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41-Service Manual TDI Injection and Glow Plug System (8-Cyl 4 0 LTR 4-Valve Common Rail ASE)

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0% found this document useful (0 votes)

47 views84 pages

41-Service Manual TDI Injection and Glow Plug System (8-Cyl 4 0 LTR 4-Valve Common Rail ASE)

Uploaded by

rockrapdude

We take content rights seriously. If you suspect this is your content, claim it here.

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Service

Workshop Manual
Audi A8 2003 ➤
TDI injection and glow plug system
AG. AUDI AG (8-cyl. 4.0 ltr.any4-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI does not guarantee or accept liability

valve common rail)with respect to the correctness of information in this document. Copyright by AUDI AG.

Engine ID ASE

Edition 03.2014

Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
23 - Mixture preparation - injection
28 - Glow plug system
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.

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 © 2014 Audi AG, Ingolstadt A0051006520

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

Contents

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Servicing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when using testers and measuring instruments during a road test . . . . 1
1.2 To avoid injury and/or damage to the injection and glow plug system, note the following:
........................................................................ 1
1.3 Safety precautions when working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 System layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.7 Exploded view - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 Exploded view - intake manifold (part 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.9 Exploded view - intake manifold (part 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.10 Removing and installing intake manifold (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.11 Removing and installing intake manifold (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.12 Removing and installing air cleaner (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.13 Removing and installing air cleaner (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.14 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.15 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.16 Performing adaption of correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.17 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.18 Measuring return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . 27
1.19 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 30
1.20 Removing and installing high-pressure pipes between distributor housing (function block) and
high-pressure pump / fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.21 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.22 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.23 Removing and installing high-pressure pump and gear-type fuel system pressurisation
pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.24 Bleeding fuel system after installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.25 Checking for leaks in fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.26 Exploded view - toothed belt for high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.27 Removing and installing toothed belt for high-pressure pump . . . . . . . . . . . . . . . . . . . . . . 53
1.28 Removing and installing air mass meter (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.29 Removing and installing air mass meter (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.30 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 64
1.31 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2 Removing and installing engine control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.1 Wiring and component check with test box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . . . . . . . 69
2.2 Renewing diesel direct injection system control unit J248 (master control unit) . . . . . . . . 72
2.3 Renewing diesel direct injection system control unit 2 J494 (slave control unit) . . . . . . . . 75

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.1 Checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.2 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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 i
Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

ii Contents
Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

23 – Mixture preparation - injection

1 Servicing diesel direct injection sys‐
tem
(ARL003790; Edition 03.2014)

1.1 Safety precautions when using testers

and measuring instruments during a
road test
Note the following if testers and measuring instruments have to
be used during a road test:

WARNING

Accidents can be caused if the driver is distracted by test

equipment while road-testing, or if test equipment is not prop‐
erly secured.
Persons sitting in the front passenger's seat could be injured if
the airbag is triggered in an accident.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Test equipment must always be secured on the rear seat
with a strap and operated from the rear seat by a second
person.
Press the DONE button when you are ready for the test drive.

1.2 To avoid injury and/or damage to the in‐

jection and glow plug system, note the
following:
♦ Persons wearing a pacemaker should not lean over the engine
compartment while the engine is running, as the injectors use
high voltage pulses.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off the ignition before connecting or discon‐
necting injection or ignition system wiring or tester cables.
♦ Always switch off the ignition before cleaning the engine.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. The fault memory should therefore be inter‐
rogated and (if necessary) erased after completing the tests
and any repair work that may be required.

1. Servicing diesel direct injection system 1

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

1.3 Safety precautions when working on the

fuel system

WARNING

The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the fuel lines and the fuel can reach a
temperature of 100 °C on vehicles with common rail en‐
gine, even after the engine is switched off. Allow the fuel
to cool down before disconnecting the lines - danger of
scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Risk of injury - fuel system operates under pressure.
♦ If the battery is not disconnected, the fuse for the fuel
pump control unit - J538- must be removed as a precau‐
tionary measure before opening the fuel system because
the fuel pump will otherwise be activated by the contact
switch on the driver's door.
♦ Wrap a clean cloth around the connection before opening
the fuel system. Then release pressure by carefully loos‐
ening the connection.
♦ Wear protective gloves.
♦ Wear safety goggles.

Caution

♦ Observe notes on procedure for disconnecting the battery

⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting
and connecting battery .

• Clean tools and workbench etc. before working on the injection

system. 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
• Carefully clean connection pointswith
and the surrounding area
respect to the correctness of information in this document. Copyright by AUDI AG.

with engine cleaner or brake cleaner and dry thoroughly before

opening.
• When removing components, plug all open connections im‐
mediately with suitable clean sealing caps.
• Do not remove sealing caps from components until immedi‐
ately prior to installation. Keep components that are to be re-
used in new, sealable plastic bags.
• Before installing, check the injectors and their surroundings
visually; they must be undamaged and clean. Make sure the
injector bores in the cylinder head are clean. Wipe out if nec‐
essary using a clean cloth, taking care not to cause damage.
Do not use sharp objects of any kind.
• If the high-pressure fuel lines are to be re-used, you must mark
them before removal. High-pressure pipes must always be re-
installed on the same cylinder.
• Take care not to damage the injectors when removing the old
copper seals.
• Check all new O-rings for damage before installing. Lubricate
O-rings with engine oil or assembly oil before installing.

2 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

• Position high-pressure pipes so they are free of stress. Tighten

all unions lightly to start with before tightening to final torque.
• Never attempt to bend high-pressure fuel lines to shape.
• When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
• Press the fuel return hoses onto the injectors by hand from
above so that they engage audibly on each injector (do not
press in the release pins when doing this). Then press down
the release pin after connecting the return line. Check that the
fuel return hoses are seated securely by pulling them by hand
from above. Also check that they seal properly (fuel pressure
in return line as far as pressure retention valve: between 8 and
10 bar).
• Do not dismantle individual common rail components. If there
is a fault, the complete components must be renewed.
• When the engine is running, do not perform any repairs to the
common rail system.
• Do not bleed the common rail system by unfastening high-
pressure components after the engine has been started.
• All cable ties which are released or cut open when removing
must be refitted in the same position when installing.
• When the fuel system is open: Do not work with compressed
air if this can be avoided. Do not move the vehicle unless ab‐
solutely necessary. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Also ensure that no diesel fuel comes into contact with thedocument. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.

1.4 Checking vacuum system

Special tools and workshop equipment required
♦ 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
♦ Lines porous or leaking
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.

1. Servicing diesel direct injection system 3

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– If an entry is stored in the event memory, check the vacuum

lines leading to the corresponding component and also check
the other vacuum lines leading to other components.
– If it is not possible to build up pressure with the hand vacuum
pump - VAS 6213- or if the pressure drops again immediately,
check the hand vacuum pump and connecting hoses for leaks.

1.5 Overview of fitting locations

Components A to I are not shown on the exploded view.

1 - Electronics box in plenum

chamber
❑ Diesel direct injection
system control unit -
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
J248-with
with altitude
respect sen‐ of information in this document. Copyright by AUDI AG.
to the correctness
sor (for cylinders 1, 4, 6,
7)
❑ Diesel direct injection
system control unit 2 -
J494- (for cylinders 2, 3,
5, 8)
❑ Glow plug relay - J52- in
relay and fuse holder in
electronics box (plenum
chamber) ⇒ page 6
❑ Glow plug relay 2 -
J495- in relay and fuse
holder in electronics box
(plenum chamber)
⇒ page 6
❑ Terminal 30 voltage
supply relay - J317-
❑ Relay and fuse holder in
electronics box, plenum
chamber
2 - Connector
❑ For Hall sender - G40-
(camshaft position sen‐

4 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

sor)
3 - Fuel temperature sender - G81-
4 - Intake manifold flap motor - V157-
❑ Cylinder bank 1
5 - Mechanical exhaust gas recirculation valve
6 - Distributor housing (function block)
7 - Fuel pressure regulating valve - N276-
8 - High-pressure pump
❑ With fuel metering valve - N290-
❑ With gear-type fuel system pressurisation pump
9 - Fuel pressure sender - G247-
10 - Mechanical exhaust gas recirculation valve
11 - Intake manifold flap 2 motor - V275-
❑ Cylinder bank 2
12 - Air mass meter 2 - G246-
❑ In air cleaner housing
13 - Injectors
❑ Cylinder bank 2
14 - High-pressure reservoir (rail)
❑ Cylinder bank 2
15 - Throttle valve module 2 - J544-
16 - EGR valve 2 - N213-
❑ Cylinder bank 1
17 - Oil pressure sender - G10-
18 - Oil temperature sender - G8-
19 - Coolant temperature sender - G62-
20 - Exhaust gas recirculation valve - N18-
21 - Throttle valve module - J338-
❑ Cylinder bank 2
22 - High-pressure reservoir (rail)
❑ Cylinder bank 1
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
23 - Injectors 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.
❑ Cylinder bank 1
❑ Removing and installing ⇒ page 35
24 - Air mass meter - G70-
❑ In air cleaner housing
A - Brake light switch - F- and brake pedal switch - F47-
❑ In footwell on brake pedal
B - Accelerator position sender - G79-
❑ In footwell on accelerator pedal
❑ ⇒ page 6
C - Fuel pump relay - J17-
❑ Relay and fuse holder in luggage compartment (right-side), relay position 3
❑ ⇒ page 7

1. Servicing diesel direct injection system 5

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

D - Terminal 30 voltage supply relay - J317-

❑ Relay and fuse holder in electronics box, plenum chamber
❑ ⇒ page 6
E - Charge pressure sender - G31- with intake air temperature sender - G42-
❑ In charge air cooler (left-side) ⇒ page 7
F - Charge air cooling pump relay - J536-
❑ Relay and fuse holder in front footwell (right-side)
❑ ⇒ page 7
G - Starter motor relay - J53- and starter motor relay 2 - J695-
❑ Relay and fuse holder in front footwell (right-side)
❑ ⇒ page 7
H - Engine speed sender - G28-
❑ ⇒ page 7
I - Glow plugs
❑ Removing and installing ⇒ page 79

Accelerator position sender - G79-

Relay and fuse holder in electronics box, plenum chamber

Location of relays (model year 2003)
1 - Glow plug relay - J52-
2 - Glow plug relay 2 - J495-
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
3 - Terminal 30 voltage supply relay - J317-
with respect to the correctness of information in this document. Copyright by AUDI AG.

