AUDI A8 D3 4E 2002-2009 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Audi Model: A8 Chassis Code: D3 (4E) Production Years Covered: 2002-2009 Codes Engine Codes 2 8L V6: BDX, CJB Engine Codes 3 0L V6: ASN, BBJ Engine Codes 3 2L V6 Fsi: BKH, BPK Engine Codes 3 7L V8 Motronic: BFL Engine Codes 4 2L V8 Motronic: BFM, BGK Engine Codes 4 2L V8 Fsi: BVJ Engine Codes 5 2L V10 Fsi: BSM Engine Codes 6 0L V12 Motronic: BHT, BSB, BTE Engine Codes 3 0L V6 Tdi: ASB, BNG Engine Codes 4 0L V8 Tdi: ASE Engine Codes 4 2L V8 Tdi: BMC, BVN Transmission Codes Automatic 6 Speed: 09L, 09E 👋 Introduction Market Position Vehicle Segment: Full-size luxury sedan Competitive Analysis Key Competitors: Mercedes-Benz S-Class, BMW 7 Series, Lexus LS, Porsche Panamera Key Features Audi A8 D3 Characteristics: Renowned for its sophisticated design, advanced technology, comfortable ride, and powerful engine options, including the groundbreaking V10 FSI and V12 W12 MPI engines. Known for its Quattro all-wheel-drive system and extensive use of aluminum for weight reduction. Manual Value Proposition Manual Benefit: Provides comprehensive, dealer-level repair and maintenance information, enabling significant cost savings for owners and technicians. 📋 Manual Details Coverage Areas Vehicle Models Covered: Audi A8 D3 (4E) all variants Page Count Number Of Pages: 8200+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF Delivery Format: ZIP archive Software Requirements: Adobe Acrobat Reader, WinZip or WinRAR 📖 Manual Coverage Systems Covered Powertrain: Engine (all variants), Lubrication, Cooling, Fuel Supply, Turbocharger, Charge Air, Supercharging, Injection, Exhaust, Emission Control, Glow Plug, Common Rail, Torque Converter Transmission: Automatic Transmission (09L, 09E), Gearbox Control, Final Drive, Differential, Transporting Gearbox Chassis: Suspension (Front & Rear), Axle System (Front & Rear), Wheel Bearing, Drive Shaft, Electronic Damping Control, Dynamic Steering, Hydraulic Power Steering, Wheel and Tyre System Brakes: Hydraulic Brake System, Anti-Lock Brake System (ABS) Electrical Electronics: Battery, Alternator, Charging System, Ignition System, Lighting System, Airbag & Restraint System, MFCU (Multi-Function Communication Unit), Central Locking System, Current Flow (Wiring) Diagrams Body Interior: General Body Repair, Exterior-Interior-Trim, Wheel Housing Liner Climate Comfort: Air Conditioning System, Heating & Ventilation, Auxiliary-Supplementary Heater Infotainment Convenience: Infotainment System, Sound-Aerial-Radio-TV System, Telephone System, Navigation System, Reversing Camera System, Multi-function Steering Wheel, Voice Control System, Rear Seat Entertainment System (RSE), Night Vision System Driver Assistance: Adaptive Cruise Control, Driver Assist Systems Maintenance Maintenance Related Items: Maintenance System, Service Tools, Tightening Torque, Accelerator Mechanism, Windscreen Wash/Wipe System, Activated Charcoal Filter System Procedures Included Engine Procedures: Removing and Installing Engine, Engine Assembly Mountings, Cylinder Head Removal/Installation, Valve Gear Servicing, Lubrication System Repair, Cooling System Servicing, Turbocharger System Overhaul, Charge Air System Repair, Supercharging System Servicing, Injection System Diagnosis and Repair, Vacuum System Troubleshooting, Air Cleaner System Maintenance, Intake Manifold Servicing, Engine Control Unit (ECU) Diagnostics, Exhaust System Repair, Emission Control System Servicing, Selective Catalytic Reduction (SCR) System Maintenance, Exhaust Gas Recirculation (EGR) System Servicing, Glow Plug System Diagnosis, Ignition System Servicing, Secondary Air System Repair, Fuel Supply System Overhaul, Fuel Cooler/Filter/Pump Servicing Transmission Procedures: Transmission Control Module (TCM) diagnosis, Mechatronic Unit Servicing, ATF purging, Gearbox Control System troubleshooting, Final Drive servicing Chassis Procedures: Suspension component replacement, Axle alignment, Wheel bearing replacement, Drive shaft boot replacement, Electronic damping control system troubleshooting, Dynamic steering system diagnosis, Hydraulic power steering system maintenance, Wheel and tire service Brake Procedures: Brake system bleeding, Brake pad and rotor replacement, ABS system diagnosis and repair Electrical Procedures: Battery testing and replacement, Alternator testing and replacement, Wiring harness repair, Airbag system servicing, Central locking system troubleshooting, Lighting system repair, MFCU diagnostics Body Procedures: Body panel repair, Trim component removal and installation, Interior component servicing Climate Procedures: AC system refrigerant handling, Heater core replacement, HVAC system diagnostics Infotainment Procedures: Navigation system updates, Infotainment system troubleshooting, Audio system repair, Telephone system integration, Reversing camera system installation/repair Driver Assistance Procedures: Adaptive Cruise Control sensor calibration, Driver assistance system diagnostics Maintenance Procedures: Scheduled maintenance checks, Fluid level checks and top-ups, Filter replacement, Diagnostic troubleshooting, Component testing Technical Depth Depth Of Information: Comprehensive diagnostics, troubleshooting guides, repair procedures, maintenance schedules, specifications, wiring diagrams Target Audience: Professional mechanics and DIY enthusiasts 📊 Manual Specifications File Format File Size: 222 MB Print Quality Diagram Quality: High Definition Binding Type Binding: N/A (Digital format) Paper Type Paper Quality: N/A (Digital format) Features Searchability: Searchable text (within PDF) Navigation: Bookmarks for every chapter Installability: No extra software installation required (beyond PDF reader and extraction utility) ⚙️ Engine Specifications Primary Engine Engine Options Overview: Wide range of V6, V8, V10, and V12 gasoline (FSI and MPI) and TDI diesel engines. Performance Example Engine Specs 4 2L V8 Fsi: Displacement: 4.2L (4163 cc), Horsepower: ~350 PS, Torque: ~440 Nm Example Engine Specs 6 0L V12 Motronic: Displacement: 6.0L (5998 cc), Horsepower: ~450 PS, Torque: ~580 Nm Fuel System Fuel Injection Types: Direct...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Chassis Code:

