Audi RS4 & RS5 4.2L V8 4V Direct Injection Engine Workshop Manual

Workshop Service and Repair Manual for the Audi RS4 & RS5 4.2L 4v CSFA engine This full workshop manual set covers every component, service, repair and rebuild procedure in full Audi factory specification with clear concise step by step photographs and technical drawings for the 4.2 V8 CFSA engine with torque setting values throughout where required for fasteners and reassembly, below is an exhaustive list of the items covered within this manual. This is the most comprehensive service manual available for the RS4 and RS5 engine as used by independent garages and service centres the world over.

The following chapters are covered within this manual:

Removing and installing engine
1.1 Removing engine
1.2 Separating engine and gearbox
1.3 Securing engine to engine and gearbox support
1.4 Installing engine

Assembly mountings
2.1 Exploded view – assembly mountings
2.2 Removing and installing engine mountings
3 Engine cover panel
3.1 Removing and installing engine cover panel

Crankshaft group
1 Cylinder block (pulley end)
1.1 Exploded view – poly V-belt drive
1.2 Removing and installing poly V-belt
1.3 Removing and installing tensioner for poly V-belt
1.4 Removing and installing vibration damper
1.5 Removing and installing bracket for ancillaries
1.6 Renewing crankshaft oil seal (pulley end)

Cylinder block (gearbox end)
2.1 Exploded view – drive plate
2.2 Removing and installing drive plate
2.3 Renewing crankshaft oil seal (gearbox end)

Crankshaft
3.1 Exploded view – crankshaft
3.2 Allocation of main bearing shells
3.3 Crankshaft dimensions
3.4 Measuring axial clearance of crankshaft
3.5 Measuring radial clearance of crankshaft

Auxiliary drive
4.1 Exploded view – auxiliary drive
4.2 Removing and installing spur gear drive
4.3 Renewing oil seal for power steering pump drive
4.4 Renewing oil seal for AC compressor drive

Pistons and conrods
5.1 Exploded view – pistons and conrods
5.2 Removing and installing pistons
5.3 Checking pistons and cylinder bores
5.4 Checking radial clearance of conrod bearings

Cylinder head, valve gear
1 Cylinder head
1.1 Exploded view – cylinder head
1.2 Removing and installing cylinder head
1.3 Removing and installing cylinder headcover
1.4 Checking compression
2 Timing chain cover
2.1 Exploded view – timing chain cover
2.2 Removing and installing timing chain cover (left-side)
2.3 Removing and installing timing chain cover (right-side)
2.4 Removing and installing timing chain cover (bottom)
3 Chain drive
3.1 Exploded view – camshaft timing chains
3.2 Exploded view – drive chain for valve gear
3.3 Exploded view – drive chain for auxiliary drives
3.4 Removing and installing camshaft timing chain
3.5 Removing camshaft timing chain from camshafts
3.6 Removing and installing drive chain for valve gear
3.7 Removing and installing drive chain for auxiliary drive
4 Valve gear
4.1 Exploded view – valve gear
4.2 Measuring axial clearance of camshaft
4.3 Measuring radial clearance of camshaft
4.4 Removing and installing camshaft
4.5 Checking hydraulic valve compensation elements
4.6 Removing and installing valve stem oil seals
5 Inlet and exhaust valves
5.1 Valve dimensions
5.2 Checking valve guides
5.3 Checking valves

Lubrication
1 Sump/oil pump
1.1 Exploded view – sump/oil pump
1.2 Exploded view – sump (top section)
1.3 Engine oil
1.4 Removing and installing sump (bottom section)
1.5 Removing and installing sump (top section)
1.6 Removing and installing oil pump
1.7 Removing and installing oil level and oil temperature sender G266
1.8 Checking oil level
2 Engine oil cooler
2.1 Exploded view – engine oil cooler
2.2 Removing and installing engine oil cooler
2.3 Removing and installing engine oil cooler (front)
3 Crankcase breather
3.1 Removing and installing hose for crankcase breather system
4 Oil filter/oil pressure switches
4.1 Exploded view – oil filter housing/oil pressure switches
4.2 Removing and installing oil temperature sender G8
4.3 Checking oil pressure switch F22 / oil pressure switch for reduced oil pressure F378
4.4 Removing and installing oil pressure switch F22
4.5 Removing and installing oil pressure switch for reduced oil pressure F378
4.6 Removing and installing valve for oil pressure control N428
4.7 Checking oil pressure
4.8 Removing and installing oil filter housing
5 Oil circuit
5.1 Exploded view – oil spray jets/valves
5.2 Removing and installing oil spray jets/valves

