200 330 / 3400 300/3200 540/3000- 4000 595/3500 Bore mm 84.5 84.5 84.5 82.5 84.5 82.5 84.5 84.0 Stroke mm 82.4 92.8 93.0 93.0 92.8 93.0 92.8 90.2 Compression ratio 11.0 12.5 11.0 10.5 12.5 10.5 12.5 10.75 Engine code BFL BVJ BFM ASN BPK BBJ BSM BHT Fuel injection/Ignition Motronic ME 7.1.1 Motronic MED 9.1.1 FSI Motronic ME 7.1.1 Motronic ME 7.1.1 Motronic FSI Motronic ME 7.1.1 Motronic MED 9.1.1 FSI Motronic ME 7.1.1 RON min. 98 * See footnote 98 * See footnote 98 * See footnote 98 * See footnote 95 * See footnote 98 * See footnote 98 * See footnote 98 * See footnote Camshaft adjustment X X X X X X X X On Board Diagnostic X X X X X X X X Secondary air injection X X X X - X X X Turbocharger - - - - - - - - 2007 Audi S8 Quattro Maintenance Maintenance Procedures - A8 & S8 2007 Audi S8 Quattro Maintenance Maintenance Procedures - A8 & S8

Diesel engines DELIVERY INSPECTION Delivery inspection For additional information regarding inspection service, refer to ServiceNet, Maintenance Schedules for appropriate model year or Perfect Delivery Inspection (PDI) forms located in ServiceNet. OIL CHANGE SERVICE Oil change service For information regarding oil change service, refer to ServiceNet; Maintenance Schedules for appropriate model year. Also for oil type and usage, refer to ServiceNet; Additional information; Fluid Capacity Charts for appropriate Model and Year INSPECTION SERVICE Inspection service Engine code ASB BNG ASE BVN Emissions category EU IV EU IV EU - III EU IV Number of cylinders/valves per cylinder 6/4 6/4 8 / 4 8 / 4 Displacement L 3.0 3.0 4.0 4.2 Output kW at RPM 171/4000 155/3400 202/3750 240/ 3750 Torque Nm at RPM 450/ 15003250 450/ 15003250 650/1800-2500 650/1800-2500 Bore mm 83.0 83.0 81 83.0 Stroke mm 91.4 91.4 95.5 95.5 Compression ratio 17 17 19.5 16.4 Engine code ASB BNG ASE BVN Fuel injection Common - Rail Common - Rail Common - Rail Common - Rail CN min. 51 51 51 51 On Board Diagnostic X X X X Catalytic converter Oxidation catalyst Oxidation catalyst Oxidation catalyst Oxidation catalyst Exhaust gas recirculation X X X X Turbocharger X X X X Charge air cooler X X X X 2007 Audi S8 Quattro Maintenance Maintenance Procedures - A8 & S8

For information regarding inspection service, refer to ServiceNet, Maintenance Schedules for appropriate model year CONTACT CORROSION Contact corrosion Contact corrosion can occur if improper fastening elements (bolts, nuts, washers, etc.) are used. For this reason, only fastening elements with a special surface coating are installed. These elements can be recognized by their green color. In addition, rubber, plastic parts and adhesive are made of non-conductive material. If there are doubts as to whether parts can be reused, install new parts. DESCRIPTION OF WORK All switches, all electrical components, all displays and other operating elements: Checking function  Check following:  Lighting, headlamps, fog lights, turn signals, hazard warning flashers, taillights, rear fog lights, backup lights, brake lights, parking lights  Interior and reading lights (automatic shutoff on interior lights), illuminated storage compartment, illuminated ashtray, luggage compartment lighting, illuminated ignition  Warning buzzer for lights and/or radio left on  All switches in console  MMI function (radio, navigation, etc.)  Driver Information System (DIS)  Instrument unit with all displays, meters and lights  Two-tone horn  Windshield/headlamp wipers, headlamp cleaning system  Cigarette lighter  Electrical exterior mirrors (heated, adjustable, foldable)  Electric windows WARNING:  Only using original Audi A8 parts!  Accessories must be approved by Audi AG!  Damage due to contact corrosion is not covered by warranty! 2007 Audi S8 Quattro Maintenance Maintenance Procedures - A8 & S8

 Electric tilt/slide sunroof  Sun shade  Central locking, remote control operation, comfort closing  Electrical seat, headrest, steering wheel and seatbelt height adjustment  Heated seats and rear seat bench, heated steering wheel Final drive (automatic transmission): Check oil level, add oil if necessary Automatic Transmission --> - 39 - FINAL DRIVE, DIFFERENTIAL , 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE or 39 - FINAL DRIVE, DIFFERENTIAL , 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE Continuously Variable Transmission (CVT) --> - 39 - FINAL DRIVE, DIFFERENTIAL , 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE or 39 - FINAL DRIVE, DIFFERENTIAL , 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE Wheel bolts: Tighten to correct torque setting Center cap Fig. 1: Identifying Removal Hook Courtesy of VOLKSWAGEN UNITED STATES, INC.  The removal hook - A - for removing the center cap is located in the vehicles tool kit. Wheel bolts The adapter to loosen/tighten the anti-theft wheel bolts is located with the vehicle tool kit. NOTE:  Be sure to tighten wheel bolts in diagonal sequence to the following specified torque: Tightening torque Nm 2007 Audi S8 Quattro Maintenance Maintenance Procedures - A8 & S8

2006 AUDI S8 Service and Repair Manual

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