B - Glow plug fuse

C - Glow plug fuse 2
Location of relays (as of model year 2004)
1 - Glow plug relay - J52-
2 - Terminal 30 voltage supply relay - J317-
3 - Glow plug relay 2 - J495-
B - Glow plug fuse
C - Glow plug fuse 2

6 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

Relay carrier in passenger's footwell

1.1 - Fuel cooling pump relay - J445-
1.2 - Charge air cooling pump relay - J536-
2 - Starter motor relay - J53-
3 - Starter motor relay 2 - J695-

Relay and fuse holder in luggage compartment (right-side)

3 - Fuel pump relay - J17-

Engine speed sender - G28-

1 - 3-pin connector
2 - Engine speed sender

Charge pressure sender - G31- with intake air temperature send‐

er - G42- 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.

1.6 System layout

Note

♦ Always read instructions for working on fuel system.

♦ Follow these instructions before starting work and while work‐
ing on the fuel system ⇒ page 2 .

1. Servicing diesel direct injection system 7

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

1 - Fuel metering valve - N290-

2 - High-pressure pump with
gear-type fuel system pressur‐
isation pump
3 - Fuel pressure sender -
G247-
❑ 35 Nm
❑ Removing and installing
⇒ page 66
4 - Distributor housing (func‐
tion block)
5 - Fuel pressure regulating
valve - N276-
❑ Removing and installing
⇒ page 64
6 - Fuel rail
❑ For cylinder bank 1
7 - Fuel rail
❑ For cylinder bank 2
8 - Injectors
❑ 5 ... 8
❑ Cylinder bank 2
❑ If they are to be re-in‐
stalled, the injectors and
high-pressure fuel pipes
must always be re-fitted
in their original positions
(i.e. on the same cylin‐
der).
❑ Removing and installing
⇒ page 35
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

9 - Injectors
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ 1 ... 4
❑ Cylinder bank 1
❑ If they are to be re-installed, the injectors and high-pressure fuel pipes must always be re-fitted in their
original positions (i.e. on the same cylinder).
❑ Removing and installing ⇒ page 35
10 - Fuel system pressurisation pump - G6-
❑ Fuel system pressurisation pump
11 - Fuel filter

1.7 Exploded view - fuel system

Note

♦ Always read instructions for working on fuel system.

♦ Follow these instructions before starting work and while work‐
ing on the fuel system ⇒ page 2 .

8 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

1 - Bracket with fuel filter

❑ Exploded view - fuel fil‐
ter ⇒ Rep. gr. 20
❑ Renewing ⇒ Rep. gr.
20
2 - Hose clip
3 - Fuel return line
4 - Fuel supply line
5 - Clip
6 - Fuel temperature sender -
G81-
7 - Banjo bolt for fuel supply
line
❑ Fuel supply
8 - Seal
9 - Fuel cooler
10 - Fuel pressure regulating
valve - N276-
❑ Cannot be re-installed
❑ Removing and installing
⇒ page 64
11 - Hose clip
12 - Bolt
❑ For distributor housing

1. Servicing diesel direct injection system 9

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

(function block)
❑ 9 Nm
13 - Seal
14 - Distributor housing (func‐
tion block)
15 - Fuel pressure sender - G247-
❑ 35 Nm
❑ Removing and installing ⇒ page 66
16 - Bracket for distributor housing
17 - Bolt
18 - Return lines
❑ Fuel return
❑ Cylinder bank 2
19 - Retaining clips
❑ For return lines
20 - Bolt
❑ Cover for injector on cylinder head cover
❑ 5.5 Nm
21 - Cover for injector
22 - Seal
23 - Hexagon flange nut
❑ For clamping piece
❑ 10 Nm
24 - Injector
❑ Use a coloured pen to mark injectors and corresponding high-pressure pipes and cylinder for re-instal‐
lation; pay attention to markings when installing
❑ Always renew copper seal when removing and installing
❑ To remove carbon deposits from the injector sealing surface, clean the injector bore in the cylinder head
with cleaning kit - VAS 6811- (it is important to do this to avoid leaks)
❑ Removing and installing ⇒ page 35
25 - Clamping piece
❑ Renew 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
26 - Fuel rail with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ For cylinder bank 2

27 - Fuel rail
❑ For cylinder bank 1
28 - High-pressure pipes
❑ For cylinder bank 1 (4x)
❑ For cylinder bank 2 (4x)
29 - High-pressure pump with gear-type fuel system pressurisation pump
30 - Fuel return lines (from injectors)
❑ Fuel return
❑ Cylinder bank 1
31 - Bypass line
❑ For fuel return
32 - Banjo bolt

10 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

❑ Fuel return

1.8 Exploded view - intake manifold (part 1)

Note

Illustration shows left-side intake manifold

2 - Bolt
❑ 10 Nm
3 - Bolt
❑ 10 Nm
4 - Cooler
❑ For exhaust gas recircu‐
lation
❑ Removing and installing
exhaust gas recircula‐
tion cooler (left-side) ⇒
Rep. gr. 26
❑ Removing and installing
exhaust gas recircula‐
tion cooler (right-side) ⇒
Rep. gr. 26
5 - Seal
❑ Renew
6 - Connecting pipe
7 - O-ring
❑ Renew
8 - Connecting pipe
9 - Bolt
❑ 10 Nm
10 - Seal
❑ Renew
11 - Intake manifold
❑ With intake manifold

1. Servicing diesel direct injection system 11

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

flap motor
❑ Do not separate compo‐
nents
❑ Right-side: intake manifold flap motor - V157-
❑ Left-side: intake manifold flap motor 2 - V275-
❑ Removing and installing intake manifold (left-side) ⇒ page 13
❑ Removing and installing intake manifold (right-side) ⇒ page 17
12 - Bolt
❑ Do not unscrew
13 - Bolt
❑ 10 Nm
14 - Gasket
❑ Renew
15 - Seal
❑ Renew
16 - Throttle valve module
❑ Left-side: throttle valve module 2 - J544-
❑ Right-side: throttle valve module - J338-
17 - O-ring
❑ Renew

1.9 Exploded view - intake manifold (part 2)

Note

Removing intake manifold (left-side) ⇒ page 13 ; removing in‐

take manifold (right-side) ⇒ page 17 .

12 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

1 - 8 Nm
2 - Bottom section of intake
manifold
3 - Gasket
❑ Renew
4 - Intake manifold
5 - Intake manifold flap motor
❑ Can only be renewed as
one unit with intake
manifold
❑ Right-side: intake mani‐
fold flap motor - V157-
❑ Left-side: intake mani‐
fold flap motor 2 - V275-
6 - Bolt
❑ Do not unscrew

1.10 Removing and installing intake manifold

(left-side)
Special tools and workshop equipment required
♦ Socket, 14 mm - 3150-
♦ Torque wrench - V.A.G 1331- (5...50 Nm)
♦ Ratchet - V.A.G 1331/1-
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.

1. Servicing diesel direct injection system 13

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

Removing

Note

All cable ties which are released or cut open when removing must
be refitted in the same position when installing.

– Remove engine cover panel (refer to instructions for removing

and installing ⇒ page 24 ). 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
– Move lock carrier to service position ⇒ General
with respect body repairs,
to the correctness of information in this document. Copyright by AUDI AG.
exterior; Rep. gr. 50 .

14 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Remove air hose (front left) -arrows-.

– Detach air intake pipe (front left) from engine -arrows-.

– Pivot air intake pipe away to the side.

Note

Cable ties do not have to be opened.

– Unbolt exhaust gas recirculation valve - N18- -1- and exhaust

gas recirculation valve 2 - N213- -2- from intake manifolds.

– Unscrew bolts -1 ... 4-.

– Take out connecting pipe between left and right intake mani‐
folds.

1. Servicing diesel direct injection system 15

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Remove bolts -arrows-.

– Move electrical wiring clear at rail element and injector pipes.

WARNING

Observe rules for cleanliness when working on the injection

system ⇒ page 2 .

– Unscrew union nuts -3 ... 8- (counterhold pressure pipe con‐

nections).
– Remove bolts -1- and -2-.
– Take off rail element.
– Unplug electrical connector at glow plug on No. 5 cylinder.

– Unplug electrical connector -1- at intake manifold flap 2 motor

- V275- .
– Remove bolts -arrows-.
– Take off intake manifold together
Protected by with intake
copyright. Copying manifold
for private flap
or commercial mo‐ in part or in whole, is not
purposes,
tor. 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.

Note

♦ Watch dowel sleeves when removing intake manifold.

♦ Block off intake ports in cylinder head with clean rags.

Installing

Note

♦ Reinstall all cable ties in the same locations when assembling.

♦ Renew gaskets, seals and O-rings.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue .

– Make sure dowel sleeves are in place before installing intake

manifold.

16 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Tighten bolt -4- last when installing connecting pipe between

left and right intake manifolds.
– Tighten union nuts on high-pressure pipes hand-tight initially.
– Ensure that high-pressure pipes are not under tension.

– by
Protected Tocopyright.
tighten unions
Copying of high-pressure
for private pipes,
or commercial purposes, use
in part or in torque wrench
whole, is not
permitted -unless
V.A.G 1331-
authorised by with ratchet
AUDI AG. AUDI AG - V.A.G 1331/1-orand
does not guarantee acceptsocket,
any liability14 mm
- 3150-
with respect .
to the correctness of information in this document. Copyright by AUDI AG.