D3 (4E)

Production Years Covered:

2002-2009

Codes

Engine Codes 2 8L V6:

BDX, CJB

Engine Codes 3 0L V6:

ASN, BBJ

Engine Codes 3 2L V6 Fsi:

BKH, BPK

Engine Codes 3 7L V8 Motronic:

Engine Codes 4 2L V8 Motronic:

BFM, BGK

Engine Codes 4 2L V8 Fsi:

Engine Codes 5 2L V10 Fsi:

Engine Codes 6 0L V12 Motronic:

BHT, BSB, BTE

Engine Codes 3 0L V6 Tdi:

ASB, BNG

Engine Codes 4 0L V8 Tdi:

Engine Codes 4 2L V8 Tdi:

BMC, BVN

Transmission Codes Automatic 6 Speed:

09L, 09E

👋 Introduction

Market Position

Vehicle Segment:

Full-size luxury sedan

Competitive Analysis

Key Competitors:

Mercedes-Benz S-Class, BMW 7 Series, Lexus LS, Porsche Panamera

Key Features

Audi A8 D3 Characteristics:

Renowned for its sophisticated design, advanced technology, comfortable ride, and powerful engine options, including the groundbreaking V10 FSI and V12 W12 MPI engines. Known for its Quattro all-wheel-drive system and extensive use of aluminum for weight reduction.

Manual Value Proposition

Manual Benefit:

Provides comprehensive, dealer-level repair and maintenance information, enabling significant cost savings for owners and technicians.

📋 Manual Details

Coverage Areas

Vehicle Models Covered:

Audi A8 D3 (4E) all variants

Page Count

Number Of Pages:

8200+

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

File Format:

Delivery Format:

ZIP archive

Software Requirements:

Adobe Acrobat Reader, WinZip or WinRAR

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (all variants), Lubrication, Cooling, Fuel Supply, Turbocharger, Charge Air, Supercharging, Injection, Exhaust, Emission Control, Glow Plug, Common Rail, Torque Converter

Transmission:

Automatic Transmission (09L, 09E), Gearbox Control, Final Drive, Differential, Transporting Gearbox

Chassis:

Suspension (Front & Rear), Axle System (Front & Rear), Wheel Bearing, Drive Shaft, Electronic Damping Control, Dynamic Steering, Hydraulic Power Steering, Wheel and Tyre System

Brakes:

Hydraulic Brake System, Anti-Lock Brake System (ABS)

Electrical Electronics:

Battery, Alternator, Charging System, Ignition System, Lighting System, Airbag & Restraint System, MFCU (Multi-Function Communication Unit), Central Locking System, Current Flow (Wiring) Diagrams

Body Interior:

General Body Repair, Exterior-Interior-Trim, Wheel Housing Liner

Climate Comfort:

Air Conditioning System, Heating & Ventilation, Auxiliary-Supplementary Heater

Infotainment Convenience:

Infotainment System, Sound-Aerial-Radio-TV System, Telephone System, Navigation System, Reversing Camera System, Multi-function Steering Wheel, Voice Control System, Rear Seat Entertainment System (RSE), Night Vision System

Driver Assistance:

Adaptive Cruise Control, Driver Assist Systems

Maintenance Maintenance Related Items:

Maintenance System, Service Tools, Tightening Torque, Accelerator Mechanism, Windscreen Wash/Wipe System, Activated Charcoal Filter System

Procedures Included

Engine Procedures:

Removing and Installing Engine, Engine Assembly Mountings, Cylinder Head Removal/Installation, Valve Gear Servicing, Lubrication System Repair, Cooling System Servicing, Turbocharger System Overhaul, Charge Air System Repair, Supercharging System Servicing, Injection System Diagnosis and Repair, Vacuum System Troubleshooting, Air Cleaner System Maintenance, Intake Manifold Servicing, Engine Control Unit (ECU) Diagnostics, Exhaust System Repair, Emission Control System Servicing, Selective Catalytic Reduction (SCR) System Maintenance, Exhaust Gas Recirculation (EGR) System Servicing, Glow Plug System Diagnosis, Ignition System Servicing, Secondary Air System Repair, Fuel Supply System Overhaul, Fuel Cooler/Filter/Pump Servicing

Transmission Procedures:

Transmission Control Module (TCM) diagnosis, Mechatronic Unit Servicing, ATF purging, Gearbox Control System troubleshooting, Final Drive servicing

Chassis Procedures:

Suspension component replacement, Axle alignment, Wheel bearing replacement, Drive shaft boot replacement, Electronic damping control system troubleshooting, Dynamic steering system diagnosis, Hydraulic power steering system maintenance, Wheel and tire service

Brake Procedures:

Brake system bleeding, Brake pad and rotor replacement, ABS system diagnosis and repair

Electrical Procedures:

Battery testing and replacement, Alternator testing and replacement, Wiring harness repair, Airbag system servicing, Central locking system troubleshooting, Lighting system repair, MFCU diagnostics

Body Procedures:

Body panel repair, Trim component removal and installation, Interior component servicing

Climate Procedures:

AC system refrigerant handling, Heater core replacement, HVAC system diagnostics

Infotainment Procedures:

Navigation system updates, Infotainment system troubleshooting, Audio system repair, Telephone system integration, Reversing camera system installation/repair

Driver Assistance Procedures:

Adaptive Cruise Control sensor calibration, Driver assistance system diagnostics

Maintenance Procedures:

Scheduled maintenance checks, Fluid level checks and top-ups, Filter replacement, Diagnostic troubleshooting, Component testing

Technical Depth

Depth Of Information:

Comprehensive diagnostics, troubleshooting guides, repair procedures, maintenance schedules, specifications, wiring diagrams

Target Audience:

Professional mechanics and DIY enthusiasts

📊 Manual Specifications

File Format

File Size:

222 MB

Print Quality

Diagram Quality:

High Definition

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper Quality:

N/A (Digital format)

Features

Searchability:

Searchable text (within PDF)

Navigation:

Bookmarks for every chapter

Installability:

No extra software installation required (beyond PDF reader and extraction utility)

⚙️ Engine Specifications

Primary Engine

Engine Options Overview:

Wide range of V6, V8, V10, and V12 gasoline (FSI and MPI) and TDI diesel engines.