Cooling
1 Cooling system/coolant
1.1 Connection diagram – coolant hoses
1.2 Draining and filling cooling system
1.3 Checking cooling system for leaks
2 Coolant pump/thermostat assembly
2.1 Exploded view – coolant pump and thermostat
2.2 Removing and installing electrical coolant pump
2.3 Thermostat opening values
2.4 Removing and installing coolant pump
2.5 Removing and installing coolant temperature sender G62
2.6 Removing and installing map-controlled engine cooling system thermostat F265

Coolant pipes
3.1 Exploded view – coolant pipes
3.2 Removing and installing coolant pipes (front)
3.3 Removing and installing coolant pipes (top front)
3.4 Removing and installing coolant pipes (front centre)

Radiator/radiator fans
4.1 Exploded view – radiator/radiator fans
4.2 Exploded view – radiator cowl and radiator fans
4.3 Removing and installing radiator
4.4 Removing and installing radiator fans
4.5 Removing and installing auxiliary radiator

Mixture preparation – injection
1 Injection system
1.1 Overview of fitting locations – injection system
1.2 Checking fuel system for leaks
1.3 Reducing pressure in high-pressure section of the injection system

Vacuum system
2.1 Exploded view – vacuum system
2.2 Checking vacuum system
3 Injectors
3.1 Removing and installing injectors
3.2 Cleaning injectors
4 Air cleaner
4.1 Exploded view – air cleaner housing
4.2 Removing and installing air cleaner housing
4.3 Removing and installing air filter element

Intake manifold
5.1 Exploded view – intake manifold (top section)
5.2 Exploded view – intake manifold (bottom section) with fuel rail
5.3 Removing and installing intake manifold (top section)
5.4 Removing and installing intake manifold (bottom section) with fuel rail
5.5 Removing and installing throttle valve module J338 / J544

Senders and sensors
6.1 Removing and installing fuel pressure sender G247 / G624
6.2 Checking fuel pressure and residual pressure (up to high-pressure pump)

Engine control unit
7.1 Removing and installing engine control unit J623
7.2 Wiring and component check with isolator boxes VAS 6606

High-pressure pump
8.1 Exploded view – high-pressure pump
8.2 Removing and installing high-pressure pump
8.3 Removing and installing high-pressure pipe
9 Lambda probe
9.1 Exploded view – Lambda probe
9.2 Removing and installing Lambda probe

Exhaust system
1 Exhaust pipes/silencers
1.1 Exploded view – silencers
1.2 Separating exhaust pipes/silencers
1.3 Removing and installing front silencers
1.4 Stress-free alignment of the exhaust system
1.5 Aligning tailpipes
1.6 Checking the exhaust system for leaks
1.7 Checking function of exhaust flap

Exhaust manifolds
2.1 Exploded view – exhaust manifold
2.2 Removing and installing exhaust manifolds

Secondary air system
3.1 Exploded view – secondary air system
3.2 Removing and installing secondary air pump V101 / V189
3.3 Removing and installing combination valve
3.4 Checking combination valve for correct operation and leaks
3.5 Removing and installing senders for secondary air pressure G609 / G610

Ignition system
1 Ignition system
1.1 Exploded view – ignition system
1.2 Test data, spark plugs
1.3 Removing and installing ignition coils
1.4 Removing and installing knock sensor
1.5 Removing and installing Hall senders
1.6 Removing and installing engine speed sender G28