– Install lock carrier with attachments ⇒ General body repairs,

exterior; Rep. gr. 50 .
– Install front bumper ⇒ General body repairs, exterior; Rep. gr.
63 .
– Deactivate jacking mode. ⇒ Rep. gr. 43
– Adjust headlights ⇒ Rep. gr. 94 .
Tightening torques
Component Nm
Intake manifold to cylinder head 10
Rail element to cylinder head 22
Union nut to fuel pipe 25
Exhaust gas recirculation cooler to intake mani‐ 10
fold
Connecting pipe to intake manifold 10
Front air intake pipe to engine 10
Hose clips for air hoses 5

1.11 Removing and installing intake manifold

(right-side)
Special tools and workshop equipment required
♦ Socket, 14 mm - 3150-
♦ Torque wrench - V.A.G 1331- (5...50 Nm)

1. Servicing diesel direct injection system 17

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

♦ Ratchet - V.A.G 1331/1-

Removing

Note

All cable ties which are released or cut open when removing must
be refitted in the same position when installing.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Move lock carrier
permitted unlessto service
authorised by position.
AUDI AG. AUDI ⇒ AGGeneral body repairs,
does not guarantee or accept any liability
exterior; Rep. gr. to50
with respect the correctness of information in this document. Copyright by AUDI AG.

– Detach air intake pipe (front right) from engine -arrows-.

– Pivot air intake pipe away to the side.

Note

Cable ties do not have to be opened.

18 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Unclip electrical connector -1- at crankcase breather pipe.

– Detach crankcase breather pipe -arrows-.
– Pivot crankcase breather pipe to the side.

Note

The hose at the bottom does not have to be disconnected.

– Unbolt exhaust gas recirculation valve - N18- -1- and exhaust

gas recirculation valve 2 - N213- -2- from intake manifolds.

– Unscrew bolts -1 ... 4-.

– Take out connecting pipe between left and right intake mani‐
folds.

– Remove bolts -arrows-.

– Move electrical wiring clear at rail element and injector pipes.

WARNING

Observe rules for cleanliness when working on the injection

system ⇒ page 2 .

1. Servicing diesel direct injection system 19

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Unscrew union nuts -3 ... 8- (counterhold pressure pipe con‐

nections).
– Remove bolts -1- and -2-.
– Take off rail element.

– Detach electrical connector -1- at intake manifold flap motor -

V157- .
– Remove bolts -arrows-.
– Take off intake manifold together with intake manifold flap mo‐
tor.

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Watch dowel sleeves when
permitted removing
unless intake
authorised by manifold.
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.
♦ Block off intake ports in cylinder head with clean rags.

Installing

Note

♦ Reinstall all cable ties in the same locations when assembling.

– Make sure dowel sleeves are in place before installing intake

manifold.

– Tighten bolt -4- last when installing connecting pipe between

left and right intake manifolds.
– Tighten union nuts on high-pressure pipes hand-tight initially.
– Ensure that high-pressure pipes are not under tension.

20 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– To tighten unions of high-pressure pipes, use torque wrench

- V.A.G 1331- with ratchet - V.A.G 1331/1- and socket, 14 mm
- 3150- .
– Install lock carrier with attachments ⇒ General body repairs,
exterior; Rep. gr. 50 .
– Install front bumper ⇒ General body repairs, exterior; Rep. gr.
63 .
– Deactivate jacking mode. ⇒ Rep. gr. 43
– Adjust headlights ⇒ Rep. gr. 94 .
Tightening torques
Component Nm
Intake manifold to cylinder head 10
Rail element to cylinder head 22
Union nut to fuel pipe 25
Exhaust gas recirculation cooler to intake mani‐ 10
fold
Connecting pipe to intake manifold 10
Crankcase breather pipe to A/C compressor 25
Front air intake pipe to engine 10
Hose clips for air hoses 5

1.12 Removing and installing air cleaner (left-

side)
Removing
– Remove bolts -arrows- from top section of air cleaner housing.
– Detach air cleaner housing (top section) and take out air filter
element.

1. Servicing diesel direct injection system 21

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Cover air mass meter -1- with a clean cloth and clean out bot‐
tom and top sections of air cleaner housing.
Installing
To ensure the proper function of the air mass meter - G70- it is
important to observe the following instructions.
– Blow out water drain hose 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 meter and
air intake hose (engine intake side).
– Check for dirt in air duct leading to air filter element.

Note

♦ Always use genuine part for air filter element.

♦ Make sure no dirt gets into the air cleaner housing.
♦ 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.
♦ Do not use any lubricants containing silicone when assem‐
bling.

– When installing the air filter element, check that it is properly

centred in the retainer in the air cleaner (bottom section).
– Fit the top section of the air cleaner carefully on the bottom
section, without using force. Make sure the top section of the
air cleaner is fitted straight on the air filter element (note posi‐
tion of sealing lip on air filter element).
– Then screw top section of air cleaner back onto bottom sec‐
tion.
– The remaining installation steps are carried out in the reverse
sequence.

1.13 Removing and installing air cleaner

(right-side)
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
Removing with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove cover for right suspension turret; to do so, detach

spreader clips -1- and unscrew bolted joint -2-.
– Pull cover out of retainers -arrows-.

22 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Remove bolts -arrows-.

– Detach top section of air cleaner housing (right-side) and take
out air filter element.

Note

♦ Always use genuine part for air filter element.

– When installing the air filter element, check that it is properly

1. Servicing diesel direct injection system 23

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

1.14 Removing and installing engine cover

panel
Removing
– First pull off the engine cover panel with both hands at the
points marked -1-, and then at the points marked -2- (do not
jerk the cover panel away, and do not try to pull on one side
only).
Installing
– To avoid damage, do not strike the engine cover panel with
your fist or with any kind of tool.
– Position engine cover panel on engine (note locations of oil
filler neck and oil dipstick).

– First press engine cover panel with both hands into its rubber
grommets at the points marked -3-, and then at the points
marked -4-.

1.15 Checking injectors

There are four ways of checking the injectors. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Performing adaption of correction values for injectors 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.
⇒ page 24
• Checking for injectors sticking open ⇒ page 25
• Measuring return flow rate of injectors with engine running
⇒ page 27
• Checking return flow rate of injectors at starter cranking speed
⇒ page 30

1.16 Performing adaption of correction val‐

ues for injectors
The “Injector delivery calibration” function serves to correct the
injection rates for each cylinder of a common rail system individ‐
ually across the entire operating range.

24 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

The 6-digit adaption values -Item 1- are marked separately on

each injector. They may consist of letters and/or numbers (ASCII
code).
When a new injector is installed, the adaption value for the new
injector must be stored in the corresponding engine control unit.
Cylinders 1, 4, 6 and 7: master engine control unit
Cylinders 2, 3, 5 and 8: slave engine control unit
When one or both engine control units are renewed, the appro‐
priate injector delivery calibration values must be stored in the
new control unit(s):
Examples:
If the master engine control unit is renewed, the injector delivery
calibration values must be re-adapted for cylinders 1, 4, 6 and 7.
If the slave engine control unit is renewed, the injector delivery
calibration values must be re-adapted for cylinders 2, 3, 5 and 8.
The adaption procedure is described in Guided Fault Finding.
(The procedure is also described in Guided Functions)

1.17 Checking for injectors sticking open

If one of the injectors is sticking open, this means that the injector
needle is not closing fully and fuel escapes into the cylinder.
Special tools and workshop equipment required
♦ Hand vacuum pump - VAS 6213-

♦ Use a return line to make an -adapter-.

Procedure
– Remove engine cover panel.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Clean all fuel rail connections with engine
permitted unless authorised cleaner
by AUDI AG. ordoes
AUDI AG brake
not guarantee or accept any liability
cleaner and dry. with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Servicing diesel direct injection system 25

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

WARNING

Always read instructions for working on fuel system.

Follow these instructions before starting work and while work‐
ing on the fuel system ⇒ page 2 .

Note

Check all cylinders in turn.

26 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Pull off retaining clips -arrows- from fuel return lines.

– Disconnect fuel return hoses from injectors.
– Connect adapter to return line connection of injector to be tes‐
ted after adapter has been cleaned and blown out.
– Generate a vacuum of -500 mbar using the hand vacuum
pump - VAS 6213- .
If the vacuum reading remains the same for 30 seconds, the in‐
jector is OK.
In the case of a faulty injector, the vacuum will fall back to 0 bar
within 2 to 3 seconds.
Repeat test if necessary; note drop in vacuum reading on hand
vacuum pump - VAS 6213- .
– Renew faulty injectors ⇒ page 35 .
Installing fuel return lines
– Check O-ring for fuel return line connection for damage and
deformation.
If O-ring is damaged or deformed, renew O-ring.

Note

Lubricate all seals with engine oil or assembly oil before installing.

– Press the return lines firmly onto the injectors from above so
that they engage audibly on each injector. Then re-fit the re‐
taining clips. Check that the return lines are seated securely
by pulling them by hand from above.
Bleeding fuel system and checking for leaks
– Run engine at idling speed for several minutes (do not press
accelerator) and then switch off. Fuel system will bleed itself
automatically.
– Check the entire fuel system for leaks.
Renew the affected component if leakage occurs.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.

Note

If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the
Protected engineCopying
by copyright. and erase the
for private event memory.
or commercial purposes, in Then
part or in whole, is not
continue the roadunless
permitted test.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.

1.18 Measuring return flow rate of injectors

with engine running
Checking return flow rate if engine does not start ⇒ page 30
Special tools and workshop equipment required

1. Servicing diesel direct injection system 27

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

♦ Return flow meter - VAS 6684- or meter - V.A.G 1348/2B-

WARNING

Always read instructions for working on fuel system.

Follow these instructions before starting work and while work‐
ing on the fuel system ⇒ page 2 .