Performance

Example Engine Specs 4 2L V8 Fsi:

Displacement: 4.2L (4163 cc), Horsepower: ~350 PS, Torque: ~440 Nm

Example Engine Specs 6 0L V12 Motronic:

Displacement: 6.0L (5998 cc), Horsepower: ~450 PS, Torque: ~580 Nm

Fuel System

Fuel Injection Types:

Direct Injection (FSI) and Multi-Point Injection (MPI), Common Rail TDI for diesel variants

Engine Management

ECUs Covered:

Engine Control Units (ECU) for all listed engine variants

🔧 Transmission

Standard

Standard Transmission Type:

6-speed Tiptronic automatic transmission (09L)

Optional

Optional Transmission Type:

6-speed automatic transmission (09E) - often associated with higher performance engines

Features

Transmission Features:

Tiptronic manual shifting mode, Quattro all-wheel drive integration

Fluid Specifications

Atf Type:

Refer to manual for specific ATF part numbers and specifications (e.g., G 055 005, G 055 025 depending on transmission)

📐 Dimensions

Exterior

Wheelbase:

Approx. 2,944 mm (Standard) / 3,096 mm (Long Wheelbase)

Length:

Approx. 5,050 mm (Standard) / 5,170 mm (Long Wheelbase)

Width:

Approx. 1,894 mm

Height:

Approx. 1,420 mm

Weights

Curb Weight Range:

Approx. 1,800 kg to 2,100+ kg depending on engine and configuration

Gvw Gross Vehicle Weight:

Refer to vehicle specific VIN plate

Cargo

Trunk Volume:

Approx. 500 liters

🛡️ Safety Features

Ratings

Euro Ncap Rating:

Likely 4 or 5 stars for models from this era (specific year dependent)

Active Features

Active Safety Systems:

ABS, EBD (Electronic Brake-force Distribution), ESP (Electronic Stability Program), Traction Control (ASR), Adaptive Cruise Control (ACC), Parking Assist Systems

Passive Features

Passive Safety Features:

Front, side, and curtain airbags, Pre-tensioning seatbelts, ISOFIX child seat anchors, Active headrests

💡 Technology Features

Infotainment

Infotainment System:

MMI (Multi Media Interface) system, offering control over navigation, audio, climate, and vehicle settings.

Driver Assistance

Advanced Driver Assistance:

Adaptive Cruise Control (ACC), Parking sensors (front and rear), Lane Assist (optional), Night Vision System (optional)

Connectivity

Connectivity Features:

Bluetooth connectivity for telephones, Optional TV tuner, Audi Music Interface (AMI) on later models.

Lighting

Lighting Technology:

Xenon Plus headlights, LED daytime running lights (post-facelift), Adaptive headlights (AFS).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Variable timing (e.g., 15,000 km or 12 months, or based on Oil Quality Sensor/LongLife service, refer to manual for specific engine and oil type)

Maintenance Schedule Coverage:

Covers all scheduled maintenance items and intervals for engine, transmission, chassis, and electrical systems.

Fluid Specifications

Engine Oil Specifications:

Multiple specifications depending on engine (e.g., VW 502 00, VW 504 00, VW 507 00). Manual will list precise requirements for each engine.

Coolant Type:

G12 or G12+ (e.g., G12 EVO) antifreeze/coolant concentrate

Brake Fluid Type:

DOT 4 or DOT 5.1

Known Issues

Common A8 D3 Issues:

Air suspension issues (compressor, struts), ignition coil failures (especially on early models), thermostat housing leaks, power steering leaks, MMI (Multi Media Interface) system glitches, cam chain tensioner wear (on some early V8 models), potential for electrical gremlins.

📚 Vehicle History

Brand Heritage

Audi Legacy:

Audi has a long history of producing high-quality, technologically advanced automobiles, particularly known for its luxury sedans and its pioneering Quattro all-wheel-drive system.

Model Evolution

D3 Generation Introduction:

The D3 generation (4E) was introduced in late 2002 as a successor to the D2 generation. It represented a significant step forward in design, technology, and luxury.

Facelifts And Updates:

The D3 received a significant facelift in 2005, introducing updated styling (including Audi's new corporate grille), revised engines (including FSI technology), and enhanced technology features.

Production

Manufacturing Location:

primarily Ingolstadt, Germany

🏆 Awards & Recognition

Recognitions

Design Awards:

The A8 D3 was generally well-received for its sophisticated and understated design, often praised by automotive critics.

Ratings

Comfort Ride Quality:

Consistently rated highly for ride comfort and handling balance, particularly with the optional adaptive air suspension.

Certifications

Engineering Recognition:

The D3 platform was recognized for its advanced engineering, particularly its lightweight aluminum construction (Audi Space Frame) and sophisticated electronic systems.