Checking return flow rate of injectors (cylinder bank 1)

A certain amount of excess fuel is returned from every injector
(return flow rate). If the return flow rate at one injector is relatively
high compared to the other injectors, that injector is probably de‐
fective.
– Remove engine cover panel (refer to instructions for removing
and installing ⇒ page 24 ).
– Clean all return line connections with engine cleaner or brake
cleaner and dry.
– Using hose clamp (up to Ø 25 mm) - 3094- , clamp off common
return line behind cylinder No. 4 to prevent fuel coming out at
the disconnected return lines.

– Pull off retaining clips -arrows- from fuel return lines.

– Pull return lines off all four injectors and connect four test ho‐
ses (approx. 90 cm long) to return connections.

Note

Take care to keep all components clean. No dirt must be allowed

to get into the disconnected return lines or the open connections
on the injectors.

– Secure hoses with retaining clips.

28 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Feed the four hoses into meter.

– Start engine and let it idle for several minutes.
– If the return flow rate at one or more injectors is so high that
the engine will not start (or is difficult to start), this will be ap‐
parent while the starter is being operated: the measuring tube
belonging to the defective injector will fill up noticeably faster.
– If the engine starts, there should be no significant difference
between the return flow rates at the four return connections
(with the engine warm and idling at about 650 rpm).
The return flow rate should not exceed 20 ml per minute at each
cylinder.
If an injector does not meet this specification, renew the injector
concerned ⇒ page 35 .
– Press the return lines onto the injectors from above so that
they engage audibly on each injector. Then re-fit the retaining
clips. Check that the return lines are seated securely by pulling
them by hand from above.
If specification is met, check cylinder bank 2.
Checking return flow rate of injectors (cylinder bank 2)

– Pull off retaining clips from fuel return lines.

– Pull return lines off all four injectors and connect four test ho‐
ses (approx. 90 cm long) to return connections.

Note

Take care to keep all components clean. No dirt must be allowed

to get into the disconnected return lines or the open connections
on the injectors.

– Secure hoses with retaining clips.

– Using hose clamp (up to Ø 25 mm) - 3094- , clamp off common

return line behind cylinder No. 8 to prevent fuel coming out at
the disconnected return lines.

1. Servicing diesel direct injection system 29

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Feed the four hoses into meter.

– Start engine and let it idle for several minutes.
– If the return flow rate at one or more injectors is so high that
the engine will not start (or is difficult to start), this will be ap‐
parent while the starter is being operated: the measuring tube
belonging to the defective injector will fill up noticeably faster.
– If the engine starts, there should be no significant difference
between the return flow rates at the four return connections
(with the engine warm and idling at about 650 rpm).
The return flow rate should not exceed 20 ml per minute at each
cylinder.
If an injector does not meet this specification, renew the injector
concerned ⇒ page 35 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Installing fuel return lines

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.

– Check O-ring for fuel return line connection for damage and
deformation.
If O-ring is damaged or deformed, renew O-ring.

Note

Lubricate all seals with engine oil or assembly oil before installing.

Note

If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the event memory. Then
continue the road test.

1.19 Checking return flow rate of injectors at

starter cranking speed
Only perform this test if the engine does not start at all.
Special tools and workshop equipment required

30 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

♦ Return flow meter - VAS 6684- or meter - V.A.G 1348/2B-

♦ Lengths of hose to fit return line connections on injectors

WARNING

Always read instructions for working on fuel system.

Follow these instructions before starting work and while work‐
ing on the fuel system ⇒ page 2 .

Procedure
Each injector normally has a relatively low return flow rate. If the
return flow rate at one injector is relatively high compared to the
other injectors, that injector is probably defective.
– Remove engine cover panel (refer to instructions for removing
and installing ⇒ page 24 ).
– Clean all return line connections with engine cleaner or brake
cleaner and dry.
– Pull off retaining clips -arrows- from fuel return lines.
– Pull return lines off all four injectors and connect four test ho‐
ses (approx. 90 cm long) to return connections.

Note

Take care to keep all components clean. No dirt must be allowed

to get into the disconnected return lines or the open connections
on the injectors.

– Secure hoses with retaining clips.

1. Servicing diesel direct injection system 31

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Feed the four hoses into meter.

– Operate starter three times (wait approx. 20 seconds each
time after operating starter to prevent it from overheating).
♦ Specification of return flow rate: 0 ml
– If fuel comes out of one injector, that injector must be renewed
⇒ page 35 .
Installing fuel return lines
– Check O-ring for fuel return line connection for damage and
deformation.
If O-ring is damaged or deformed, renew O-ring.

Note

Lubricate all seals with engine oil or assembly oil before installing.

– Push the return line connections carefully over the new seals
and onto the injectors. The catch should engage audibly. Then
press release pin down carefully.
If specification is met, check cylinder bank 2.
Checking return flow rate of injectors (cylinder bank 2)

– Pull off retaining clips from fuel return lines.

– Pull return lines off all four injectors and connect four test ho‐
ses (approx. 90 cm long) to return connections.
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.
Note

Take care to keep all components clean. No dirt must be allowed

to get into the disconnected return lines or the open connections
on the injectors.

– Secure hoses with retaining clips.

32 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Feed the four hoses into meter.

Note

Lubricate all seals with engine oil or assembly oil before installing.

– Push the return line connections carefully over the new seals
and onto the injectors. The catch should engage audibly. Then
press release pin down carefully.
– Erase entry in event memory using a diagnostic tester.
Bleeding fuel system and checking for leaks
– Run engine at idling speed for several minutes (do not press
accelerator) and then switch off. Fuel system will bleed itself
automatically.
– Check the entire fuel system for leaks.
Renew the affected component if leakage occurs.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
section of the fuel system again for leaks.
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.

Note

1.20 Removing and installing high-pressure

pipes between distributor housing (func‐
tion block) and high-pressure pump /
fuel rail

WARNING

Always read instructions for working on fuel system.

Follow these instructions before starting work and while work‐
ing on the fuel system ⇒ page 2 .

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1331- with ratchet - V.A.G 1331/1-
♦ Socket, 14 mm - 3150-

1. Servicing diesel direct injection system 33

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

Removing
– Remove engine cover panel (refer to instructions for removing
and installing ⇒ page 24 ).
– Using commercial cleaning solution etc., clean connections of
all high-pressure pipes that have to be opened before remov‐
ing.
– Dry all components after cleaning.

Note

♦ High-pressure pipes between fuel rail and injectors must be

marked on removal. High-pressure pipes must always be re-
installed in the same position.
♦ Counterhold at pressure pipe connections when loosening un‐
ion nuts.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Seal off open connections on pipes
permitted unless immediately
authorised with
by AUDI AG. AUDI suitable
AG does not guarantee or accept any liability
caps. with respect to the correctness of information in this document. Copyright by AUDI AG.

34 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Open union nuts on the relevant high-pressure pipe using

socket (14 mm) - 3150- .
Installing

Note

♦ The high-pressure pipes can normally be used again. Before

re-installing them in the vehicle, check the taper seats for dis‐
tortion and cracks.
♦ The bore of the pipe must not be distorted, restricted or oth‐
erwise damaged.

– Blow out high-pressure pipes

Protected with compressed
by copyright. Copying for privateair before re-
or commercial purposes, in part or in whole, is not
installing. 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.
– Lubricate threads of union nuts with fuel.
– Tighten union nuts hand-tight to start with. Make sure that
connections are not under tension.
– Then tighten union nuts to specified torque (counterhold at
pressure pipe connection).
Tightening torque
Component Nm
High-pressure pipes 25
– Run engine at moderate speed for several minutes and then
switch off.
– Check the entire fuel system for leaks.
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.
– After completing the repair, road-test the vehicle over a dis‐
tance of at least 20 km. Accelerate with full throttle at least
once. Then inspect the high-pressure section of the fuel sys‐
tem again for leaks.

Note

If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the fault memory. Then con‐
tinue the road test.

1.21 Removing and installing injectors

WARNING

Always read instructions for working on fuel system.

Follow these instructions before starting work and while work‐
ing on the fuel system ⇒ page 2 .

Special tools and workshop equipment required

♦ Socket, 14 mm - 3150-
♦ Locking pin - 3242-
♦ Diesel injection pump locking pin - 3359-

1. Servicing diesel direct injection system 35

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

♦ Torque wrench - V.A.G 1331- (5...50 Nm)

♦ Ratchet - V.A.G 1331/1-
♦ Puller - T40059-
♦ Multi-purpose tool - VW 771-
♦ Cleaning kit - VAS 6811-
Removing

Note

♦ Crankshaft must be at TDC position when removing injectors

for cylinders 1, 2, 4 (cylinder bank 1) and 5, 6, 7, 8 (cylinder
bank 2).
♦ When removing the injector for cylinder 3 the crankshaft must
be turned 90° (1/4 turn) further.

– Remove engine cover panel (refer to instructions for removing

and installing ⇒ page 24 ). 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
– Move lock carrier to service position. ⇒ General body with
repairs,
respect to the correctness of information in this document. Copyright by AUDI AG.
exterior; Rep. gr. 50
– Unscrew bolts -2- on anti-roll bar clamps uniformly and re‐
move.
– Pivot anti-roll bar -1- down.

Note

Place a cloth under the engine to catch escaping engine oil.

– Unscrew plug from sump (top section).

WARNING

To avoid any risk of injury, do not rotate the crankshaft while

feeling for the TDC drilling with your finger.

36 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Turn crankshaft in direction of engine rotation -arrow- ...

– ... until TDC bore -1- in crank web is visible through inspection
hole in top section of sump.
– Screw locking pin - 3242- into bore (20 Nm); if necessary, turn
crankshaft backwards and forwards slightly to fully centralise
locking pin.

– Unscrew sealing plug -1- from inspection hole for camshaft

TDC position from cylinder head (right-side).
– Insert diesel injection pump locking pin - 3359- to check wheth‐
er TDC slot is located below inspection hole -arrow-.
♦ If diesel injection pump locking pin - 3359- can be inserted
approx. 40 mm, camshaft is at TDC position.
♦ If diesel injection pump locking pin - 3359- can only be inserted
30 mm, camshaft has not reached TDC position. In this case,
pull out diesel injection pump locking pin - 3359- , turn crank‐
shaft 1 complete revolution further and insert locking pin again.

– Remove cover for right suspension turret; to do so, detach

spreader clips -1- and unscrew bolted joint -2-.
– Pull cover out of retainers -arrows-.

1. Servicing diesel direct injection system 37

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Remove bolts -arrows-.

– Detach top section of air cleaner housing (right-side). Cover
air mass meter with a clean cloth.

– Detach oil filler neck. To do this, lift tab -2- and turn oil filler
neck clockwise -arrow-.

Note

Item -1- can be disregarded. 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

Cylinder bank 1
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Move electrical wiring clear of rail element (right-side).

WARNING

♦ Observe rules for cleanliness when working on the injec‐

tion system ⇒ page 2 .
♦ Identify cylinder numbers on injectors.
♦ Used injectors must always be re-installed on the same
cylinder.

– Unscrew union nut -1- on rail element (right-side).

– Unscrew union nuts -4 ... 7- (counterhold pressure pipe con‐
nections).

– Remove bolts -2- and -3-.

– Place rail element on intake manifold.
– Unplug electrical connectors -2 ... 5-.
– Unscrew wiring guide from cylinder head (right-side)
-arrows-.

38 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Pull off retaining clips for return line -1-.

– Pull return line off injectors.
Cylinder bank 2
– Move electrical wiring clear of rail element (left-side).

WARNING

♦ Observe rules for cleanliness when working on the injec‐

tion system ⇒ page 2 .
♦ Identify cylinder numbers on injectors.
♦ Used injectors must always be re-installed on the same
cylinder.

– Unscrew union nut -3- on rail element (left-side).

– Unscrew union nuts -4 ... 7- (counterhold pressure pipe con‐
nections).

– Remove bolts -1- and -2-.

– Take off rail element (left-side).
– Unplug electrical connectors -2 ... 5-.
– Unscrew wiring guide from cylinder head (left-side) -arrows-.

– Pull off retaining clips for return line -1-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Pull return line off injectors.
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.
Both cylinder banks:

– Unscrew covers for injectors on both cylinder heads

-arrows-.
– Pull covers upwards and turn them 1/4 turn (90°).

1. Servicing diesel direct injection system 39

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Remove nuts securing injectors on both cylinder heads

-arrows-.

WARNING

♦ Identify cylinder numbers on injectors.

♦ Used injectors must always be re-installed on the same
cylinder.

– To remove injectors, use puller - T40059- -1- and multi-pur‐

pose tool - VW 771- -2-.

– Screw puller - T40059- -1- onto the injector that is being re‐
moved and knock out the injector using multi-purpose tool -
VW 771- -2-.

Note

The illustration shows cylinder No. 6 as an example.

– Pull out injectors for cylinders 1, 2 and 4 on cylinder head

(right-side)
– Pull out all injectors on cylinder head (left-side).

Note

When removing the injector for cylinder 3 the crankshaft must be

turned 90° (1/4 turn) further.

– Remove locking pin - 3242- .

– Turn crankshaft 90° (1/4 revolution) in normal direction of ro‐

tation -arrow-.

40 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Pull out injector for No. 3 cylinder on cylinder head (right-side).

Important instructions for installing injectors:
♦ Clamping piece
♦ Copper seal
♦ O-ring for injector bore
♦ O-ring for fuel return line connection

Note

♦ Note identification marks for cylinder allocation when re-in‐

stalling high-pressure pipes.
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
♦ The high-pressure pipes canto the
with respect becorrectness
re-usedofafter performing
information the Copyright by AUDI AG.
in this document.
following checks:
♦ Check taper seats of high-pressure pipes for deformation and
cracks.
♦ The bore of the pipe must not be distorted, restricted or oth‐
erwise damaged.
♦ Corroded pipes must not be used again.

If a used injector is being re-installed:

– Spray tip of injector nozzle with rust-releasing spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Clean off deposits under the copper seal using a suitable scra‐
per.
– Renew seal for injector.
– To prevent damage to the new O-ring, lubricate it with oil and
carefully push it onto the fuel return line connection.
Continued (same procedure for used and new injectors):

Note

Lubricate all O-rings with assembly oil, engine oil or diesel fuel
before installing.

Caution

Risk of damage to injector sealing surface.

♦ To remove carbon deposits from the injector sealing sur‐
face, clean the injector bore in the cylinder head with
cleaning kit - VAS 6811- .

– Install injector.
– Tighten union nuts on high-pressure pipes hand-tight initially.
– Ensure that high-pressure pipes are not under tension.

1. Servicing diesel direct injection system 41

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– To tighten unions of high-pressure pipes, use torque wrench

- V.A.G 1331- with ratchet - V.A.G 1331/1- and socket, 14 mm
- 3150- .
– Install injector for No. 3 cylinder on cylinder head (right-side).

WARNING

To avoid any risk of injury, do not rotate the crankshaft while

feeling for the TDC drilling with your finger.

– Turn crankshaft 1 3/4 revolutions in direction of engine rotation

-arrow- ...

– ... until TDC bore -1- in crank web is visible again through in‐
spection hole in top section of sump.
– Screw locking pin - 3242- into bore (20 Nm); if necessary, turn
crankshaft backwards and forwards slightly to fully centralise
locking pin.

– Insert diesel injection pump locking pin - 3359- in drilling -1- to

check whether TDC slot is located below inspection hole.
♦ If diesel injection pump locking pin - 3359- can be inserted
approx. 40 mm, camshaft is at TDC position.
♦ If diesel injection pump locking pin - 3359- can only be inserted
30 mm, camshaft has not reached TDC position. In this case,
pull out locking pin 3359, turn crankshaft 1 complete revolution
further and insert pin once again.
– Install injectors for cylinders 1, 2, 4, 5, 6, 7 and 8.

42 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Remove locking pin - 3242- from crank web.

– Screw in plug for TDC inspection hole in top section of sump,
using new seal.

1. Servicing diesel direct injection system 43

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Remove diesel injection pump locking pin - 3359- from in‐

spection hole for camshaft TDC position.
– Screw in plug for camshaft TDC inspection hole.
– Install anti-roll bar. ⇒ Rep. gr. 40
– Install lock carrier with attachments ⇒ General body repairs,
exterior; Rep. gr. 50 .
– Install front bumper ⇒ Rep. gr. 63 .
– Deactivate jacking mode. ⇒ Rep. gr. 43
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Adjust headlights ⇒ Rep. gr. 94 . 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.
Tightening torques
Component Nm
Injector in cylinder head 10
Cover for injector to cylinder head 5
renew
Rail element to cylinder head 22
High-pressure pipes 25
Screw plug in top section of sump 35
Screw plug in cylinder head 18
When one or more injectors have been renewed, the “Injector
delivery calibration values” for the new injectors must be pro‐
grammed in the corresponding engine control unit.
Additionally, check that the correct “Injector delivery calibration
values” for all the remaining injectors are stored in the corre‐
sponding control unit. Do not enter new values for the “Injector
delivery calibration” if the correct values are already stored.
♦ The values of the injectors for cylinders 1, 4, 6 and 7 are stored
in the master engine control unit.
♦ The values of the injectors for cylinders 2, 3, 5 and 8 are stored
in the slave engine control unit.
Bleeding fuel system and checking for leaks
– Run engine at moderate speed for several minutes and then
switch off.

Note

The fuel system is self-bleeding; do not open the high-pressure

connections.

– Switch off ignition.

– Carefully check the entire fuel system including all 6 return line
connections for leaks (the fuel return lines can only be re‐
newed together with the pressure retention valve as one unit).
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.

44 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

Note

1.22 Exploded view - high-pressure pump

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 - 22 Nm 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 - Toothed belt sprocket
❑ For high-pressure pump
❑ Remove using puller -
T40064- ⇒ page 46
3 - 70 Nm
❑ Use counterhold tool -
T40053- to loosen and
tighten ⇒ page 46
4 - 22 Nm
5 - Idler roller
6 - Front bracket
❑ For high-pressure pump
7 - Fuel return hose
8 - Seals
❑ Renew
9 - Banjo bolt
❑ 22 Nm
10 - Fuel supply line
11 - High-pressure pump
❑ Removing and installing
⇒ page 46
12 - 22 Nm
13 - 22 Nm
14 - Bracket
15 - 22 Nm

1. Servicing diesel direct injection system 45

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

Loosening toothed belt sprocket

– Use counterhold tool - T40053- when loosening and tightening
central nut.

Pulling off toothed belt sprocket

– Use puller -T40064- to pull off belt sprocket.

1.23 Removing and installing high-pressure

pump and gear-type fuel system pres‐
surisation pump
The high-pressure pump and gear-type fuel system pressurisa‐
tion pump are combined as one unit.

WARNING

Always read instructions for working on fuel system.

Follow these instructions before starting work and while work‐
ing on the fuel system ⇒ page 2 .

Special tools and workshop equipment required

♦ Socket, 14 mm - 3150-
♦ Torque wrench - V.A.G 1331- (5...50 Nm)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Ratchet - V.A.G 1331/1- 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.

♦ Counterhold tool - T40053-

46 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

♦ Puller -T40064-

Removing
– Remove engine cover panel (refer to instructions for removing
and installing ⇒ page 24 ).
– Drain cooling system. ⇒ Rep. gr. 19
– Move lock carrier to service position. ⇒ General body repairs,
exterior; Rep. gr. 50
– Remove intake manifold (left-side). ⇒ Rep. gr. 15
– Remove mechanical exhaust gas recirculation valve (left-
side). ⇒ Rep. gr. 26
– Remove cooler (left-side) for exhaust gas recirculation. ⇒
Rep. gr. 26
– Unplug electrical connectors -4- and -6-.
– Remove high-pressure pipes -1- and -2- (counterhold at pipe
connections on high-pressure pump).
– Remove banjo bolt -3-.
– Disconnect fuel return hose -5- at fuel distributor housing.
– Remove bolts -7- and take off fuel distributor housing.
– Unplug electrical connector -3-.
– Remove banjo bolt -2-.

– Remove bracket -1- for fuel distributor housing.

– Remove toothed belt for high-pressure pump ⇒ page 53 .
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. Servicing diesel direct injection system 47

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Release clamps -arrows- and lift off rear toothed belt cover
-1-.

– Remove central nut for high-pressure pump (use counterhold

tool - T40053- ).

– Pull toothed belt sprocket off high-pressure pump using puller

-T40064- .

48 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Remove bolts -arrows-.

– Take high-pressure pump off front bracket.
Installing
Installation is carried out in the reverse order; note the following:

Note

♦ Renew seals.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue .

– Tighten union nuts on high-pressure pipes hand-tight initially.

– Ensure that high-pressure pipes are not under tension.

– To tighten unions of high-pressure pipes, use torque wrench

- V.A.G 1331- with ratchet - V.A.G 1331/1- and socket, 14 mm
- 3150- .
– Install toothed belt for high-pressure pump ⇒ page 53 .
– Install cooler (left-side) for exhaust gas recirculation. ⇒ Rep.
gr. 26
– Install mechanical exhaust gas recirculation valve (left-side).
⇒ Rep. gr. 26
– Install intake manifold (left-side). ⇒ Rep. gr. 15
– Install lock carrier with attachments ⇒ General body repairs,
exterior; Rep. gr. 50 .
– Install front bumper ⇒ General body repairs, exterior; Rep. gr.
63 .
– Fill cooling system. ⇒ Rep. gr. 19
– Deactivate jacking mode. ⇒ Rep. gr. 43
– Adjust headlights ⇒ Rep. gr. 94 .
– Bleed fuel system before first engine start ⇒ page 50 .
– Check fuel system for leaks ⇒ page 51 .
Tightening torques
Component Nm
High-pressure pump to 22
front bracket
Toothed belt sprocket to high-pressure pump 70
Bracket for high-pressure pump to
High-pressure pump 22
Protected by copyright. CopyingCylinder
for private orblock 22or in whole, is not
commercial purposes, in part
Bracketpermitted
for fuel distributor housing to high-pres‐ 10
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.
sure pump
Fuel supply line to high-pressure pump 25
Fuel distributor housing to bracket 10
Banjo bolt to fuel distributor housing 9
High-pressure pipe to fuel distributor housing 25

1. Servicing diesel direct injection system 49

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

1.24 Bleeding fuel system after installing

high-pressure pump
After installation, the high-pressure pump must first be filled with
fuel before the engine is started (the pump must not be allowed
to run while still empty).

Note

♦ When installing the high-pressure fuel pump, it is essential to

ensure that no dirt enters the fuel system.
♦ Only remove sealing plugs immediately prior to installation of
fuel pipes.
♦ There must be sufficient fuel in the tank.

Bleeding fuel system

Proceed as follows to fill high-pressure pump with fuel.
– Connect battery charger ⇒ Rep. gr. 27
– Switch on ignition for 100 seconds.
– Switch off ignition.
– Switch on ignition again for 100 seconds.

Note

♦ The fuel pump is activated for 100 seconds each time the ig‐
nition is switched on.
♦ This ensures that a supply of fuel without air bubbles is present
at the high-pressure pump intake.

– Unplug connector from fuel pressure regulating valve - N276-

so that engine does not start when starter motor is operated.
Overview of fitting locations ⇒ page 4
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Operate starter motor for 3 x 13 seconds. (Waitunless
permitted approx.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
20 seconds each time after operating starter to prevent it from
with respect to the correctness of information in this document. Copyright by AUDI AG.

overheating.)
– Re-attach connector on fuel pressure regulating valve -
N276- .
– Erase fault in fault memory using diagnostic tester.
– Start engine.
– After bleeding fuel system, leave engine running at moderate
speed for a few minutes and then switch off again.
– Check fuel system for leaks.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.

Note

50 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Interrogate event memory.

1.25 Checking for leaks in fuel system

– Start the engine and let it run at medium speed for a few mi‐
nutes.
– Switch off ignition.
– Check fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.

Note

1.26 Exploded view - toothed belt for high-pressure pump

1. Servicing diesel direct injection system 51

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

1 - 22 Nm
2 - 150 Nm
❑ Use counterhold tool -
T40063- when loosen‐
ing and tightening
⇒ page 52
3 - Damper weight
4 - Toothed belt
❑ For high-pressure pump
❑ Removing and installing
⇒ page 53
5 - Toothed belt sprocket
6 - 22 Nm
7 - Idler roller
8 - Toothed belt sprocket
❑ For high-pressure pump
❑ Remove using puller -
T40064- ⇒ page 53
9 - 70 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Use counterhold tool - permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
T40053- when loosen‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
ing and tightening
⇒ page 53
10 - Tensioning roller

Unbolting damper weight

– Use counterhold tool -T40063- when loosening and tightening
central bolt.

52 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

Loosening toothed belt sprocket

– Use counterhold tool - T40053- when loosening and tightening
central nut.

Pulling off toothed belt sprocket

– Use puller -T40064- to pull off belt sprocket.

1.27 Removing and installing toothed belt for

high-pressure pump
Special tools and workshop equipment required
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Support
permitted bracket
unless authorised - 10AG.
by AUDI - 222
AUDIA-AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Adapters - 10 - 222 A /21-
♦ Drill bit, ∅ 4.5 mm

Removing

Note

All cable ties which are released or cut open when removing must
be refitted in the same position when installing.

1. Servicing diesel direct injection system 53

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Move lock carrier to service position. ⇒ General body repairs,

exterior; Rep. gr. 50
– Remove cover above coolant expansion tank -arrows-.
– Pull off rubber seal -1- on plenum chamber covers.

– Detach plenum chamber covers -2- and -3-.

– Use screwdriver to pry off cover caps on wiper arms and un‐
screw hexagon nuts.
– Pull wiper arms off wiper shafts.
– Remove dust and pollen filter. ⇒ Rep. gr. 87

Note

Cover air duct at air conditioner housing with clean cloth to pre‐
vent anything falling in.

– Unscrew bolts on left and right -arrows- for cowl panel grille
-1-.
– Carefully pull cowl panel grille off retainer at windscreen.

– Unscrew body brace -arrow-.

54 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Remove cover for suspension turret (left-side); to do so, re‐

move nut -1- and detach spreader clip -2-.

– Remove bolt -arrow-.

– Pivot bracket for air conditioner pipe to one side.

Note

To prevent damage to the air conditioner compressor and refrig‐

erant pipes/hoses, ensure that the pipes and hoses are not
stretched, kinked or bent.

– Remove cover for right suspension turret; to do so, detach

spreader clips -1- and unscrew bolted joint -2-.
– Pull cover out of retainers -arrows-.

– Remove bolts -arrows- on fuel filter bracket.

Note

Fuel filter remains in engine compartment with fuel lines connec‐

ted.

1. Servicing diesel direct injection system 55

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Attach support bracket - 10 - 222 A- with adapters - 10 - 222

A /21- onto suspension turrets.
♦ Adapters are marked for left and right side of vehicle.
♦ The adapters - 10 - 222 A /21- are attached by means of the
rear securing bolts -3- for the body brace.
♦ The centre support points of the adapters are positioned on
the front bolts for the body brace.
♦ The knurled screw -1- must be screwed down until the support
plate rests on the suspension turret.

– Secure spindles of support bracket - 10 - 222 A- to rear engine

lifting eyes.
– Take up weight of engine on spindles of support bracket (con‐
siderable weight has to be supported).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove bolts -arrows- and detach bracket
permitted for charge
unless airbycool‐
authorised AUDI AG. AUDI AG does not guarantee or accept any liability
er (left-side). with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

Items -1- and -2- can be disregarded.

– Remove bolt -arrow- for air intake pipe (left-side).

56 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Remove bolts -arrows- and detach bracket for charge air cool‐
er (right-side).

Note

Items -1- and -2- can be disregarded.

– Remove bolt -arrow- for air intake pipe (right-side).

– Unscrew subframe bolts -1- and -3-.

Note

Bolts -Item 2- for engine mounting do not have to be loosened.

– Detach oil filler neck. To do this, lift tab -2- and turn oil filler
neck clockwise -arrow-.
– Remove bolt -1- on mounting for torque reaction support.

1. Servicing diesel direct injection system 57

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Lower engine on spindles of support bracket ...

– ... until cylinder head cover is just slightly above bracket for
torque reaction support -arrow-.

– Disconnect vacuum hose -arrow- leading to brake servo.

– Move vacuum hose clear towards right side of vehicle (first
disconnect the thin hose located below).
– Move electrical wiring clear at rear of engine.

– Release clamps -arrows- and detach toothed belt cover.

– Pivot toothed belt cover to the rear and disengage retaining
pegs on bottom side of toothed belt cover.

58 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Unscrew bolt -arrow- for tensioning roller.

– Take off tensioning roller and toothed belt for high-pressure
pump.
Installing
Installation is carried out in the reverse order; note the following:
Note correct tightening torques.

Note

Reinstall all cable ties in the same locations when assembling.

– Apply pressure to tensioning roller by hand and lock in position

with a 4.5 mm ∅ drill bit.

– Note correct installation position when securing tensioning

roller.
♦ Retaining lugs -2- on tensioning roller must contact cast pro‐
jection -1- on front bracket for high-pressure pump, as illus‐
trated.
– Fit toothed belt for high-pressure pump on sprockets.

1. Servicing diesel direct injection system 59

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Pull drill bit out of locating holes -arrow-.

– Install subframe. ⇒ Rep. gr. 40
– Install body brace. ⇒ Rep. gr. 40
– Install lock carrier with attachments ⇒ General body repairs,
exterior; Rep. gr. 50 .
– Install front bumper ⇒ General body repairs, exterior; Rep. gr.
63 .
– Deactivate jacking mode. ⇒ Rep. gr. 43
– Install wiper arms. ⇒ Rep. gr. 92
– Adjust headlights ⇒ Rep. gr. 94 .
Tightening torques
Component Nm
Tensioning roller to high-pressure pump 22
Engine cross member to longitudinal member 68
Bracket for torque reaction support to subframe 40
Mounting for torque reaction support 23

1.28 Removing and installing air mass meter

(left-side)
Removing 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
– Remove bolts -arrows-. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Detach top section of air cleaner housing (left-side).

Note

Make sure components are kept clean; cover air mass meter with
a clean cloth. Keep dirt away from air mass meter.

– Remove front left wheel.

Note

Secure brake disc with one wheel bolt.

– Remove front section of wheel housing liner (front left). ⇒ Rep.

gr. 66

– Working from wheel housing (left-side), pull rubber grommet

-1- off bottom section of air cleaner housing.
– Disconnect air intake hose -2- from bottom section of air clean‐
er housing.

60 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Detach electrical connector -1- at air mass meter.

– Remove bolts -arrows-.
– Detach bottom section of air cleaner housing (left-side).

– Remove bolts -arrows-.

– Detach air duct from top section of air cleaner housing.

1. Servicing diesel direct injection system 61

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Remove bolts -arrows-.

– Detach air mass meter from air duct.
Installing
To ensure the proper function of the air mass meter - G70- it is
important to observe the following instructions.

Note

♦ Hose connections and hoses for charge air system must be

free of oil and grease before assembly. Do not use any lubri‐
cants containing silicone when assembling.
♦ Always use genuine part for air filter element.
♦ Do not use any lubricants containing silicone when assem‐
bling.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue .

– Blow out water drain hose 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 meter and
air intake hose (engine intake side).
– Check for dirt in air duct leading to air filter element.
– When installing the air filter element, check that it is properly
centred in the retainer in the air cleaner (bottom section).
– Fit the top section of the air cleaner carefully on the bottom
section, without using force. Make sure the top section of the
air cleaner is fitted straight on the air filter element. Note po‐
sition of sealing lip on air filter element (to prevent air leaks).
– Then screw top section of air cleaner back onto bottom sec‐
tion.
– Installation is performed in the reverse sequence.

1.29 Removing and installing air mass meter

(right-side)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Removing 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.
– Remove engine cover panel (refer to instructions for removing
and installing ⇒ page 24 ).
– Remove cover for right suspension turret; to do so, detach
spreader clips -1- and unscrew bolted joint -2-.
– Pull cover out of retainers -arrows-.

62 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Remove bolts -arrows-.

– Detach top section of air cleaner housing (right-side).

Note

Make sure components are kept clean; cover air mass meter with
a clean cloth. Keep dirt away from air mass meter.

– Remove front right wheel.

Note

Secure brake disc with one wheel bolt.

– Remove front section of wheel housing liner (front right). ⇒

Rep. gr. 66

– Working from wheel housing (right-side), pull rubber grommet

-1- off bottom section of air cleaner housing
– Disconnect air intake hose -2- from bottom section of air clean‐
er housing.

– Detach electrical connector -1- at air mass meter.

– Remove bolts -arrows-.
– Detach bottom section of air cleaner housing (right-side).
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.

– Remove bolts -arrows-.

– Detach air duct from top section of air cleaner housing.

1. Servicing diesel direct injection system 63

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Remove bolts -arrows-.

– Detach air mass meter from air duct.
Installing
To ensure the proper function of the air mass meter - G70- it is
important to observe the following instructions.

Note

♦ Hose connections and hoses for charge air system must be

– Blow out water drain hose with compressed air.

1.30 Removing and installing fuel pressure

regulating valve - N276-
Special tools and workshop equipment required
♦ Torque wrench
♦ Open-end spanner insert, 30 mm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Pliers (e.g.
permitted water
unless pump
authorised pliers)
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.
The fuel pressure regulating valve is located in the fuel distributor
housing (function block). It maintains a constant pressure in the
rail and the injector pipes (high-pressure circuit).
If the pressure in the rail is too high, the regulator valve opens to
allow some of the fuel to flow back from the rail to the fuel tank
via a return line.
If the pressure in the distributor housing is too low, the valve
closes and thus seals off the high-pressure section of the system
from the low-pressure section.
Overview of fitting locations ⇒ page 4

64 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

Note

The fuel pressure regulating valve - N276- cannot be re-used.

Removing
– Remove engine cover panel (refer to instructions for removing
and installing ⇒ page 24 ).
– Before removal, clean area around thread for fuel pressure
regulating valve using commercial cleaning solution etc. (no
dirt must enter the opening in the fuel rail).

Note

Clean carefully; cleaning solution must not enter the electrical

connector.

– Dry off fuel pressure regulating valve.

– Detach electrical connector.
– Slacken union nut (counterhold at hexagon flats on housing).
Then unscrew and remove by hand.
– Extract dirt from opening in rail (threads and sealing surface).
Do not use metal tools, etc.

Note

Seal off opening in rail immediately with a suitable plug.

Installing
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
Note
with respect to the correctness of information in this document. Copyright by AUDI AG.

Check that the sealing surfaces and threads on the new fuel
pressure regulating valve are not damaged. Check sealing sur‐
face at opening in rail.

– Lubricate O-ring on regulating valve with fuel.

– Screw on union nut by hand.
– Align regulating valve so that connecting wire is free of tension
after connector is attached.
– Hold regulating valve in this position by holding hexagon flats
on housing of regulating valve with pliers (water pump pliers
or similar).
– Use suitable torque wrench with an open-end spanner insert
(30 mm) to tighten union nut.
Tighten union nut in 2 stages.
Stage 1: 60 +/-5 Nm (counterhold hexagon flats on housing)
Then back off union nut 90° (counterhold hexagonal flats on
housing).
Stage 2: 80 + 5 Nm (counterhold hexagon flats on housing)
– After installation, run engine at moderate speed for several
minutes and then switch off.

1. Servicing diesel direct injection system 65

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Check fuel system for leaks.

– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.
– Interrogate fault memory again.

1.31 Removing and installing fuel pressure

sender - G247-
The fuel pressure sender - G247- continuously measures the
pressure in the high-pressure system and sends a voltage signal
to the diesel direct injection system control unit - J248- (master
control unit).
Overview of fitting locations ⇒ page 4
Removing
– Remove engine cover panel (refer to instructions for removing
and installing ⇒ page 24 ).
– Before removal, clean area around thread for fuel pressure
sender using commercial cleaning solution etc. (no dirt must
enter the opening in the rail).

Note

Clean carefully; cleaning solution must not enter the electrical

connector.

– Dry off fuel pressure sender.

– Detach electrical connector.
– Unscrew and remove fuel pressure sender.
– Extract dirt from opening in rail (threads and sealing surface).
Do not use metal tools, etc.

Note

Seal off opening in rail immediately with a suitable plug to prevent

dirt from entering.

Installing
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
Note with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ The fuel pressure sender - G247- does not have a seal; in‐
stead, it has a deformable sealing lip.
♦ Check that sealing surfaces (deformable sealing lip) and
threads on fuel pressure sender - G247- are not damaged. If
inspection of fuel pressure sender - G247- shows that it is OK,
it can be used again.
♦ Also check sealing surface at opening in rail.
♦ The beginning of the thread and the deformable sealing lip of
the fuel pressure sender - G247- must be lubricated with Mo‐
lykote grease.

– If the old fuel pressure sender is being re-installed, twist off the
old seal with pliers.

66 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Fit the new seal using the grease supplied to hold seal in place.
– Screw in fuel pressure sender by hand.
– Then tighten fuel pressure sender - G247- to specified torque.
♦ Tightening torque: 35 +/-3 Nm
Bleeding fuel system and checking for leaks
– After installation, run engine at moderate speed for several
minutes and then switch off.

Note

The fuel system is “self-bleeding”; do NOT open the high-pres‐

sure connections.

– Interrogate fault memory and erase, if necessary.

– Switch off ignition.
– Carefully check the entire fuel system for leaks.
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.

Note

– After road test interrogate the fault memory again.

1. Servicing diesel direct injection system 67

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

2 Removing and installing engine con‐

trol units

68 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

2.1 Wiring and component check with test

box - V.A.G 1598/42-

Note

♦ The test box has 105 contacts. 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
diagrams, Electrical fault finding and Fitting locations.
♦ 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 Protected
to the engine control
by copyright. unit
Copying for itself
private at the same
or commercial time.
purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ The advantage
with respect toof
thethis is thatof information
correctness the electronic engine
in this document. control
Copyright sys‐AG.
by AUDI
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.

WARNING

To prevent irreparable damage to the electronic components,

select appropriate measuring range before connecting the
measuring cables and observe the test requirements.

– Switch off ignition and remove ignition key.

– Remove cover from plenum chamber (right-side).

Note

♦ The two engine control units are identical from the outside.
However, if both control units are removed, they must be
marked before removal so they are not interchanged on re-
installation.
♦ Master engine control unit 1: mark “M” (for example)
♦ Slave engine control unit 2: mark “S” (for example)

Item -1- is the diesel direct injection system control unit - J248-
(master control unit 1).

2. Removing and installing engine control units 69

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

Item -2- is the diesel direct injection system control unit 2 - J494-
(slave control unit 2).
The removal procedure is the same for both engine control units.

To help prevent unauthorised access to the connectors on the

engine control units, the control unit -1- is bolted to a metal casing
-5- by means of shear bolts -3- and -4- and a locking plate -2-.

Special tools and workshop equipment required

♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle attach‐
ment -2- from wiring harness repair set - VAS 1978 B-
♦ Small, commercially available mole grips -3-

WARNING

70 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

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 neces‐
sary and would cause overheating of the control unit.

– Select settings on hot air blower as shown in illustration, i.e.

set temperature potentiometer -2- to maximum heat output
and two-stage air flow switch -3- to position 3.

– Apply heat to the threads of the shear bolts on the connector

side as shown in the illustration for approx. 25 to 30 seconds.

WARNING

2. Removing and installing engine control units 71

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Unscrew shear bolts using mole grips (see arrow in illustra‐

tion).
– The two shear bolts screwed into the control unit do not need
to be heated. They should be removed without being heated.
– Detach metal locking plate from control unit connectors.
– Release connectors on engine control unit and unplug con‐
nectors.
– Connect test box - V.A.G 1598/42- to wiring harness connec‐
tor. The earth clip on the test box must be connected to the
negative battery terminal. 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 appropriate repair procedures.
Installing engine control unit
Installation is performed in the reverse sequence. After installa‐
tion, the protective housing must be re-fitted on the control unit.
Use new shear bolts.

Note

After completion of the Guided Fault Finding routine, the tester

will attempt to erase the fault memories of all control units. If this
is not successful, the remaining faults registered in the memories
must be rectified until all faults can be erased.

2.2 Renewing diesel direct injection system

control unit - J248- (master control unit)
Engine management for the V8-TDIR (common rail) is handled
by two engine control units.
The two engine control units communicate via a separate CAN
bus.
The diesel direct injection system control unit - J248- (master
control unit) informs diesel direct injection system control unit 2 -
J494- (slave control unit) which functions it has to perform.
The two engine control units are identical from the outside. How‐
ever, if both control units are removed, they must be marked
before removal so they are not interchanged on re-installation.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Master engine control unit 1: mark “M” (for permitted
example) 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.
Slave engine control unit 2: mark “S” (for example)
Removing
– Connect vehicle diagnostic, testing and information system -
VAS 5051B- and select vehicle system “01 - Engine electron‐
ics” from list. When doing this, the ignition must be switched
on.
The display on vehicle diagnostic, testing and information system
- VAS 5051B- will show the control unit identification and the cod‐
ing -2-.

72 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Always start by displaying the control unit identification and

printing it out.
– Remove cover from plenum chamber (right-side).
Item -1- is diesel direct injection system control unit - J248- (mas‐
ter control unit).

Item -2- is diesel direct injection system control unit 2 - J494-

(slave control unit).

To help prevent unauthorised access to the connectors on the

engine control units, the engine control unit -1- is bolted to a metal
casing -5- by means of shear bolts -3- and -4- and a locking plate
-2-.

Special tools and workshop equipment required

♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle attach‐
ment -2- from wiring harness repair set - VAS 1978 B-
♦ Small, commercially available mole grips -3-

2. Removing and installing engine control units 73

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

WARNING

– Select settings on hot air blower as shown in illustration, i.e.

set temperature potentiometer -2- to maximum heat output
and two-stage air flow switch -3- to position 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.

– Apply heat to the threads of the shear bolts on the connector

side as shown in the illustration for approx. 25 to 30 seconds.

WARNING

74 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Unscrew shear bolts using mole grips (see arrow in illustra‐

tion).

– The two shear bolts screwed into the control unit do not need
to be heated. They should be removed without being heated.
– Detach metal locking plate from control unit connectors.
– Remove two bolts securing diesel direct injection system con‐
trol unit - J248- (master control unit) and pull control unit
forwards.
– Release connectors on diesel direct injection system control
unit - J248- and unplug connectors.
– Take out old diesel direct injection system control unit - J248-
and install new control unit.
Installing

Note

♦ Installation is performed in the reverse sequence. After instal‐

lation, the locking plate must be re-fitted on the control unit.
Use new shear bolts.
♦ After renewing the engine control unit you must also adapt the
injector delivery calibration values for the new engine control
unit (injector delivery calibration values influence engine pow‐
er output and exhaust emissions).
♦ If only the master control unit ( diesel direct injection system
control unit - J248- ) is renewed, the following injectors must
be re-adapted: cylinders 1, 4, 6 and 7.

The procedure to follow after connecting the new engine control

unit is described in Guided Fault Finding.
– Activate engine control unit in “Guided Functions” mode, “Re‐
new engine control unit” ⇒ Vehicle diagnostic tester.

2.3 Renewing diesel direct injection system

control unit 2 - J494- (slave control unit)
Engine management for the V8-TDIR (common rail) is handled
by two engine control units.
The two engine control units communicate via a separate CAN
bus.
The diesel direct injection system control unit - J248- (master
control unit) informs diesel direct injection system control unit 2 -
J494- (slave control unit) which functions it has to perform.
The two engine control units are identical from the outside. How‐
ever, if both control units are removed, they must be marked
before removal so they are not interchanged on re-installation.
Master engine control unit 1: mark “M” (for example)
Slave engine control unit Protected
2: markby“S” (for example)
copyright. Copying for private or commercial purposes, in part or in whole, is not

Removing
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.

– Connect vehicle diagnostic, testing and information system -

VAS 5051B- and select vehicle system “11 - Engine electron‐
ics 2” from list. When doing this, the ignition must be switched
on.

2. Removing and installing engine control units 75

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

The display on vehicle diagnostic, testing and information system

- VAS 5051B- will show the control unit identification and the cod‐
ing -2-.
– Always start by displaying the control unit identification and
printing it out.
– Remove cover from plenum chamber (right-side).
Item -1- is diesel direct injection system control unit - J248- (mas‐
ter control unit).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Item -2- is diesel direct injection system controlpermitted
unit 2 unless
- J494-authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
(slave control unit). with respect to the correctness of information in this document. Copyright by AUDI AG.

To help prevent unauthorised access to the connectors on the

engine control units, the engine control unit -1- is bolted to a metal
casing -5- by means of shear bolts -3- and -4- and a locking plate
-2-.

Special tools and workshop equipment required

♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle attach‐
ment -2- from wiring harness repair set - VAS 1978 B-
♦ Small, commercially available mole grips -3-

76 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

WARNING

– Select settings on hot air blower as shown in illustration, i.e.

set temperature potentiometer -2- to maximum heat output
and two-stage air flow switch -3- to position 3.

– Apply heat to the threads of the shear bolts on the connector

side as shown in the illustration for approx. 25 to 30 seconds.

WARNING

Heating the thread of the locking plate also heats up the shear
bolts and parts of the metal housing. 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.
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. Removing and installing engine control units 77

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

– Unscrew shear bolts using mole grips (see arrow in illustra‐

tion).
– The two shear bolts screwed into the control unit do not need
to be heated. They should be removed without being heated.
– Detach metal locking plate from control unit connectors.
– Remove two bolts securing diesel direct injection system con‐
trol unit 2 - J494- and pull control unit forwards.
– Release connectors on diesel direct injection system control
unit 2 - J494- and unplug connectors.
– Take out the old diesel direct injection system control unit 2 -
J494- and install the new control unit.
Installing

Note

♦ Installation is performed in the reverse sequence. After instal‐

lation, the protective housing must be re-fitted on the control
unit. Use new shear bolts.
♦ After renewing the engine control unit you must also adapt the
injector delivery calibration values for the new engine control
unit (injector delivery calibration values influence engine pow‐
er output and exhaust emissions).
♦ If only the slave control unit ( diesel direct injection system
control unit 2 - J494- ) is renewed, the following injectors must
be re-adapted: cylinders 2, 3, 5 and 8.

The procedure to follow after connecting the new engine control

unit is described in Guided Fault Finding.
– Activate engine control unit in “Guided Functions” mode, “Re‐
new engine control unit” ⇒ Vehicle diagnostic tester.

78 Rep. gr.23 - Mixture preparation - injection

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

28 – Glow plug system

1 Checking glow plug system
– Detach glow plug connectors from glow plugs.
– Connect portable multimeter (voltage test range) to one glow
plug connector and engine earth.
– Start final control diagnosis and activate glow plug relay.
Specification: approx. battery voltage (every 5 seconds)
If specification is not obtained:
– Rectify any open/short circuit as necessary. ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations

1.1 Checking glow plugs

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.
• Battery voltage at least 11.5 Volt.
– Switch off ignition.
– Detach glow plug connectors from glow plugs.
– Connect diode test lamp wire using auxiliary clips from auxili‐
ary measuring set - V.A.G 1594C- to battery positive (+).
– Place test probe of diode test lamp on each glow plug in turn.
If diode lights up: glow plug OK.
If diode does not light up: fit a new glow plug

1.2 Removing and installing glow plugs

Special tools and workshop equipment required
♦ U/J extension and socket, 10 mm - 3220-

Removing
– Switch off ignition.
– Detach glow plug connectors from glow plugs.
– Clean glow plug openings in cylinder head; make sure no dirt
gets into cylinder.

1. Checking glow plug system 79

Audi A8 2003 ➤
TDI injection and glow plug system (8-cyl. 4.0 ltr. 4-valve common rail) - Edition 03.2014

Note

♦ Cleaning procedure:
♦ Glow plugs must still be fitted.
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
openings, let it work in briefly, and blow out with compressed
air.
♦ Then clean the glow plug openings using a cloth moistened
with oil.

– To slacken the glow plugs use special tool U/J extension and
socket, 10 mm - 3220-
Installing

Note

Before installing, coat threads of glow plugs with high-tempera‐

ture paste ⇒ Parts catalogue , servicing materials.

– To tighten the glow plugs use special tool U/J extension and
socket, 10 mm - 3220- with a suitable torque wrench.
♦ Tightening torque: 18 Nm
– Attach glow plug connectors correctly and make sure they are
securely fitted.

80 Rep. gr.28 - Glow plug system

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